dnvgl-cp-0483 mass and serial produced engines ... · pdf filednvgl-cp-0483 edition november...

The content of this service document is the subject of intellectual property rights reserved by DNV GL AS ("DNV GL"). The useraccepts that it is prohibited by anyone else but DNV GL and/or its licensees to offer and/or perform classification, certificationand/or verification services, including the issuance of certificates and/or declarations of conformity, wholly or partly, on thebasis of and/or pursuant to this document whether free of charge or chargeable, without DNV GL's prior written consent.DNV GL is not responsible for the consequences arising from any use of this document by others.

The electronic pdf version of this document, available free of chargefrom http://www.dnvgl.com, is the officially binding version.

DNV GL AS

CLASS PROGRAMME

General

DNVGL-CP-0483 Edition November 2016

Mass and serial produced engines -Alternative product certification scheme

FOREWORD

DNV GL class programmes contain procedural and technical requirements including acceptancecriteria for obtaining and retaining certificates for objects and organisations related toclassification.

© DNV GL AS November 2016

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

This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of thisdocument. 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 responsibilityfor loss or damages resulting from any use of this document.

Cha

nges

- c

urre

nt

Class programme — DNVGL-CP-0483. Edition November 2016 Mass and serial produced engines - Alternative product certification scheme

DNV GL AS

CHANGES – CURRENT

This is a new document.

Con

tent

s


DNV GL AS

CONTENTS

Changes – current.................................................................................................. 3

Section 1 General....................................................................................................51 Introduction.........................................................................................52 Objective..............................................................................................53 Scope................................................................................................... 54 Application...........................................................................................55 Request for manufacturing survey arrangement................................. 6

Section 2 Testing and certification of engines in manufacturer’s works..................71 Category A - Mass-produced engines...................................................72 Category B1 - Serial produced engines................................................83 Category B2 - Serial produced engines................................................94 Category B3 - Serial produced engines..............................................10

Section 3 Overview of testing depending on engine category...............................111 General.............................................................................................. 112 Category A engines, bore ≤ 300 mm................................................. 113 Category B1 engines, bore ≤ 300 mm............................................... 124 Category B2 engines, 300 mm < bore ≤ 400 mm.............................. 135 Category B3 engines, bore > 400 mm............................................... 166 DNV GL requirement to be present at the workshop tests................. 19

Changes – historic................................................................................................20

Sec

tion

1


DNV GL AS

SECTION 1 GENERAL

1 IntroductionThe Society’s rules for classification DNVGL-RU-SHIP Pt.1 Ch.1 Sec.4 [2.5] accepts that a manufacturingsurvey arrangement (MSA) may be established with the manufacturer as an alternative to the surveydescribed in the applicable rule chapters when the procedures and processes of a manufacturer's qualitysystem are in compliance with the rules. See DNVGL-CP-0337 Certification of materials and components forgeneral requirements and conditions for establishment of an MSA.

2 ObjectiveThe objective of this programme is to describe an alternative product certification scheme for mass or serialproduced reciprocating internal combustion trunk engines, including the establishment of MSA. Reciprocatinginternal combustion trunk engines are in this programme designated as engines.For engines to be certified based on an MSA established in accordance with DNVGL-CP-0337 and thisprogramme, parts of the Society's verification scope will be based on verification of the manufacturer'squality system and, hence, the manufacturer's ability to control product quality, as an alternative to theSociety attending certain tests as specified in the MSA.Application of an MSA established and maintained in accordance with DNVGL-CP-0337 and this programmerepresents an equivalent way of verifying compliance with DNV GL rules for mass or serial produced engines.

3 ScopeWhen establishing an MSA, the manufacturer and the Society shall agree on the scope of tests that shall becovered by the MSA. This programme gives a maximum scope of tests that may be covered by an MSA formass or serial produced engines, i.e. tests that based on the MSA may be documented with works certificatesas an alternative to VL certificates. See DNVGL-RU-SHIP Pt.1 Ch.3 Sec.5.

4 Application

4.1 Type approvalAn MSA will cover specific engine types/engine series. A condition for MSA of mass or serial produced enginesis that the engine types to be covered by the MSA are type approved. See DNVGL-RU-SHIP Pt.4 Ch.3 Sec.1for requirements regarding type approval and drawings/documentation subject to approval.

4.2 Mass production and categories of enginesThis programme may be applied for MSA of engines produced in mass or in series. The MSA will cover eithermass or serially produced engines within the following categories:

Category A – Engines with cylinder bore of ≤ 300 mm and produced in mass.

Category B – Engines produced in series.

Category B1 – Engines with a bore of ≤ 300 mm

Category B2 – Engines with a bore of > 300 mm and ≤ 400 mm

Category B3 – Engines with a bore of > 400 mm

Sec

tion

1


DNV GL AS

For the purpose of this programme, mass or serial production of engines is defined as follows:

— The materials and components used are manufactured in compliance with all the production and qualitycontrols specified by the engine manufacturer and recognized by DNV GL.

— The engine components shall be manufactured on machining units which have been specially adjusted forthat purpose and for which are subjected to the inspections necessary to ensure quality assurance.

— The engine components shall completely satisfy the engine manufacturer's quality requirements, shall beinterchangeable and shall be able to be fitted without reworking or adaptation.

— Category A – Mass produced engines:

— The engine type is produced in a considerable number where normal production often is for otherapplications than the marine use and that engines for DNV GL class are randomly taken from theproduction.

— Category B – Serially produced engines:

— The engine type is produced mainly for the marine application, normally not to stock, but for specificprojects.

DNV GL will decide which engine types/engine series meet the requirements for the application of thisprogramme.

4.3 Components supplied by subcontractorsComponents supplied by subcontractors and castings and forgings which are used in the manufacture of, oras spare parts for engines of category A and category B shall be manufactured in the same way as describedin [4.2]. The inspections necessary for quality assurance shall comply with the agreed MSA.

5 Request for manufacturing survey arrangementRequest for MSA for an engine type/engine series shall be submitted to the Society by the enginemanufacturer. The application form may be obtained by contacting the local DNV GL office.

Sec

tion

2


DNV GL AS

SECTION 2 TESTING AND CERTIFICATION OF ENGINES INMANUFACTURER’S WORKS

1 Category A - Mass-produced enginesThis sub-section specifies requirements for testing of category A engines to be installed onboard DNV GLclassed vessels and produced in accordance with an agreed MSA.

1.1 Component testsAll testing of components as defined in the DNV GL rules, may be documented with test report (TR). Thesecomponents shall be marked with evidence of the tests applied. Stamping of individual components by DNVGL is not required. Details are defined in Sec.3 Table 1.

1.1.1 For tests of the materials of crankshaft, connecting rods and crankshaft bolts, the certificate (accordingto ISO 10474/EN 10204 – 3.1) completed by the works shall be prepared and filed for later assessment byDNV GL. The certificate shall indicate the requirements and the actual test results. It shall be possible toidentify the components by reference to the certificate. Validation of certificates by DNV GL is not required.

1.1.2 The engine manufacturer shall ensure that the spares and stock parts subject to mandatory inspectionconform to the current rules. The manufacturer shall mark the parts so that they can be recognized asoriginal spares. Stamping of individual components by DNV GL is not required.

1.2 Workshop test

1.2.1 Engines to be installed onboard DNV GL classed vessels are subject to a workshop test according toDNVGL-RU-SHIP Pt.4 Ch.3 Sec.1 [4]. Exceptions shall be agreed upon with DNV GL.

1.2.2 DNV GL reserves the right to require a special test program according to the character of theinstallation.

1.2.3 For main engines and the prime movers of electric generators the rated power shall be verified asminimum power.

1.2.4 DNV GL does not need to be present during the workshop test.

1.3 Engine documents to be available at the manufacturerThe following documents shall be made available for later assessment by DNV GL:

— the engine manufacturer's confirmation that the engine subject to certification meets the enginemanufacturer's quality requirements on which the MSA is based

— certificates for testing of crankshaft, connecting rod and crankshaft bolt material— workshop test acceptance protocol validated by the engine manufacturer.

1.4 Engine certification1.4.1 Engines below 300 kWProduct certification is not required for engines below 300 kW. A copy of the type approval certificate (TA)and the workshop test report will be sufficient.

1.4.2 Engines above 300 kWMass produced engines above 300 kW shall be certified by DNV GL according to the agreed MSA.

Sec

tion

2


DNV GL AS

2 Category B1 - Serial produced enginesThis sub-section describes the minimum requirements for testing of category B1 engines to be installedonboard DNV GL classed vessels and produced in accordance with an agreed MSA.

2.1 Component testsAll testing of components as defined in the DNV GL rules, except crankshaft and connecting rod forgings,may be documented with works certificates. These components shall be marked with evidence of the testsapplied. Stamping of individual components by DNV GL is not required. Details are defined in Sec.3 Table 2.

2.1.1 All works certificates shall be prepared and filed for later assessment by DNV GL. The certificates shallindicate test results. It shall be possible to identify the components by reference to the certificate. Validationof certificates by DNV GL is not required.


2.2 Workshop tests




2.2.4 DNV GL attendance at workshop testing of engines shall be agreed upon in the MSA.

2.3 Engine documents to be available at the manufacturerThe following documents shall be made available for later assessment by DNV GL:


— reports and works certificates— workshop test acceptance protocol validated by the engine manufacturer.

2.4 Engine certification2.4.1 Engines below 300 kWProduct certification is not required for engines below 300 kW. A copy of the type approval certificate (TA)and the workshop test report (TR) will be sufficient.

2.4.2 Engines above 300 kWSerial produced engines of category B1 and above 300 kW shall be certified by DNV GL.

Sec

tion

2


DNV GL AS

3 Category B2 - Serial produced enginesThis subsection describes the minimum of requirements for testing of category B2 engines to be installedonboard DNV GL classed vessels and produced in accordance with an agreed MSA.

3.1 Component testsAll testing of components as defined in the DNV GL rules, except crankshaft and connecting rod forgings,may be documented with works certificate. These components shall be marked with evidence of the testsapplied. Stamping of individual components by DNV GL is not required. Details are defined in Sec.3 Table 3.



3.2 Workshop tests




3.2.4 DNV GL shall be present during the workshop test of propulsion engines. Attendance at workshoptesting of auxiliary engines shall be agreed upon in the MSA.

3.3 Engine documents to be available at the manufacturerThe following documents shall be made available for assessment by DNV GL during the workshop test:



3.4 Engine certificationSerial produced engines of category B2 shall be certified by DNV GL.

Sec

tion

2


DNV GL AS

4 Category B3 - Serial produced enginesThis subsection describes the minimum of requirements for testing of category B3 engines to be installedonboard DNV GL classed vessels and produced in accordance with an agreed MSA.

4.1 Component testsAll testing of components as defined in the DNV GL rules, except crankshafts and connecting rod forgings,may be documented with works certificates. These components shall be marked with evidence of the testsapplied. Stamping of individual components by DNV GL is not required. Details are defined in Sec.3 Table 4.



4.2 Workshop tests

4.2.1 Engines to be installed onboard DNV GL classed vessels are subject to a workshop test according toDNVGL-RU-SHIP Pt.4 Ch.3 Sec.1 [4]. Exceptions to be agreed upon with DNV GL.



4.2.4 DNV GL shall be present during the workshop test of all engines.

4.3 Engine documents to be available at the manufacturerThe following documents shall be made available for assessment by DNV GL during the workshop test:



4.4 Engine certificationSerial produced engines of category B3 shall be certified by DNV GL.

Sec

tion

3


DNV GL AS

SECTION 3 OVERVIEW OF TESTING DEPENDING ON ENGINECATEGORY

1 GeneralThe information given in this section is for information and is intended to make the development of MSAsmore easy and efficient.Testing of components depends on engine size and production arrangements. Testing of components shall asa minimum be carried out according to the following tables. Agreements shall be clearly stated in the MSA.

2 Category A engines, bore ≤ 300 mmComponents of category A engines shall be subject to testing and certification as follows:

Table 1 Certificates required for category A engines

Object Additional description Certificate type Issued by Certificationstandard*

Component certificate TR

C+M

UT+CDCrankshaft

Dimensional control

3.1Manufacturer ISO 10474/

EN 10204


C+M

UT+CDConnecting rod with cap

Dimensional control


EN 10204


C+M

UT+CDCoupling bolts for crankshaft

Dimensional control


EN 10204

C+MAccumulator of common railfuel or servo oil systemAll engines with accumulatorswith a capacity of > 0.5 l

Pressure testing3.1 Manufacturer

ISO 10474/EN 10204

High pressure fuel injectionpump body Hydraulic testing 3.1 Manufacturer

ISO 10474/EN 10204

High pressure fuel injectionvalves (only for not auto-fretted)

Hydraulic testing 3.1 ManufacturerISO 10474/EN 10204

Turbocharger Component certificate 3.1 ManufacturerISO 10474/EN 10204

Torsional vibration damper Component certificate 3.1 ManufacturerISO 10474/EN 10204

Sec

tion

3


DNV GL AS

Object Additional description Certificate type Issued by Certificationstandard*

*Unless otherwise specified the certification standard is DNV GL rules.

C – Chemical composition M – Mechanical properties

UT – Ultrasonic testing CD – Crack detection by MPI or DP

TR = Test report issued by the manufacturer based on the DNV GL rules (see DNVGL-RU-SHIP Pt.1 Ch.3 Sec.5 [2]).

3 Category B1 engines, bore ≤ 300 mmComponents of category B1 engines shall be subject to testing and certification as follows:

Table 2 Certificates required for category B1 engines

Object Additional description Certificate type Issued by

Component certificate VL Society

C+M W Manufacturer

UT+CD NDT report ManufacturerCrankshaft

Dimensional control W Manufacturer


C+M W Manufacturer

UT+CD NDT report ManufacturerConnecting rod with cap


Component certificate W Manufacturer

C+M W Manufacturer

UT+CD NDT report ManufacturerCoupling bolts for crankshaft


C+M W ManufacturerAccumulator of common rail fuel orservo oil systemAll engines with accumulators with acapacity of > 0.5 l

Hydraulic testing 1) W Manufacturer

High pressure fuel injection pumpbody

Hydraulic testing 1) TR Manufacturer

High pressure fuel injection valves(only for not auto-fretted)

Hydraulic testing 1) TR Manufacturer

Turbocharger


Torsional vibration damper

Design to be type approved TA Society

Sec

tion

3


DNV GL AS


C+M = Material properties including chemical composition and mechanical properties. It includes also surface hardening(hardness, depth and extent), peening and rolling (extent and applied force).

NDT report = Non-destructive test report (see DNVGL-RU-SHIP Pt.1 Ch.3 Sec.5 [2]). Non destructive examination meanse.g. ultrasonic testing, crack detection by MPI or DP.

VL = Product certificate issued by the Society based on the DNV GL rules (see DNVGL-RU-SHIP Pt.1 Ch.3 Sec.5 [2]).

W = Works certificate issued by the manufacturer based on the DNV GL rules (see DNVGL-RU-SHIP Pt.1 Ch.3 Sec.5 [2]).


TA = DNV GL type approval certificate issued by the Society (see DNVGL-RU-SHIP Pt.1 Ch.3 Sec.5 [2]).

1) Hydraulic testing shall be applied on the water/oil side of the component equal to 1.5 times the maximum workingpressure. High pressure parts of the fuel injection system shall be tested at pressure equal to 1.5 maximum workingpressure or maximum working pressure plus 300 bar, whichever is the less. Where design or testing features mayrequire modification of these test requirements, special consideration may be given. Dimensional control includessurface condition.

4 Category B2 engines, 300 mm < bore ≤ 400 mmComponents of category B2 engines shall be subject to testing and certification as follows:




C+M W ManufacturerWelded bedplate

UT+CD NDT report Manufacturer


C+M W ManufacturerBearing transverse girders cast steel



C+M W ManufacturerWelded frame box


Component certificate W Society

C+M W Manufacturer




C+M W Manufacturer



Sec

tion

3


DNV GL AS



C+M W Manufacturer



C+M W ManufacturerAccumulator of common rail fuel orservo oil systemAll engines with accumulators with acapacity of > 0.5 l


High pressure fuel injection pumpbody Hydraulic testing 2) W Manufacturer

High pressure fuel injection valves(only for not auto-fretted) Hydraulic testing 2) W Manufacturer

C+M W ManufacturerCylinder liner



C+M W Manufacturer

UT+CD NDT Report ManufacturerCylinder head, cast steel

Pressure testing W Manufacturer

Cylinder head, nodular cast-/lamellar cast iron Hydraulic testing 2) W Manufacturer


C+M W Manufacturer

UT+CD NDT report ManufacturerForged cylinder head


C+M W ManufacturerBolts and studs for main bearings


C+M W ManufacturerBolts and studs for cylinder heads


C+M W Manufacturer

UT+CD NDT report ManufacturerBolts and studs for connecting rods

Thread making TR report Manufacturer

C+M W ManufacturerHigh pressure fuel injection pipesincluding common fuel rail Hydraulic testing 2)

for those that are not auto-frettedW Manufacturer

C+M W ManufacturerHigh pressure common servo oilsystem Hydraulic testing 2) W Manufacturer

Sec

tion

3


DNV GL AS


C+M W ManufacturerCooler, both sides 1)


P ≥ 400 kW/cyl

Engine block, lamellar cast iron Hydraulic testing 2) W Manufacturer

M W ManufacturerEngine block, nodular cast iron


P ≥ 800 kW/cyl

C+M W ManufacturerPiping, pumps, actuators, etc.for hydraulic drive of valves, ifapplicable Hydraulic testing 2) W Manufacturer

Engine driven pumps (oil, water,fuel, bilge) Hydraulic testing 2) W Manufacturer

C TR Manufacturer

UT (for full contact between basicmaterial and bearing metal) TR ManufacturerBearings for main and crankpin


Turbocharger Component certifcate VL Society

Torsional vibration damper Design to be type approved TA Society







1) Charge air cooler need only be tested on the water side2) Hydraulic testing shall be applied on the water/oil side of the component equal to 1.5 times the maximum working

pressure. High pressure parts of the fuel injection system shall be tested at pressure equal to 1.5 maximum workingpressure or maximum working pressure plus 300 bar, whichever is the less. Where design or testing features mayrequire modification of these test requirements, special consideration may be given. Dimensional control includessurface condition.

Sec

tion

3


DNV GL AS

5 Category B3 engines, bore > 400 mmComponents of category B3 engines shall as a minimum be subject to certification as follows:




C+M W ManufacturerWelded bedplate



C+M W ManufacturerBearing transverse girders, caststeel



C+M W ManufacturerWelded frame box



C+M W Manufacturer




C+M W Manufacturer




C+M W Manufacturer



C+M W ManufacturerAccumulator of common rail fuel orservo oil system

All engines with accumulators with acapacity of > 0.5 l


C+M W ManufacturerCylinder liner


Component certificate W ManufacturerCylinder head, cast steel

C+M W Manufacturer

Sec

tion

3


DNV GL AS




Cylinder head, nodular cast-/lamellar cast iron



C+M W Manufacturer

UT+CD NDT report ManufacturerCylinder head, forged


C+M W ManufacturerBolts and studs for main bearings


C+M W ManufacturerBolts and studs for cylinder heads


C+M W Manufacturer

UT+CD NDT report ManufacturerBolts and studs for connecting rods

Thread making TR report Manufacturer

C+M W ManufacturerHigh pressure fuel injection pipesincluding common fuel rail Hydraulic testing 2),

for those that are not auto-frettedW Manufacturer

C+M W ManufacturerHigh pressure common servo oilsystem Hydraulic testing 2) W Manufacturer

C+M W ManufacturerCooler, both sides 1)



C+M W ManufacturerPiston crown, cast steel



C+M W ManufacturerForged piston crown


P ≥ 400 kW/cyl

Engine block, lammelar cast iron


M W ManufacturerEngine block, nodular cast iron


Sec

tion

3


DNV GL AS


P ≥ 800 kW/cyl

C+M W ManufacturerPiping, pumps, actuators, etc.for hydraulic drive of valves, ifapplicable Hydraulic testing 2) W Manufacturer

Engine driven pumps (oil, water,fuel, bilge) Hydraulic testing 2) W Manufacturer

C TR Manufacturer

UT (for full contact between basicmaterial and bearing metal) TR ManufacturerBearings for main and crankpin


Turbocharger Component certificate VL Sociaty

Torsional vibration damper Design to be type approved TA Society







1) Charge air cooler need only be tested on the water side2) Hydraulic testing shall be applied on the water/oil side of the component equal to 1.5 times the maximum working

pressure. High pressure parts of the fuel injection system shall be tested at pressure equal to 1.5 maximum workingpressure or maximum working pressure plus 300 bar, whichever is the less. Where design or testing features mayrequire modification of these test requirements, special consideration may be given. Dimensional control includessurface condition.

Sec

tion

3


DNV GL AS

6 DNV GL requirement to be present at the workshop testsDNV GL requires to be present at the workshop test depending on the engine size and application. Table 5shows the minimum requirement and should be used as guidance. Final agreement shall be agreed upon inthe MSA.

Table 5 DNV GL attendance at workshop tests

Engine size Mass produced engines Serial produced engine

P ≤ 300 kW Attendence not required Attendance not required

P > 300 kW and D < 300 mm Attendance not required Attendance shall be agreed upon

300 mm < D ≤ 400 mm Not applicableProp. engines to be attendedAux. engine to be agreed upon

D > 400 mm Not applicable All engines to be attended

D = cylinder bore diameter (mm)

Cha

nges

– h

isto

ric


DNV GL AS

CHANGES – HISTORICThere are currently no historical changes for this document.

DNV GLDriven by our purpose of safeguarding life, property and the environment, DNV GL enablesorganizations to advance the safety and sustainability of their business. We provide classification andtechnical 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 widerange of industries. Operating in more than 100 countries, our 16 000 professionals are dedicated tohelping our customers make the world safer, smarter and greener.

SAFER, SMARTER, GREENER

dnvgl-cp-0483 mass and serial produced engines ... · pdf filednvgl-cp-0483 edition november...

Documents