1085V002 Statement of Required Tests Small Shear Block Disposal Container 773 SOT Attachment 4.docx

Statement of Required Tests – Small Shear Block Disposal Container Per Portsmouth Naval Shipyard Drawing 2370A0000389, REV ORIG

1. WELDING REQUIREMENTS:

1.1. WELD SIZES IN THIS DRAWING ARE MINIMUM ACCEPTABLE. MINIMUM BEVEL ANGLE ON ALL BEVEL WELDS IS 45-DEGREES PER SINGLE BEVEL GROOVE.

1.2. WELDING SHALL BE PERFORMED TO REFERENCE A BY QUALIFIED WELDERS.

1.3. CORNERS MAY BE CHAMFERED TO CLEAR FILLETS OF PREVIOUSLY DEPOSITED WELDS. CLOSE THESE CHAMFERS BY WELDING WHERE POSSIBLE.

1.4. WELDS SHALL BE SEQUENCED TO MINIMIZE DISTORTION. WHERE DISTORTION DOES OCCUR, STRAIGHTENING PER REFERENCE A SHALL BE PERFORMED TO ACHIEVE TOLERANCES OF THE DRAWING.

1.5. VISUALLY INSPECT ALL WELDS ACCORDING TO REFERENCE A.

1.6. PERFORM A MAGNETIC PARTICLE TEST (MT) INSPECTION OF THE SPECIFIED WELDS (SPECIFIED IN NOTE 10B) PER REFERENCE C. USE THE ACCEPTANCE CRITERIA OF REFERENCE D CLASS 3 FOR WELDS AND FORGINGS/WROUGHT MATERIAL FOR BASE MATERIAL.

2. SAFETY HOIST RING LOAD TEST REQUIREMENTS:

THE 1/2-13 UNC-2B SAFETY HOIST RING LIFT HOLE (IN THE TOP, PC 4) IS PROVIDED FOR LIFTING AND HANDLING. PROOF TEST VALUES ARE FOR A WORKING LOAD LIMIT (WLL) OF 2,500 LBS.

TORQUE-BASED PROOF TEST OF SAFETY HOIST RING HOLES:

2.1. OBTAIN A SOCKET HEAD CAP SCREW (UNC-2A OR UNC-3A, ASTM A574 OR ASME B18.3, 1/2"-13 UNC, MINIMUM 2.00" SHANK LENGTH (EXCLUDING HEAD) FULLY THREADED, HEAVY HEX NUT (ASTM A194/A194M GRADE 2H, UNC-2B, 1/2"-13) AND A HARDENED WASHER (TO FIT THE 1/2"-13 CAP SCREW, ASTM F436, TYPE 1, CIRCULAR).

2.2. THREAD THE NUT ONTO THE CAP SCREW UNTIL THE LEADING SURFACE OF THE NUT IS AT THE REQUIRED LENGTH OF THREAD ENGAGEMENT (0.78 +0.00/-0.04 INCHES FOR THE 1/2"-13 CAP SCREW). THE TOLERANCE ON THREAD ENGAGEMENT IS +5/-0% WITH A MINIMUM TOLERANCE OF 1/32 INCH (SEE FIGURE 1).

2.3. APPLY MOLYKOTE P37 (OR EQUIVALENT) LUBRICANT TO THE THREADS ABOVE AND STARTING AT THE LEADING SURFACE OF THE NUT (SEE FIGURE 1). THREAD THE NUT FULLY ONTO THE LUBRICATED THREADS OF THE CAP SCREW AND APPLY LUBRICANT TO THE TRAILING SURFACE OF THE NUT. DO NOT LUBRICATE THE LOWER CAP SCREW THREADS. IN THIS ARRANGEMENT, ONLY THE PORTION OF THE THREADS ON THE CAP SCREW THAT ENGAGE THE NUT ARE LUBRICATED. THE CAP SCREW THREADS THAT ENGAGE THE TAPPED HOLE OF THE COMPONENT ARE NOT LUBRICATED.

2.4. INSPECT THE LIFT HOLE THREADS FOR LUBRICATION, DIRT AND DEBRIS. CLEAN AS NECESSARY (REMOVING ALL LUBRICATION, DIRT, AND DEBRIS). INSTALL THE PROOF TEST ASSEMBLY (CAP SCREW, NUT AND WASHER) INTO THE TAPPED HOLE TO THE REQUIRED DEPTH OF THREAD ENGAGEMENT OF 0.78 +0.00/-0.04 INCHES FOR THE 1/2"-13 CAP SCREW (SEE FIGURE 1).

2.5. WHILE RESTRAINING THE CAP SCREW, TORQUE THE NUT TO 28 +1/-0 FT-LBS (THE TOLERANCE IS +5/-0%). RE-CHECK THE TORQUE ON THE NUT.

2.6. AFTER TEN MINUTES, REMOVE THE PROOF TEST ASSEMBLY. REMOVE ANY TRANSFERRED LUBRICANT (1X VISUAL CONFIRMATION OF REMOVAL REQUIRED) FROM THE TAPPED HOLE AND SURROUNDING SURFACES AT THE COMPLETION OF PROOF TESTING.

2.7. PRIOR TO AND AFTER PROOF TEST, VISUALLY (1X) INSPECT THE TOP (PC 4) FOR SIGNS OF DEFORMATION, CRACKS, OR DAMAGE THAT MAY AFFECT THE LIFTING CAPACITY OF THE THREADED HOLE.

2.8. PERFORM A 2B "GO/NO-GO" GAGE CHECK OF THE THREADED HOIST RING HOLE IN THE TOP (PC 4). THE "GO" GAGE ACCEPTANCE CRITERIA IS THAT THE GO GAGE CAN BE FULLY INSERTED INTO THE THREADED HOLE. THE "NO-GO" GAGE ACCEPTANCE CRITERIA IS THAT THE NO-GO GAGE DOES NOT ENTER THE THREADED HOLE MORE THAN THREE COMPLETE TURNS.

2.9. PRIOR TO AND AFTER PROOF TEST, PERFORM A MAGNETIC PARTICLE TEST (MT) INSPECTION PER REFERENCE C OF THE SPECIFIED PORTION OF THE TOP PLATE (PC 4) SHOWN ON SHEET 8. USE THE ACCEPTANCE CRITERIA OF REFERENCE D CLASS 3 FOR WELDS AND FORGING/WROUGHT MATERIAL FOR BASE MATERIAL.

2.10. PROVIDE WRITTEN DOCUMENTATION THAT THE ABOVE PROOF TEST AND NDT REQUIREMENTS WERE SATISFACTORILY PERFORMED.

2.11. FOLLOWING SATISFACTORY COMPLETION OF PROOF TEST, PERMANENTLY MARK LOAD TEST INFORMATION IN THE AREA INDICATED ON SHEET 8. ENSURE THAT THE MARKING WILL NOT INTERFERE WITH SAFETY HOIST RING INSTALLATION. MARK THE HOLE WITH THE FOLLOWING:

"FOR LIFTING OF LID ONLY

SPS CAPACTIY: 300 LBS.

LOAD TEST/ NDT DUE DATE: N/A, SF 10

LID NUMBER 'XX'"

WHERE 'XX' IS THE UNIQUE SERIAL NUMBER MATCHING THE LID TO THE SPECIFIC CONTAINER.

3. LIFTING LUG LOAD TESTING REQUIREMENTS:

THE TWO LIFTING LUGS (PC 5) THAT ARE WELDED TO THE SIDES OF THE CONTAINER ARE TO BE LOAD TESTED USING A VERTICAL TENSION LOAD. THE LOAD TEST VALUES ARE FOR A WORKING LOAD LIMIT (WLL) OF 2,400 LBS. EACH.

3.1. PRIOR TO AND AFTER PERFORMING THE LOAD TEST, PERFORM A VT (VISUAL TEST) INSPECTION OF THE ATTACHMENT WELDS OF EACH LIFT LUG (PC 5), THE ACCESSIBLE BASE METAL OF EACH LIFT LUG (PC 5), THE SURROUNDING BASE METAL OF THE CONTAINER WALL (PC 2), THE WELDS ATTACHING THE WALLS (PC 2), THE WELDS ATTACHING THE WALLS (PC 2) TO THE BASE (PC 1), AND THE EXTERIOR WELDS ATTACHING THE WALLS (PC 2) TO THE FLANGE (PC 3). ENSURE THERE IS NO APPARENT DEFORMATION, CRACKS, OR OTHER APPARENT DAMAGE OF THESE LOAD BEARING PARTS.

3.2. PRIOR TO AND AFTER THE LOAD TEST, PERFORM A MT (MAGNETIC PARTICLE) TEST INSPECTION OF THE ATTACHMENT WELDS OF EACH LIFT LUG (PC 5), THE ACCESSIBLE BASE METAL OF EACH LIFT LUG (PC 5), THE WELDS ATTACHING THE WALLS (PC 2 TO PC 2), THE WELDS ATTACHING THE WALLS (PC 2) TO THE BASE (PC 1), THE EXTERIOR WELDS ATTACHING THE WALLS (PC 2) TO FLANGE (PC 3) PER REFERENCE C. USE THE ACCEPTANCE CRITERIA OF REFERENCE D, CLASS 3 FOR WELDS AND FORGINGS/WROUGHT MATERIAL FOR BASE METAL.

3.3. PROOF LOAD TEST THE LIFT LUGS (PC 5) AS FOLLOWS: RESTRAIN THE SBDC OR USE TEST WEIGHTS AS NECESSARY TO TEST BOTH PADEYES SIMULTANEOUSLY TO 7,775 LBS (150% LOAD TEST) UP TO 8,164 LBS (155% LOAD TEST). THE LOAD TEST PLAN IS SHOWN IN FIGURE 2 (SHEET 10). HOLD THE TEST LOAD FOR A MINIMUM OF 10 MINUTES.

3.4. FOLLOWING SATISFACTORY COMPLETION OF THE LOAD TEST, DOCUMENT AND PROVIDE WRITTEN CERTIFICATION OF LOAD TESTING, VT INSPECTION TESTS, AND MT INSPECTION TESTS (INCLUDE THE TEST DATES). ENSURE DOCUMENTATION CLEARLY SPECIFIES PERFOMANCE OF "PRE" AND "POST" LOAD TESTING INSPECTIONS, INSPECTION METHODS USED, ACCEPTANCE CRITERIA USED, AND ITEMS (PIECES, AREAS, AND WELDS) THAT WERE INSPECTED.

3.5. CONTRACTOR(S) PERFORMING NDT PROCEDURES IN ACCORDANCE WITH NAVSEA PUBLICATION T9074-AS-GIB-010/271 (REFERENCE C) ARE REQUIRED TO DEVELOP AND MAINTAIN A WRITTEN PROCEDURE THAT HAS BEEN QUALIFIED TO MEET THE REQUIREMENTS OF NAVSEA PUBLICATION T9074-AS-GIB-010/271. A COPY OF THE QUALIFIED PROCEDURE SHALL BE INCLUDED WITH THE NDT DOCUMENTATION REQUIRED BY THIS DRAWING (FOR ENGINEERING REVIEW).

3.6. FOLLOWING SATISFACTORY COMPLETION OF LOAD TESTING, PERMANENTLY MARK ADJACENT TO EACH OF THE LIFT LUGS (PC 5) AS SHOWN ON SHEET 5. MARK THE CONTAINERS WITH THE FOLLOWING:

"SPS CAPACITY: 2,400 LBS

LOAD TEST/NDT DUE DATE: N/A SF 10

UNLOADED WEIGHT = X,XXX LBS (RECORDED IN NOTE 8)

MAX LOADED WEIGHT = 4,000 LBS.

MIN SLING LENGTH 2 FT.

CONTAINER NUMBER XX"

WHERE XX IS THE UNIQUE SERIAL NUMBER OF THE CONTAINER MATCHING THE LID AND LOAD TEST CERTIFICATION PAPERWORK.

REFERENCES:

A. AWS D1.1/D1.1M; Structural Welding Code B. AWS A2.4; Standard symbols for welding, brazing and nondestructive examination C. NAVSEA Technical Publication T9074-AS-GIB-010/271; Requirements for nondestructive testing methods D. MIL-STD-2035; Nondestructive testing acceptance criteria.