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1 STANDARD FOR CERTIFICATION No Offshore Service Modules MAY 2013 The electronic pdf version of this document found through is the officially binding version The content of this service document is the subject of intellectual property rights reserved by Det Norske Veritas AS (DNV). The user accepts that it is prohibited by anyone else but DNV and/or its licensees to offer and/or perform classification, certification and/or verification services, including the issuance of certificates and/or declarations of conformity, wholly or partly, on the basis of and/or pursuant to this document whether free of charge or chargeable, without DNV's prior written consent. DNV is not responsible for the consequences arising from any use of this document by others.2 FOREWORD DNV is a global provider of knowledge for managing risk. Today, safe and responsible business conduct is both a license to operate and a competitive advantage. Our core competence is to identify, assess, and advise on risk management. From our leading position in certification, classification, verification, and training, we develop and apply standards and best practices. This helps our customers safely and responsibly improve their business performance. DNV is an independent organisation with dedicated risk professionals in more than 100 countries, with the purpose of safeguarding life, property and the environment. Standards for Certification Standards for Certification (previously Certification Notes) are publications that contain principles, acceptance criteria and practical information related to the Society's consideration of objects, personnel, organisations, services and operations. Standards for Certification also apply as the basis for the issue of certificates and/or declarations that may not necessarily be related to classification. Det Norske Veritas AS May 2013 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, and is believed to reflect the best of contemporary technology. The use of this document by others than DNV is at the user's sole risk. DNV does not accept any liability or responsibility for loss or damages resulting from any use of this document.3 Changes Page 3 CHANGES General This document supersedes Standard for Sertification 2.7-2, December 1995 and amendments November Text affected by the main changes in this edition is highlighted in red colour. However, if the changes involve a whole chapter, section or sub-section, normally only the title will be in red colour. Main Changes All sections have been extensively revised and extended to include all temporary offshore service equipment which may be mounted on a frame or inside a container. The focus is on the safety of this equipment and any hazards it may introduce to the installation on which it is placed. Editorial Corrections In addition to the above stated main changes, editorial corrections may have been made.4 Contents Page 4 CONTENTS 1. Introduction Relationship with other standards, codes and regulations General Objective...6 Definitions Referenced Class Rules, Regulations and Standards Abbreviations Structural Technical Requirements General Transport Loads Offshore Installation Induced Loads Securing to offshore installation High Stressed Locations Safety Related Technical Requirements General Environmental Requirements Noise Asbestos Declarations...13 Electrical Systems Ignition Prevention Fire & Gas Detection Communications Fire Fighting Passive Fire Protection Escape Heating, Ventilation and Air Conditioning Module Service Types Modules for Important Services Module Types Specific Requirements for Functional Groups Offshore Installations not intended for hydrocarbon related activities Installation and Hook-up General Interfaces between module and offshore installation Instructions for hook-up/installation Marking and instructions Information plate Marking of Equipment Approval and Certification Procedures General Application for Certification Approval Schemes Design Assessment Survey and testing Certification of existing containers Retention of certificates...39 Appendix A. Certificate for Offshore Service Module... 405 Sec.1 Introduction Page 5 1 Introduction This Standard for Certification has been issued in order to collect into one document a suitable collection of requirements with relevant appropriate references to various international codes and standards which are applicable to the design and installation of offshore service modules. Offshore service modules are designed to perform temporary services on offshore installations and may be placed on different offshore installations and units in different national waters. This Standard for Certification applies basic requirements from other DNV Rules and Standards to service modules and has been based primarily on recognised practices for the offshore industry. It is intended that the standard will be suitable for global usage. It should, however, be noted that some shelf or flag states may have stricter or other requirements than those given in this standard. Modules designed and manufactured in compliance with DNV are intended to meet the basic requirements of SOLAS, MODU code and DNV Offshore Standards relevant to the functions of the equipment and as applicable at date this standard was issued. All subject to adequate installation of the equipment when located on the offshore installation (which is out with the scope of this standard). 1.1 Relationship with other standards, codes and regulations The International Maritime Organization (IMO) The requirements in the SOLAS Code apply for offshore service modules utilised on ships and certain floating offshore installations. The requirements in the MODU Code apply for offshore service modules utilised on floating offshore drilling units, including jack-up installations. This applies irrespective of the time such modules are installed and used. DNV is intended to meet the basic safety requirements of SOLAS and MODU code with regard to escape provision, fire detection and fire protection DNV Rules for Classification of Ships / DNV Offshore Standards. Offshore Service Modules that are installed on a DNV Classed Offshore Installation may be subject to classification requirements, either in main class or other class notations. DNV includes the basic requirements of these documents, for main class items, when applied to temporary installations. DNV is not intended to replace certification to the DNV Rules for Classification of Ships/DNV Offshore Standards for permanently installed equipment or conversions. When equipment is located on a DNV Classed Offshore Installation it is required to be assessed by DNV to ensure any aspects which interface with a class systems have been correctly installed and to ensure that general safety principles have been adhered. This focusses on the location and installation of the equipment and additionally confirms specific installation/hook-up requirements detailed within the DNV Certificate has been adequately addressed. It is not the intention of this standard to address the requirements for commissioning on a DNV Class unit, these remain the responsibility of the vessel/offshore unit owner/ manager Relationship to previous revision of standard This revision of the standard contains multiple updates to requirements as well as encompassing a broader range of equipment types. Equipment which was certified to previous revisions of this standard may not meet all the applicable requirements of this revision. Design assessment to previous revisions of this standard shall not be conducted following release of this revision.6 Sec.2 General Page 6 2 General 2.1 Objective The objective of this Standard for Certification is to set requirements for offshore equipment modules but focussed on the safety impact to the offshore installation upon which the equipment is installed. When installed and used on floating offshore installations, service containers are subject to the regulations applicable to an offshore installation (i.e., IMO MODU/SOLAS, Class, flag state and national regulations). When offshore service containers are installed and used on fixed offshore installations, national regulations will apply. It has been recognised that individual interpretations of all the various codes and standards may sometimes lead to conflicting requirements. This Standard for Certification intends to prescribe solutions which will provide an equivalent level of safety as the codes and standards referred to throughout this document. Certification by DNV provides a document which may be presented to users of the module to document its technical standard and safety performance. The certificate also defines conditions for transportation to, and installation on, an offshore installation. 2.2 Definitions Accommodation Space Those used for public spaces, corridors, lavatories, cabins, offices, hospitals, cinemas, games and hobbies rooms, pantries containing no cooking appliances and similar spaces. Public spaces are those portions of the accommodation which are used for halls, dining rooms, lounges and similar permanently enclosed spaces. Category A Machinery Space: All spaces which contain internal combustion-type machinery used either for main propulsion or for other purposes where such machinery has in the aggregate a total power of not less than 375 kw or which contain any oil-fired boiler or oil fuel unit; and trunks to such spaces. Equipment mass, TE: The mass in kilograms (kg) of insulation and all permanently fitted or installed equipment, etc. Certified Safe equipment: Certified safe equipment is equipment certified by an independent national test institution or competent body to be in accordance with a recognised standard for electrical apparatus in hazardous areas. Essential/safety system: Module integrated systems including required utilities, which are provided to prevent, detect or warn of an accidental event and/or mitigate its effect. This may include; lighting fire and Gas Detection Systems shutdown Systems PA/GA Systems supplies from emergency power or UPS sources fire protection and extinguishing system. Fitted out mass, TF: The mass in kilograms (kg) of the container ready for use, including both the structural mass and the equipment mass, i.e. TF = TS + TE 1) The term tare mass, T, as used for offshore containers in DNV 2.7-1, is not suitable for offshore service containers. The tare mass of a service container is fitted out mass, TF. Gas tight: Doors, walls or dampers which will maintain a pressure differential between adjacent areas, the allowable leakage rate will not exceed 0.5 m 3 / m 2 h at +50Pa. Important Services: Services provided by the module to the offshore installation which are critical to the safety of the offshore installation or modules that prevent, protect or mitigate from the effects of an accidental event. Examples may include accommodation units, emergency generator units, well intervention equipment. Low flame spread: A surface, which in accordance with the IMO Fire Test Procedures (FTP) Code, will adequately restrict the spread of flame.7 Sec.2 General Page 7 Manned: Manned for more than 2 hours in every 24 hour period. If the manning is located at an external position requirements around emergency lighting and ventilation are not mandatory. Non-combustible material: Material which neither burns nor gives off flammable vapours in sufficient quantity for self-ignition when heated to approximately 750ºC, this being determined in accordance with the IMO Fire Test Procedures (FTP) Code. Offshore container: A portable container with a maximum gross mass not exceeding 25,000 kg, for repeated use in the transport of goods or equipment, handled in open seas, to, from or between fixed and/or floating offshore installations and ships. See DNV for a more detailed definition. Offshore Installation: This is used as a short term and may be a fixed offshore installation, a mobile offshore unit or a ship on which the module may be located. Offshore service module: A unit built and equipped for a special service task, mainly for temporary installation, on offshore installations. This applies equally to offshore frames with equipment but for ease of reference we will refer throughout the standard to Offshore Service modules. Payload, P: The maximum permissible mass in kilograms (kg) of cargo or loose equipment which may safely be transported by the container. Portable Offshore Unit: A POU (Portable Offshore Unit) is a package or unit intended for repeated or single offshore transportation and installation/lifting. POU s may also be designed for subsea lifting. See DNV for more detailed definition. Primary deck covering: Deck covering which will not readily ignite in accordance with the IMO Fire Test Procedures (FTP) Code. Rating, R: Maximum gross mass of the container and its cargo in kilograms (kg). The Rating consists of the mass of the structure, fitted equipment and the payload, i.e. R=TF + P. Source of Release Point or location from which a flammable substance may be released into the room or building such that an explosive gas atmosphere could be formed. Standard fire test: A test in which specimens of the relevant bulkheads or decks are exposed in a test furnace to temperatures corresponding approximately to the standard time-temperature in accordance with the test method specified in the IMO Fire Test Procedures (FTP) Code. Structural mass (TS): The mass in kilograms (kg) of structural components, including both primary and secondary structure. Unmanned: Areas which are not manned as defined above. 2.3 Referenced Class Rules, Regulations and Standards The following standards include provisions which, through reference in the text, constitute provisions of this standard. The latest issue of the references will be used unless otherwise agreed. Other recognised standards may be used provided it can be demonstrated that these meet or exceed the requirements of the standards referenced below: IMO Requirements: CSC, IMO Convention for Safe Containers IMO FSS, International Code for Fire Safety Systems IMO FTP, International Code for Application of Fire Test Procedures MSC.1/Circ Unified Interpretation of SOLAS Chapter II-2 on the number and arrangement of portable fire extinguishers on board ships MODU, IMO Code Mobile Offshore Drilling Units SOLAS, IMO Convention Safety of Life at Sea.8 Sec.2 General Page 8 DNV Classification Note No. 8 Conversion Of Ships DNV Offshore Standards: DNV-OS-A101- Safety Principles and Arrangements DNV-OS-D101- Marine and Machinery Systems and Equipment DNV-OS-D201- Electrical Installations DNV-OS-D301- Fire Protection DNV-OS-E101- Drilling Plant DNV-OS-E201- Oil and Gas Processing Systems DNV-OS-E402- Offshore Standard for Diving Systems. DNV Rules for Ships Pt.3, Ch.1 - Hull Structural Design DNV Service Specification DNV-DSS-105- Rules for Classification of Diving Systems DNV Standard DNV-DS-E403- Standard for Surface Diving Systems DNV Standard for Certification: DNV STC 1.2 Type Approval DNV STC 2.22 Lifting Appliances DNV STC 2.4 Environmental Test Specification for Instrumentation and Automation Equipment DNV STC Offshore Containers DNV STC Portable Offshore Units. IEC Publications: IEC Series - Explosive atmospheres IEC Series - Electrical installations in Ships IEC Series - Mobile and fixed offshore units Electrical installations. NORSOK Publications: Norsok E-001 Electrical Systems Norsok Z-015 Temporary Equipment. 2.4 Abbreviations CCR DNV EMC EN ESD EU/EEA F&G FSS FTP IEC IMDG IMO IP LEL MODU MOU P & ID PA/GA PFP PLC POU SOLAS STC UPS Central Control Room Det Norske Veritas Electro Magnetic Compatibility European Normative Standard Emergency Shutdown European Union / European Economic Area Fire and Gas Fire Safety Systems Fire Test Procedure International Electro-technical Commission The International Maritime Dangerous Goods Code International Maritime Organisation Ingress Protection Lower Explosive Limit IMO Code Mobile Offshore Drilling Units Mobile Offshore Unit Piping and Instrumentation Diagram Public Address / General Alarm Passive Fire Protection Programmable Logic Controller Portable Offshore Unit IMO Convention Safety of Life at Sea DNV Standard for Certification Uninterruptable Power Supply 9 Sec.3 Structural Technical Requirements Page 9 3 Structural Technical Requirements 3.1 General Service modules will be subject to static or dynamic loads during transport and handling, and while installed on an offshore installation. Such loads may be either external, e.g. environmental loads, or internal, e.g. from a winch or machinery in the module. 3.2 Transport Loads There are three structural categories related to the transport requirements. Units certified to DNV must, as a minimum, be certified in accordance with one of the following: Offshore containers certified by DNV according to DNV (includes IMO/MSC/Circ.860). Portable Offshore Units certified by DNV according to DNV Ship type service containers Not for lifting between vessels and/or offshore installations at sea. Guidance note 1: Offshore containers certified by another organisation shall only be considered for DNV modules on a case by case basis. Guidance note 2: Building units as ISO/CSC containers will facilitate international transport by sea, since such units can be carried as standardized cargo units on container carriers and other dry cargo ships. Modules that are not ISO/CSC containers will normally be transported as special cargo. Modules built according to ISO freight container standards, ISO 1496 must be certified to IMO s Convention for Safe containers, CSC. The structural requirements in ISO 1496 and CSC are related to transport and handling, and are not generally relevant for units when installed on ships or offshore installations and as such will be subject to the additional requirements outlined in this Section. Figure 1 below defines the Relationships for Structural assessment Figure 3-1 Containers - Various use and related structural assessments Additional fittings for lifting In addition to the pad eyes and slings used for offshore handling, some containers and portable offshore units are built with extra sets of fittings for lifting and handling. These may include, for example, pad eyes that are only used for moving the module internally on an offshore installation. Such equipment, including the supporting structure, must be dimensioned according to DNV Standard for Certification No. 2.22, Lifting Appliances. These additional lifting fittings must not be used to lift a module to or from a supply vessel. This will be stated in the certificate and is to be clearly marked on the module.10 Sec.3 Structural Technical Requirements Page Offshore Installation Induced Loads General Offshore Service Modules categorised for Important Service (as defined in 2.2) shall be assessed for nontransport related loads i.e. service modules shall be designed for the loads imposed from the ship or offshore unit on which it is installed. It should be noted that offshore installation induced loads are the responsibility of the end user to define, but a vendor may select values for approval to suit his intended client market. Allowable bending and shear stresses shall be taken as 160f 1 and 90f 1 N/mm 2 respectively where f 1 is the relevant material factor (reference DNV Rules for Classification of Ships, Pt3. Ch.1) Design loads and accelerations will be specified in the DNV certificate. The thickness of walls must not be less than 4 mm. Special attention should be paid to buckling control of thin-plated structures subjected to compression stress in the face plate caused by local bending. Note: The plate flanges of corrugated/stiffened-plates should be checked for buckling in accordance with DNV Rules for Ships Pt.3 Ch.1 Sec. 13. The compression stress σ b in the plate flange, induced by lateral pressure and local bending of the plate profile, should not exceed the critical buckling stress times utilisation factor for normal load level σ c x η. For loads applied on normal load level η = e-n-d---of---n-o-t-e External / Environmental Loads For installation on ships, the strength will be calculated according to Pt.3, Ch.1, Sec.10 of the Rules for Classification of Ships. Two types of sea loads may be applicable depending upon the offshore installation and location: Sea pressure. Accelerations due to vessel motion. These loads will vary according to vessel type and the actual location on vessel, in general environmental loads on MOUs will be less than those on ships. Table 3-1 and Table 3-2 below define the applicable minimum ratings; these are simplified values based on DNV Rules for Classification of Ships, Pt.3, Ch.1, Sec.4. Where considered appropriate more accurate loads may be calculated to these rules or to DNV Classification Note 8. Note: The level of these factors will ensure that service modules can be placed in most locations on most of the ships used offshore. ---e-n-d---of---n-o-t-e--- Table 3-1 Sea pressure loads Strength level Location on Vessel Sea pressure load* Level 1 Exposed location Sea pressure = 30 MPa Level 2 Protected location Sea pressure = 15 MPa Special Case As specified on certificate Sea pressure to be agreed on a case by case basis *Average pressure over whole container wall Table 3-2 Accelerations Strength level Vessel Type Accelerations (m/s 2 ) Vertical (Note) (g a v ) Horizontal 0.67 a t Level 1 High accelerations a v = 15m/s 2 / 5m/s 2 a h = 6 m/s 2 Level 2 Moderate accelerations a v = 13m/s 2 / 7m/s 2 a h = 4 m/s 2 Special Case As specified on certificate Acceleration to be agreed on a case by case basis Note; Assessment shall consider compression and tensile forces; the first figure is intended to maximize the compressive effect, the second figure is intended to maximize the tensile effect.11 Sec.3 Structural Technical Requirements Page 11 Strength Level 1 -Sea pressures and accelerations will be suitable for installation on most Offshore Support Vessels. This level should be chosen for service module that may be placed in any location on a vessel. Strength Level 2 - Sea pressures and accelerations will normally be sufficient for installation on FPSOs and other larger ships, and for installation in protected / low acceleration locations on offshore support vessels Accidental Loads Offshore service modules for Important Services may be required to be evaluated against accidental collision, grounding or similar events in order to accommodate for safe securing. Modules installed on vessels which are covered by classification requirements must be evaluated for a minimum longitudinal acceleration of 0.5g o in the forward direction and 0.25g o in the aft direction Other service loads Service modules may be subject to other particular loads specified below, (or combinations). Wind Loads acting on module structure should not be taken less than 2.5 kn/m 2, unless otherwise documented. Snow and Ice Loads - Ice accretion from sea spray, snow, rain and air humidity should be considered, where relevant. Snow and ice loads may be reduced or neglected if snow and ice removal procedures are established. Blast Loads Shall be considered if a service module is to be located in an unprotected area close to a hazardous area. Blast loads must be in accordance with DNV-OS-A101 unless otherwise specified. Loads internal to the module (e.g. winch loads, pressure loads, etc.) must be considered where relevant to the specific module type. 3.4 Securing to offshore installation Service modules must be able to be secured safely to the offshore installations, either by having suitable fittings for securing or structural parts suitable for bolting or welding to a deck. For securing on ships refer to DNV Classification Note No. 8 Sec 3. Securing devices and bolts must be safe against unwanted opening or release. Securing devices such as container twistlocks may be used, but must be mechanically secured in the locked position. Only manually operated twistlocks can be used, not semi-automatic or fully automatic twistlocks. Securing devices shall be certified by DNV. The main pad eyes on offshore container or portable offshore unit shall not be utilised as securing points. Service modules may be stacked to two or more levels on offshore installations. Securing and support loads based on the loads described in 3.3 must be taken into account. Where one container acts as a supporting structure for another container, this must be considered and evaluated on a case-by-case basis. 3.5 High Stressed Locations For offshore service modules intended for long term use in a single high stress location on an vessel or mobile offshore unit it will be necessary to evaluate the effect of repetitive cyclic loading from vessel motions or service loads. Fatigue criteria are a project specific matter which cannot be define at the manufacturers design stage and as such are not covered within the scope of this standard.12 Sec.4 Safety Related Technical Requirements Page 12 4 Safety Related Technical Requirements 4.1 General Detailed Requirements The details given in this chapter describe the technical requirements which apply to an offshore service module; some requirements are generic and will apply to all units. Others are specific and shall only be applied when defined in Hazardous vs Safe Area Modules located on open deck on an offshore installation shall be suitably rated for the actual rating of zone in which they are located, but it is important to recognise that all equipment is required to be made safe in case of accidental release of gas. This means that any equipment which remains electrically energised or has the potential to have surface temperatures in excess of 200 C following shutdown on gas detection shall be designed and installed to meet the requirements of minimum zone 2 and in some cases zone 1. Equipment which remains energised during gas detection or produces a hot surface shall meet a minimum of Gas Group IIA and Temperature Class T Alternative solutions Alternative solutions may be substituted where shown to provide an equivalent or higher level of integrity or safety than the requirements under this standard. Justification of alternative solutions shall be documented. Where alternative solutions have been accepted this shall be documented on the DNV certificate. 4.2 Environmental Requirements Modules shall be suitable for defined environmental conditions. Table 4-1 is applicable to all modules, Table 4-2 shall be considered for particular modules designed for Important Services as defined in 2.2. Table 4-1 Environmental Conditions All Modules Outside Ambient 20 Temperature: o C to +45 C Up to 96% without condensation when heating is provided (mounted indoors) or 100% with Humidity: condensation when mounted outdoors. All electrical equipment shall be selected and installed so as to avoid EMC problems. Electromagnetic Reference standards which can be used to demonstrate compliance: Compatibility IEC (Immunity) IEC (Emissions) The maximum operational inclination for the module should be specified. This maximum shall be defined at the point where continued operation of the equipment changes to a level where it Inclination presents a risk to the operator, offshore installation or if there is an increase in surface temperature beyond 200 C. Should no inclination values be specified the module shall be marked on the certificate as suitable for use on a fixed offshore installation only. Table 4-2 Environnemental Conditions Important Service Modules Ref Standard for Certification 2.4 Vibration level: Vibration class B 3 to 25 Hz: 1.6 mm displacement amplitude (peak value) 25 to 100 Hz: 4 g acceleration Equipment and components on floating offshore installations shall be designed to operate satisfactorily under the following inclinations of the offshore installation: Ships All conditions List 22.5 Trim 10 Column-stabilised &self-elevating units Static Condition List 15 Trim 15 Inclination Dynamic Condition List 22.5 Trim 22.5 Emergency condition List 25 Trim 25 Other values may be accepted if justified by calculations for the particular offshore installation. Should the inclination requirements stated above not be achieved, the manufacturer should supply details of inclination that can be achieved with limitations detailed in the design assessment and DNV certificate.13 Sec.4 Safety Related Technical Requirements Page 13 Ambient temperature requirements specified in Table 4-1 are provided to align with DNV Rules for Classification of Ships and DNV Offshore Standards. Alternative temperature range shall be considered on a case by case basis and noted on the DNV certificate. 4.3 Noise Where applicable, modules shall be provided with a noise assessment to determine the working environment in or around the module. The noise level shall detail the maximum sound pressure level at 1 m from the module and the maximum point internal to the module. The need for hearing protection shall be marked on units where noise levels are in excess of 85dB. Audible alarms required by other parts of this document shall be supplemented with a warning beacon when the noise level is above 85dB. 4.4 Asbestos Declarations In accordance with SOLAS Ch.II-1 Reg.3.5 and MSC.1/Circ.1379 asbestos is prohibited from any product intended for installation on any SOLAS certified offshore installation. No asbestos is to be used in the fabrication of the module. An Asbestos free declaration is to be issued by the manufacturer. 4.5 Electrical Systems Safety Requirements Electrical equipment shall be designed and installed such that the risk of injury to personnel is minimised. Protective devices of suitable rating are required to prevent overload, excessive heating and damage in case of electrical faults. All electrical circuits for Safety related systems shall be designed to fail safe condition Components and equipment Electrical components and equipment shall be suitable for use offshore or on board ships and shall be constructed according to relevant IEC publications or other internationally recognised equivalent standards. Electrical components located in enclosures which may need to be opened for inspection or maintenance while the circuits are live shall have covers or otherwise be arranged such that touching or short circuiting of live parts is not possible. Component insulating materials shall be flame retardant according to IEC or equivalent Arrangement & location of equipment Offshore service modules are exposed to rough handling and environmental conditions during transportation and storage. In order to keep the electrical equipment safe and fit for use, the following requirements shall be met: Equipment shall be provided with mechanical protection to prevent damage during transportation and use. Electrical enclosures are normally not to be located external to the module. In the event that electrical enclosures need to be located external to the module, then they shall be located in a suitably recessed panel within the module outer frame. The equipment in the recess shall be protected from damage during transportation. (e.g. use of removable or hinged cover plates). Electrical equipment is to be protected against corrosion. A system of space heating may be required if there is a chance of humidity or condensation. The normal module heating system may be used for this if suitable. Electrical enclosures which are exposed to the outside atmosphere and which are sensitive to moisture shall be equipped with individual space heaters. This is, however, not required for simple junction boxes. The heating system shall be activated whenever practical both onshore and offshore. Portable utility equipment is to be securely fixed. The construction and fixing of all equipment shall result in the module being able to withstand the likely stresses imposed on it when the module is transported or lifted. External power outlets and sockets shall be located approximately 1500 mm above the base of the module. Internal power outlets and sockets and shall be located a minimum of 300 mm above the internal floor level. Socket outlets for a rated current in excess of 16 A shall be interlocked with a switch or have integral switching so that a plug cannot be inserted or withdrawn when the switch is in the on position. Hook-up connections shall be protected to minimise the effects of splashing water. These shall be easily accessible for hook-up and maintenance purposes, and located between 600 mm and 1500 mm above the base of the module.14 Sec.4 Safety Related Technical Requirements Page 14 External panels and/or control stations which are required to be operated by personnel during normal operation shall be located approximately 1500 mm above the base of the module. Consideration shall be given to the location of control panels and control stations within the module so as to be easily accessible to personnel operating the equipment. Connection to offshore installation power supply system modules shall be prepared for cable hook-up according to the following: Suitable junction boxes are to be arranged in recesses on the outside wall. This arrangement may also be suitable for flexible cable types provided strain relief devices are fitted. Where an A fire rating is not required the module can be fitted with cable transits for connection into junction boxes inside the module. Cable transits shall be installed as to resist smoke or fire for 60 minutes. Modules shall have their in-take circuits and components rated for defined values of nominal voltage, frequency, current, short circuit level and type of system, e.g. IT, TN-S, etc. This data shall be clearly marked at the connection point. Enclosures for termination of external cables shall be arranged such that the cables can be conveniently connected, i.e. without excessive bending of the conductor ends and without having to unscrew terminals or other parts. The offshore installation should have pre-installed junction boxes or socket outlets within a reasonable vicinity such that the modules can be conveniently connected. A load switch shall be mounted at the main power intake. The switch may be a suitable circuit breaker, a manual switch or similar, and shall be certified safe equipment rated for the hazardous area in which it is located but for a minimum of zone 2. If the module has several power sources, one switch for each power source shall be installed. The switch(es) shall be readily accessible and be operable outside its enclosure and be arranged and marked in a suitable manner in order to provide a means for manual local emergency shutdown. Each switch shall be housed in a separate enclosure or shall otherwise be arranged to enable work without accidental touching of live parts Ingress Protection Modules and their components shall have appropriate IP ratings in accordance with Table 4-3. Table 4-3 Equipment Ingress Protection Requirements Rating Typical Location IP 20 IP 55 IP 56 Lower IP rating (limited at IP44) may be accepted if suitable protective covers are provided during shipment, storage and operation otherwise components shall be at least IP 56. Consideration must be given to ingress close to the edges of the cover Electrical system main characteristics The module may be designed for single or multiple supply voltages. The certification will verify that the integrity of the voltage system is maintained throughout and that the systems are appropriately marked Earthing Electrical components mounted inside dry weather tight modules Use of IP 55 may be agreed to in special cases, provided additional safety precautions are taken to prevent sea splash both during transportation and installation. This will be noted on the DNV certificate. Electrical equipment mounted external to the module or installed in non-enclosed or open modules shall a minimum of IP 56 If water based fire extinguishing systems are provided, electrical equipment for safety functions shall be at least IP 56 Modules where liquids may be present shall be at least IP 56 or be provided with protection to limit the risk of electrical equipment being in contact with liquids Earthing of the module structure A minimum of two earth bosses mounted diagonally, suitably recessed and opposite each other, are to be welded to the main steel structure on the outside at the module s lower part. Bolts for fixing the module to the15 Sec.4 Safety Related Technical Requirements Page 15 deck are not to be regarded as an earthing connection. Main structural earth boss shall be min M12. Protected/ Power Earth and Instrument Earth shall be connected to structure via separate earth bosses not less than 1 metre apart. Welding the module to the deck is considered an alternative method of earthing Electrical System Neutral Point or Single Pole Earthing All insulated electrical and control systems within the module are to have continuous insulation monitoring. The circulating current shall not be above 30 ma. In the event of an earth fault, either automatic tripping of the affected circuits shall occur or an alarm shall be generated. If automatic tripping is not implemented, means are to be provided for transmitting the alarm signal to the offshore installation control room. If there are several circuits, one common alarm to the control room will normally be sufficient. Local galvanic isolated systems may be earthed at one point. Earth leakage circuit breakers are to be provided in the final sub-circuits or at a suitable location upstream Earthing of electrical enclosures and terminal boxes Equipment made of conductive material are to be earthed either via the copper braid of the cable, a separate earth core within the cable, or via a separate earth conductor. Where copper braid is used, this shall have a cross sectional area as defined in Table 4-4. Where non-copper earth connections are used the cross section shall be increased dependent upon the increased resistance of the material compared to copper. Hinged or bolted connections are not considered to be an earth therefore a separate earth connection shall be provided where required. All earth bars shall be located at the front of enclosures and terminal boxes. Table 4-4 Earth/Bonding Conductor Cross Sectional Area Condition Cross Sectional Area Internal panel wiring Same size as current carrying conductors however must be minimum 1.5 mm 2 Internal Static Bonding Minimum 4 mm 2 External Static Bonding Minimum 6 mm 2 Earth Conductor for Equipment (Excludes internal panel wiring) Structural Earth Connection Same cross section as the current carrying conductor up to and including 16 mm 2. 50% of the current carrying conductors cross section above 16 mm 2 Minimum 16 mm 2 however shall be at least the same size as the earth in the supply cable Earth Conductors Earth conductors shall be coloured yellow/green and shall not be used for any other purposes than earthing. Only one earth conductor shall be connected to a single terminal/earthing point. Multiple connections can be made utilising an earth bar. An exception to this arrangement can be granted for components located inside the same enclosure when utilising a terminal or crimped connections which are designed to accept multiple cable entries. External earth connections shall be secured by a minimum of M10 bolts and indoor earth connections shall be secured by a minimum of M8. All connections shall be assembled with star washers to prevent loosening due to vibration Cables All cables shall have documented compliance with the following standards or equivalent. Table 4-5 Applicable specification for cabling Cable Type Reference Standard IEC : Electrical Installations in Ships Shipboard Power Cables Power cables General Construction and Testing Requirements Instrumentation and communication IEC : Electrical Installations in Ships Cables for control and cables for use up to 250V Instrumentation circuits 150/250 V (300 V) Minimum of flame retardant according to IEC and IEC All cabling for equipment used as part of an essential/safety system shall be fire All cables resistant to IEC or IEC Essential/ safety system are defined in 2.2.16 Sec.4 Safety Related Technical Requirements Page Fixing of cables Cables are to be securely fixed and terminated in a durable manner. Cables shall be secured at a maximum distance as defined in Table 4-6. Cables shall be secured close to the gland to provide support and prevent damage to the integrity of the cable or gland. This shall be as close as possible to the cable entry without applying additional mechanical forces to the connection, and shall not be greater than 10 cable diameters from the cable entry point. Metallic ties must be used for the first securing point from the gland at each end. The routing of cabling shall be such as to ensure that it is possible to verify the required IP degree for the enclosure and that the glands are properly maintained. Table 4-6 Maximum spacing for cable securing (Horizontal runs) Outer Diameter of Cable (D) Wire Braid Armour or Un-armoured Cables (mm) Spiral Steel Wound Armoured Cables (mm) Mineral Insulated Copper Shielded Cables (mm) D 8mm mm<d 13mm mm <D 20mm mm <D 30mm D>30 mm Note: For vertical securing of cables, the above spacing can be increased by 25%. To prevent collapse of cabling in case of fires, metallic ties should be utilised. On horizontal runs photo-stable non-metallic ties may be used providing every third securing point utilises a metallic tie. The minimum bend radius of cabling shall be in accordance with the manufacturer s recommendations. In the absence of such information, the cable bending radius shall at a minimum be as recommended by IEC Reference is made to Table Conductor Sizing The cross section of conductors versus current rating is specified in IEC , Table A.3. Where multiple cables or conductors are laid in contact with each other, the de-rating factors stated in IEC , Table A.6 shall apply. The minimum cross section of power supply cables shall be 1.5 mm 2. For interconnections inside panels, the minimum cross section permitted is 1 mm 2. The minimum acceptable cross sectional area of conductors in cables for control, data and instrumentation circuits up to 150 V is 0.5 mm 2. The circuit protection when utilising this cable size shall not exceed 5A. Where data cables are not used in safety systems or in control/monitoring functions which could lead to or cause escalation of an incident, these can be accepted in internal areas down to 0.22 mm Terminations All cable conductors shall be terminated in a suitable crimped ferrule or terminal with only one conductor per terminal. An exception to this arrangement can be granted when utilising a terminal or crimped connections which are designed to accept multiple cable entries. Spare conductors shall be terminated at both ends in the same way as earth conductors. Spare conductor sleaving shall not be coloured yellow/green, but shall be marked spare. Termination methods shall be such that the cross section of conductors and braiding is not reduced, and that loosening is also prevented. Cables shall be permanently marked at each end with the identifier which is traceable to the approved drawings.17 Sec.4 Safety Related Technical Requirements Page 17 Table 4-7 Bending radii for cables Bending radii for cables rated up to 1,8/3 kv Insulation Thermoplastic or thermosetting with circular copper conductors Cable construction Covering Outer Diameter (D) Minimum internal radius of bend (x Diameter of cable) Unarmoured or unbraided Up to 25 mm 4 (a) >25 mm 6 Metal braid screened or armoured Any 6 Metal wire armoured Metal tape armoured or Any 6 Metal sheathed Composite polyester/metal laminate tape screened units or collective tape screening Any 8 Thermoplastic or thermosetting with sector Any Any 8 shaped copper conductors (a) 6 D for defined circuit integrity Bending radii for cables rated at 3.6/6(7.2) kv and above Cable construction Overall diameter (D) Minimum internal radius of bend (x Diameter of cable) Single-core cable Any 12 3-core cables Any 9 NOTE: For cables rated at 3.6/6(7.2) kv and above, employ flexible conductor stranding (Class 5) and braid insulation shields indicating a minimum bend radius of 6D for unarmoured cables and 8D for armoured cables, in concurrence with the approval of the cable manufacturer Termination of braiding, armour and screens Cables which are external or exposed on the module shall be with braid or armour. Full enclosing the cable in metallic cable pipe shall be considered as an alternative when braid/armour cannot be installed (i.e. on prefitted flying leads). Cable braiding, armour and screens are to be carried through the gland when possible and be connected to the earth bar at both ends. However, when found necessary for function or safety reasons, connection to earth at the supply end only may be used. Plastic junction boxes used for loop through of circuits may be equipped with an earth bar which is not connected to the structure, but shall otherwise be marked and used for connection of the braiding as an ordinary earth bar. When braiding, armours and screens are earthed at one end only, the other end is to be carried through the gland and connected to an insulated terminal Batteries All circuits to/from the batteries are to be provided with adequate circuit protection devices. Short circuit proof cables are to be applied between the batteries and the circuit protection device. Batteries located in modules on deck shall be in certified safe equipment enclosures suitable for at least zone 2. However, consideration must be given to the equipment being supplied. Where equipment supplied is not certified safe equipment, the batteries shall be supplied via an Ex-d isolator. Batteries shall be of a valve regulated type and not exceed 200 Vah. Any higher capacities or other types can be considered on a case-by-case basis based on requirements from DNV-OS-D Equipment located external to module The external location of components (junction boxes, control panels, pipe connections, fans, etc.) should be avoided. Components that have to be located externally shall be installed within the equipment s outer frame to avoid damage of components due to lifting and handling of the module. If located external to the module, electrical and control equipment shall be suitable for use in the applicable hazardous area zone and environmental conditions specified in 4.2 apply. Special attention is to be given to electrical components mounted external to modules and which may be directly exposed to sun radiation. Rotating machines exposed to the outdoor atmosphere shall be suitably protected against icing. Motors are not to have an external cooling fan unless the fan has been assessed as not being an ignition source and the overall equipment, including the fan, meets the ingress protection requirements.18 Sec.4 Safety Related Technical Requirements Page Programmable controllers When programmable controllers (PLCs) are used for safety functions, they shall be of types suitable for the environmental conditions as given in 4.2. Programmable controllers (including the specific firmware/software) which are used for safety functions shall be demonstrated as fail safe. The manufacturer shall be able to demonstrate the following fail safe conditions: failure of Hardware failure of Input / Output devices failure of Software / Firmware loss of electrical supply. 4.6 Ignition Prevention Requirements for electrical equipment exposed to hazardous atmospheres Certification of equipment Electrical equipment for hazardous areas shall be designed, certified and categorised according to the IEC series publications or equivalent standards. Where independent certification is required by the standards, this certification shall be carried out by an accredited Notified Body or other independent recognised institution. When the letter X is included as part of marking or certificate number, this indicates that the certification institution has specified special conditions for the safe use of the equipment. Special conditions that are dependent upon final offshore installation shall be listed in the DNV certificate. Certified safe equipment certificates may be invalidated by un-qualified repairs or modifications Non Electrical Equipment in hazardous areas. In addition to ignition risk from electrical equipment, assessments are required to ensure equipment does not present an ignition risk from mechanical (i.e. surface temperature, impact or friction), static discharge or lightening. Assessment for mechanical ignition risk shall follow the requirements of IEC series or equivalent Inspection and Installation Installation of hazardous area equipment shall be in accordance with IEC An inspection plan shall be provided in accordance with IEC Records shall be retained to demonstrate that this inspection plan has been met during the life of the module. The competence of the person carrying out the installation and inspections shall be demonstrated upon request to the satisfaction of DNV. 4.7 Fire & Gas Detection Gas detection and alarm system General All air inlets shall be fitted with a gas detector upstream of the fire or gastight damper unless all installations are of certified safe equipment and the use of tools or equipment in the area will not create any ignition potential. In certain cases it may be necessary to interface the gas system in the module with the offshore installation. Details should be provided within the operational manual on required hook-up, operation and testing. Non-enclosed modules with equipment containing a source of hydrocarbon release shall be fitted with a minimum of one gas detector. Where this is not possible special requirements shall be noted on the DNV Certificate detailing need for suitable gas detection to be provided by the offshore installation Gas detection inside the module Gas detectors will be required inside the module if the following situations exist: At all ventilation outlets, if an internal source of release is present. Inside module, if a source of release is present (e.g. paint stores, gas turbine enclosures, laboratory) or if the module contains equipment which develops a hot surface. Inside module, if disconnection of battery supplied equipment is delayed on loss of pressurisation.19 Sec.4 Safety Related Technical Requirements Page 19 Gas detection inside the module does not replace the need for gas detection at the air inlet. The air inlet, for ventilation, is the point within the non-hazardous area from which the air is drawn Gas detection system The gas detection system shall be capable of initiating the following actions, either through an integrated control system or in conjunction with the offshore installation: Table 4-8 Gas detection and alarming required actions Cause Effect Low level gas at the air inlet Audible and visible signals in the module Range 10-30% LEL signal to the offshore installation CCR shall be provided. High level gas at the air inlet Range 10-80% LEL The gas detection system shall alarm or shutdown within 10 seconds of detecting of gas at the appropriate level. A set of volt-free contacts for each of the low and high level signals to the offshore installation CCR shall be provided. When a gas detector has been activated, resetting of the gas detection system shall only be possible following manual intervention. The setting of the low and high levels of gas concentration can be adjustable. The levels defined above, for the low level and for the high level, are considered to be suitable ranges. Shelf states may stipulate other standards, e.g. EN 50381, requires high level gas shutdown at 20% LEL. Point detectors shall not be used for air velocities above 12 m/s unless specified as suitable from the detector manufacturer. The gas detection and alarm system shall be active at all times including during periods when power sources within the module are shut down. The local gas alarm station shall be connected to the same source used to supply the offshore installation fire & gas detection system or have a battery backed supply sufficient for 24-hour operation. Should the gas detection system be powered from the offshore installation emergency switchboard the requirement for supply from the battery backed supply can be reduced to 2 hrs. However, the battery supply (transitional power) run time should be confirmed by as being of the same discharge duration as the offshore installation main F&G detection system (when running on battery/ups supply) Fire detection and alarm system audible and visible signals shall be given in the module fans shall be stopped non certified safe equipment inside the module shall be isolated signal to the offshore installation CCR shall be provided fire/gas tight dampers, if fitted, shall be closed Fire detectors and alarm At least one fire detector shall be located in each area of the module which presents a fire risk. This may be omitted in small airlocks which contain only minimal certified safe equipment or no combustible materials. The type of detector shall be selected as the best suitable for early and reliable detection according to the actual fire risk. The fire alarm system shall be designed and installed with certified safe equipment for operation in a zone 1 hazardous area regardless of intended location on the offshore installation.20 Sec.4 Safety Related Technical Requirements Page 20 Table 4-9 Fire detection and alarming required actions Fire Detection Installation Type Cause Effect Module with integral fire alarm system Module without integral fire alarm system Modules fitted with an integral fire alarm system A fire alarm push button connected to the integral fire alarm system shall be mounted at a suitable place on a manned module and shall be marked Fire alarm. The fire alarm system shall initiate actions as defined in Table 4-9. The fire detection and alarm system shall be active at all times including during periods when power sources within the module are shut down. The local fire alarm system shall be connected to the same source used to supply the offshore installation fire & gas detection systems or have a battery based supply sufficient for 24- hour operation. See for suggested alternative solution Modules not equipped with an integral fire alarm system. The fire detector(s) may be connected directly to the offshore installation main fire detection system. In such cases, the module shall be arranged with suitable junction boxes for hook-up to the offshore installation system. Mounting of appropriate types of detectors may be carried out as part of the installation on board. A fire alarm push button shall be mounted at a suitable place on manned module and shall be marked Fire alarm. The push button shall be wired to a suitable junction box for connection to the offshore installation. When the fire detection system has been activated actions in accordance with Table 4-9 shall be initiated by the offshore installation s system Emergency Shutdown Initiated from Offshore Installation The module shall be provided with a means to receive an ESD signal from the offshore installation to isolate all ignition sources. This may be conducted by tripping of supply to the module. All equipment intended to stay energised after an offshore installation shutdown signal shall be certified safe equipment for a zone 1 hazardous area. 4.8 Communications Activated fire alarm by detector or manual pushbutton Activated fire alarm by detector or manual pushbutton Audible and visible signals in/around the module where persons may be present Mechanical ventilation shall be stopped Fire dampers shall close Non certified safe equipment inside the module shall be isolated signal to the offshore installation CCR shall be provided. Offshore installation shall ensure the following occur: Mechanical ventilation to the module shall be stopped Audible and visual alarms in modules where persons may be present. Non certified safe equipment inside the module shall be isolated Module fire dampers will close (on loss of power) Public address and general alarm system (PA/GA) Modules that are manned shall be fitted with loudspeaker(s) that can be connected to the offshore installation s PA/GA system. All equipment for public address and alarm systems shall be certified safe equipment for operation in zone 1 hazardous areas. In modules with noise levels are above 85 dba, the audible alarm shall be supplemented by light signals as per the offshore installation s requirements Telephone / Two way communication All manned modules shall have equipment suitable for effective two way communication with the offshore installation CCR. Telephone systems, if installed, are to be connected via the module emergency shutdown system. Certified safe equipment circuits are to be used for those parts not being shut down. PA/GA Loudspeakers and telephones shall not share the same cable. 4.9 Fire Fighting Modules with equipment considered to be a category A machinery space or accommodation space shall be fitted with a fixed fire-extinguishing system. View more
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