VI
Rules for Classification and Construction
Additional Rules and Guidelines
6
Modular Certification System
2
Guidelines for the Inspection of Mechanical and Electrotechnical Products
Edition 2009
The following Guidelines come into force on 1 August 2009
Germanischer Lloyd Aktiengesellschaft
Head Office
Vorsetzen 35, 20459 Hamburg, Germany
Phone: +49 40 36149-0
Fax: +49 40 36149-200
headoffice@gl-group.com
www.gl-group.com
"General Terms and Conditions" of the respective latest edition will be applicable
(see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys).
Reproduction by printing or photostatic means is only permissible with the consent of
Germanischer Lloyd Aktiengesellschaft.
Published by: Germanischer Lloyd Aktiengesellschaft, Hamburg
Table of Contents
VI - Part 6
GL 2009
Chapter 2
Page 3
Table of Contents
Section 1
A.
B.
Section 2
A.
Section 3
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
General Information
Scope, Application, and Implementation Principles ...................................................................
Definitions ..................................................................................................................................
1- 1
1- 1
Test System
Assignment to Test Modules ......................................................................................................
2- 1
Recognition of the Manufacturer (Test Modules II and III)
General Information ...................................................................................................................
The Certification Process ...........................................................................................................
Documents to be Submitted .......................................................................................................
Assignment of Products ..............................................................................................................
Requirements for the Manufacturer ............................................................................................
Audits .........................................................................................................................................
Additional Tests .........................................................................................................................
Recognition Certificate ..............................................................................................................
Duties of GL ...............................................................................................................................
Duties of the Manufacturer .........................................................................................................
Term of Validity .........................................................................................................................
Renewing Recognition ...............................................................................................................
Suspension or Revocation of Certification .................................................................................
Certification of Test Results .......................................................................................................
Product Marking ........................................................................................................................
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VI - Part 6
GL 2009
Section 1
B
General Information
Chapter 2
Page 1–1
Section 1
General Information
A.
1.
Scope, Application and Implementation
Principles
Scope
These guidelines apply to all products (component
parts, components, equipment, systems, etc.) subject
to mandatory testing according to the Rules for Classification and Construction of Germanischer Lloyd AG
(GL). They may be applied, in conjunction with other
applicable rules, to the inspection of other products as
well.
2.
Application
These guidelines describe the conditions and principles of implementation for the testing of products
subject to mandatory testing and of products for which
testing is requested by the manufacturer. The test
system is divided into four modules. Depending on the
product, a suitable test module (see Section 2) is applied in which the appropriate test and marking procedures are specified.
3.
Implementation principles
Products are tested according to GL's Rules for Classification and Construction. The type of test and the test
procedure are defined by GL according to the technical requirements. Manufacturers may be involved as
to the type, procedure, and implementation of the tests
if the following prerequisites have been satisfied:
–
Component part or component approval, type
test or type approval for the product in accordance with GL's Rules for Classification and
Construction
2.
Recognition certificate
A certificate showing, among other things, the product, the period for which the recognition is valid, and
the relevant documents supporting recognition of the
manufacturer.
3.
Audit
Assessment of how well suited manufacturing and
testing processes are to producing the required product
quality in accordance with GL's Rules for Classification and Construction.
4.
Type approval
Type approval shall include checking of the technical
documents, as well as testing of specimens of the
product. Particular requirements are specified in the
Rules and Guidelines.
5.
Examination of documents
Examination of the documents to be submitted to
verify that they meet the requirements of GL's Rules
for Classification and Construction.
6.
Final inspection
The manufacturer or GL performs all of the required
tests on the final product to verify that the requirements have been met.
7.
Marking
–
Recognition of the manufacturer by GL as per
Section 3
Marking of products and components following an
intermediate or final inspection in accordance with
GL's Rules for Classification and Construction. The
manufacturer may perform marking by special arrangement with GL.
–
A QM system recognized by GL
8.
–
An agreement with GL
A product part consisting of one or more component
parts.
B.
Definitions
For purposes of these guidelines, the following definitions apply:
1.
Recognition
GL certifies that the manufacturer can be involved in
the product testing process.
9.
Component
Product
The result of a manufacturing process, consisting of
one or more components.
10.
Test modules
Products are assigned to test modules. The test module
specifies, among other things, which tests are required
and who is responsible for each test.
Chapter 2
Page 1–2
11.
Section 1
B
General Information
Test certificate
Proof that the product meets GL's requirements.
12.
Products subject to mandatory testing
Products that, under GL's Rules for Classification and
Construction, have to be tested.
13.
Approval of procedures
Approval of procedures such as welding, forging, or
casting in accordance with GL's rules for construction.
VI - Part 6
GL 2009
14.
Material test
Testing to verify the required characteristics of materials. The results of a material test are documented in a
material test certificate.
15.
Intermediate inspection
An inspection of a product's individual components or
of the product as a whole upon completion of individual stages in the production process to verify that the
product or its components meet the requirements.
VI - Part 6
GL 2009
Section 2
A
Test System
Chapter 2
Page 2–1
Section 2
Test System
A.
The test modules include both tests performed by GL
and those performed by the manufacturer.
Assignment to Test Modules
Products subject to mandatory testing are assigned to
test modules as per Table 2.1. For each test module,
Table 2.2 lists the required tests, markings, documentation, requirements, and test certificates, as well as
the entity responsible for their performance or creation.
Table 2.1
GL reserves the right to make product assignments that
differ in certain cases from those shown in Table 2.1.
It remains within the discretion of GL to assign products not included in Table 2.1 to specific test modules.
Assignment of products
Test module
Product
I
Products subject to mandatory type testing and products for which type testing is performed at
the manufacturer's request.
II
All products individually subject to mandatory acceptance inspection and that do not fall under
modules III or IV, and components of products listed under module III.
III
Mass produced engines, main and emergency switchboards, diesel and emergency diesel generators, Class II pressure vessels, components of the power train, transverse thrusters, windlasses, and individual components of products listed under module IV.
IV
Main propulsion engines 1, main and auxiliary boilers, thermal oil heaters, Class I pressure vessels, steering gears.
1 May be assigned to test module III in individual cases.
Table 2.2
Test modules
Test module
I1
II
III

required
QM system recognized by GL
IV
Elements of the test modules
Examination of documents
GL
Approval of procedures
Audit
Material tests
Manufacturer
Manufacturer
or GL
Intermediate tests
Final inspection
Marking
Test Certificate issuance
GL or
as agreed
Manufacturer
Manufacturer or GL
Manufacturer 2
Manufacturer with GLendorsement or GL
GL
1
The procedure for applying Test Module I is described separately in the Guidelines for the Performance of Type Approvals "Procedure"
(VI-7-1).
2
Manufacturer's certificates only.
VI - Part 6
GL 2009
Section 3
B
Recognition of the Manufacturer (Test Modules II and III)
Chapter 2
Page 3–1
Section 3
Recognition of the Manufacturer (Test Modules II and III)
A.
General Information
When test modules II or III are applied, the manufacturer is involved in the performance of the tests. On
B.
The Certification Process
the basis of the recognition process described in B.,
GL authorizes the manufacturer to test products according to GL's Rules for Classification and Construction.
Chapter 2
Page 3–2
C.
Section 3
J
Recognition of the Manufacturer (Test Modules II and III)
Documents to be Submitted
2.
VI - Part 6
GL 2009
Follow-up audit
–
Technical data for the product
Follow-up audits are conducted annually to verify that
the prerequisites for recognition are met. GL reserves
the right to agree follow-up audits at shorter intervals
with the manufacturer.
–
Drawings, details of the materials and proof of
their quality
3.
–
Certification of the QM system (e.g. ISO 9001)
–
Description of the manufacturing processes as
well as of production and test facilities
–
Procedure specifications, work instructions, and
testing instructions for the product's manufacture
To receive product certification from GL, the manufacturer has to submit the following documents:
–
List of designated persons responsible for performing tests on the products and issuing test
certificates
–
Documentation of tests performed.
Further documents to which the manufacturer refers in
his submitted papers have to be made available to GL.
For this purpose it will be agreed whether a submission
to GL or inspection during the audit will be appropriate.
D.
Assignment of Products
If the manufacturer is involved in the tests, the product
is to be suitable for application of test modules II or
III. Test module IV may be applied to all products
subject to mandatory inspection under GL's Rules for
Classification and Construction.
E.
Requirements for the Manufacturer
The manufacturer shall satisfy the following requirements:
–
–
–
The processes, facilities, and skilled personnel
necessary to manufacture and test the products
in compliance with the requirements are to be in
place.
Certification of an adequate quality management
system, e.g., according to ISO 9001. The QM
should be certified by GL. QM systems certified
by other recognized organizations will be accepted.
Equivalent manufacturer-owned systems may be
recognized.
Designation of persons responsible for performing
tests on the products and issuing test certificates
A renewal audit is conducted after three years to renew recognition.
G.
Audits
1.
Initial audit
In the initial audit the manufacturer’s ability to meet
the recognition prerequisites for application of test
modules II and III is verified for the first time.
Additional Tests
GL reserves the right to supplement the audits by
verifying on a random basis that the manufacturer
continues to meet the requirements for recognition,
and to be present during intermediate and final testing.
H.
Recognition Certificate
Recognition of a manufacturer is certified by GL with
a recognition certificate. Such recognition is limited to
the products and product location specified on the
certificate.
I.
Duties of GL
GL is obligated to treat confidentially all information
and documents that the manufacturer entrusts to it.
Records, reports, and documents are preserved for a
period of at least ten years.
J.
Duties of the Manufacturer
1.
Performance of tests
As part of recognition process, the manufacturer shall
properly perform and document all tests prescribed by,
and agreed to in accordance with, GL's Rules for Classification and Construction. Documentation of the
tests shall be archived for a minimum of ten years and
placed at GL's disposal upon request.
2.
F.
Renewal audit
Monitoring the quality management
system
The manufacturer shall regularly review the effectiveness of its QM system through regular internal audits.
If irregularities are discovered, the manufacturer shall
take suitable corrective measures on its own. The
follow-up audits to be conducted by GL do not absolve the manufacturer of this duty.
VI - Part 6
GL 2009
3.
Section 3
O
Recognition of the Manufacturer (Test Modules II and III)
Changes
M.
Chapter 2
Page 3–3
Suspension or Revocation of Certification
The manufacturer is obligated to inform GL of
changes to its QM system or its processes to the extent
that such changes have an effect on the quality of its
products.
GL reserves the right to suspend or revoke its recognition of the manufacturer.
The same applies to changes in:
N.
–
the products' performance data
–
the designated persons
–
the test facilities
–
the test procedure and
GL test certificates shall be issued for products that
have been tested. Depending on the test module, the
test certificates are issued by either the manufacturer
with GL endorsement or GL exclusively. The certificates shall contain at least the following information:
Certification of Test Results
if relevant for classification and certification to
changes of
–
GL test certificate number
–
Product description
–
the design
–
Technical data
–
the manufacturing process
–
Manufacturer's details
–
the supply chain
–
Client
–
Test results
–
A reference to these guidelines
4.
Complaints
If there are complaints about products that are tested
by the manufacturer using test modules II or III, the
manufacturer shall notify GL and disclose the reasons
for the complaints as far as they have an effect to a
safe and reliable operation of the ship.
5.
Assisting the auditors
The manufacturer shall provide the auditors with the
assistance necessary to perform the audits. It shall also
make all relevant parts of its facilities accessible to the
auditors and allow the auditors to examine all relevant
documents to the extent necessary.
K.
Term of Validity
Recognition of the manufacturer for application of test
modules II or III is valid for a period of three years.
The start and end dates of the period of validity are
stated on the recognition certificate.
L.
Renewing Recognition
Upon expiration, recognition of the manufacturer for
application of test modules II or III may be renewed
for another three years. A request for renewal should
be submitted to GL by the manufacturer at least three
months before the recognition expires.
The test and inspection results in particular may be
annexed to the test certificate by way of reports etc.
O.
Product Marking
The manufacturer shall guarantee that all products
tested in connection with test modules II or III are
traceable. These products are to be marked with the
appropriate test certificate number and in a manner
similar to the sample stamp shown in Figure 3.1. A
mark different from that depicted in Figure 3.1 may be
arranged for valid reasons.
<test certificate number and station identifier>
<month>
3
<year>
Fig. 3.1 Example of GL stamp used to mark products tested using test modules II or III
The manufacturer may be provided with a stamp for
marking products. The stamp and stamp image remain
the property of GL and may not be transferred to third
parties. The manufacturer is obligated to ensure that the
stamp is used only for the purpose for which it is intended. After recognition expires, the stamp may no
longer be used and shall be returned to GL immediately.