2.1 PWS Mako BACs.pdf

AUXILIARY MACHINERY

PWS CATEGORY "A"

SCBA COMPRESSOR REFURBISH

0563A - 1

1.0 ABSTRACT

The purpose of this item is to inspect, service, test, and certify the Self-Contained Breathing Apparatus (SCBA)

Compressor

2.0 REFERENCES

2.1 NAVSEA Manual T6220-B1-MMC-010, Operation and

Maintenance, Breathing Air Quality Compressor and

Refilling Station

2.2 NFPA 1989, Standard on Breathing Air Quality for

Emergency Services Respiratory Protection (Available

Commercially)

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Locations: Contractor Facility

3.1.2 Quantity: Two SCBA Compressors

3.2 Item Description/Manufacturer’s Data:

3.2.1 SCBA Compressor

Mfr: MAKO Co.

Model No: 9400E3MSC (5,000 psi, 12.9 cfm)

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE: None

5.0 NOTES

5.1 None

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

7.0 STATEMENT OF WORK REQUIRED

7.1 Inspect, service, test, and certify the Self-Contained

Breathing Apparatus (SCBA) Compressor identified in

0563A - 2 para. 3.0, using References 2.1 and 2.2 as guidance.

Accomplish all tasks in accordance with the

Manufacturer’s requirements.

7.2 Conduct an inspection of the SCBA Compressor to meet

the manufacturer’s design, installation, maintenance instructions and service bulletin requirements. The inspection must encompass the entire system with particular attention to the following:

7.2.1 Conduct a visual inspection of the system

including: operator’s panel, compressor, purification system, motor, hour meter, fuses, gauges, controls, all labels and plates such as caution, warning and instruction placards, alarms, cooling systems, condensate traps and drains, pneumatic piping, hoses, pressure maintaining valve, pressure regulator, relief valves, valves and fittings.

7.2.2 Verify no unauthorized alterations have been

made to the system and components.

7.2.3 Verify a WARNING label is installed at the

purification chamber, instructing: Prior to changing purifier cartridges, performing service or maintenance, to release all air pressure in the compressor system.

7.2.4 Inspect purification and moisture separator

chambers and ensure that the anodizing is intact and there is no sign of surface corrosion

7.2.5 Inspect the audible and visual alarms and any

controls that shut down the compressor:

a. Carbon Monoxide (CO) Alarm.

b. Discharge Air High Temperature Alarm.

c. Low Oil Level and Low Oil Pressure Alarm.

d. Moisture in the compressed air at the

0563A - 3

Purification System Outlet.

e. Compressor Compartment High Temperature Alarm.

f. Inclination alarm.

7.2.6 Inspect the panel gauges and pressure relief

valves. Verify and document the calibration date.

7.2.7 Inspection of any optional accessories and

components must meet the manufacturer’s design, installation, maintenance instructions, and service bulletin requirements. Include the following:

a. Verify complete assembly of components.

b. Conduct assessment of wear and damage.

c. Verify all operating modes are inspected for proper functionality.

7.3 Conduct annual maintenance on the SCBA Compressor to

meet the manufacturer’s design, installation, maintenance instructions, and service bulletin requirements. The maintenance includes/verifies:

7.3.1 Perform all manufacturer’s recommended hourly-

based maintenance, appropriate for the machine’s current running hours, using Reference 2.1 for guidance.

7.3.2 Verify all operating fluids, including lubricant

and coolant, are at the manufacturer’s recommended levels.

7.3.3 Drain the crankcase and replace the oil and oil

filters using Reference 2.1 as guidance.

7.3.4 Inspect the condition of the drive belts

including the alignment and tension.

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7.3.5 Verify the expiration dates of the purification

cartridges and filters.

7.3.6 Lubricate all parts.

7.4 Conduct testing of the SCBA Compressor to meet the

manufacturer’s design, installation, maintenance instructions and service bulletin requirements.

Coordinate testing with MSCREP. The testing includes the following:

7.4.1 Conduct a one-hour functional performance test

of the SCBA Compressor. The test is to include the following:

a. Verify proper operation using Reference 2.1 as guidance.

b. Verify inter-stage pressures are within the manufacturer’s specifications.

c. Verify proper operation of all audible and visual alarms.

d. Verify proper operation of all shutdowns.

e. Verify set point of the Pressure Relief Valve.

f. Verify set point of the Pressure Maintaining and Regulator Valves.

g. Verify proper operation of the Emergency Stop.

7.4.2 Draw an air sample and submit it to an

accredited laboratory for air quality testing using Reference 2.2 as guidance. The breathing air must be tested for:

a. Oxygen Content

b. Carbon Monoxide Content

c. Carbon Dioxide Content

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d. Condensed Oil and Particulate Content

e. Water Content

f. Non-methane Volatile Organic Compounds (VOC) Content

g. Nitrogen Content

h. Odor

7.5 Compressed, gaseous breathing air must meet the

requirements for breathing air specified in Reference

2.2.

7.6 Following testing, set the unit up for long term

storage by removing the cartridge filter and placing a drying agent (desiccant) in the purification and in the final separator chamber. Mark the chambers with a sign that reads “Desiccant inside, remove before commissioning”

7.7 Upon completion of all inspections, tests and repairs, certify the SCBA Compressor as Ready for Issue condition.

7.8 Reports

7.8.1 Submit one electronic copy in Portable Document

Format (PDF) of the examination, servicing, and certification report for the SCBA to the MSCREP and ship’s Master upon completion of testing.

7.8.2 Submit one electronic copy in Portable Document

Format (PDF) of the Air Quality Sample results to the MSCREP. All certificates are to be signed by the manufacturer’s representative (or authorized technical representative) performing the test at the accredited laboratory.

7.8.3 When inspections, maintenance, servicing and

testing reveal any deficiency, a condition report is to be submitted to the MSCREP with

0563A - 6 recommended repairs and parts required. Submit one electronic copy in Portable Document Format

(PDF).

7.8.4 Upon completion of all inspections, maintenance, servicing, and testing, prepare and submit a typewritten Service Report documenting the final

“as released” condition of the SCBA Compressor affirming they are safe for use. Submit one electronic copy in Portable Document Format

(PDF).

7.8.5 All reports and checklists are to be completed

and signed by the person who carried out the inspections, maintenance, servicing, and testing and are to be countersigned by the Company's representative.

7.9 Manufacturer’s Representative

7.9.1 Provide the MSCREP with a signed letter of

qualification from the OEM and the certificate of training for the SCBA Compressor prior to the start of any work. Functional tests are to be performed by a manufacturer’s representative (or authorized technical representative). The representative must include a copy of his manufacturer certification with the functional test results.

7.9.2 Provide the services of a laboratory accredited

to test compressed breathing air quality to the specifications set forth in Reference 2.2.

Provide the MSCREP with written proof of qualification and accreditation from the

Authority Having Jurisdiction (AHJ).

7.9.3 Provide the services of a manufacturer’s

representative (or authorized technical representative) to perform all inspections, maintenance, servicing and testing of the SCBA

Compressor.

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7.9.4 Persons performing all inspections, maintenance, service and testing of the SCBA are to be OEM authorized service technicians.

7.9.5 Companies and persons performing maintenance and

testing are to have available the appropriate certificates, servicing manuals, service bulletins, tools, materials, and manufacturer’s replacement parts.

7.10 Reserved

7.11 Preparation of Drawings

7.11.1 Provide electronic copies of all revised and/or

updated technical documentation including drawings, technical manuals, service bulletins, parts lists, certification and test data associated with the work performed or parts supplied to the OMT REP.

8.0 GENERAL REQUIREMENTS: None additional