3389 LCHD-ESS Section E - OCT2025.docx

SECTION E – INSPECTION AND ACCEPTANCE

INSPECTION

The Contract will be managed by the Marine Design Center (MDC) of the U.S. Army Corps of Engineers (USACE) and is subject to inspection by its appointed representatives to ensure strict compliance with the terms of the Contract. No Government Representative, except the Contracting Officer, is authorized to change any provision of the specifications, nor shall the presence or absence of a Government Representative relieve the Contractor from any requirements of the Contract. The government and its authorized representatives have the right to inspect any work associated with this contract whether at the prime contractor’s facility or any other location where the work is taking place, including subcontractor’s facilities, factories, etc., at no additional cost to the government. In addition to any notifications required elsewhere in this contract, the contractor shall provide the government with a minimum of 28 days’ notice prior to tests or major inspections at facilities other than the contractor’s primary construction location to allow the government the opportunity to organize travel to witness these events.

Smoking, vaping, and/or use of electronic cigarettes is not allowed on the vessel at any time during the Construction and Testing Phases. Further, consumption of food shall not be allowed on the vessel at any time during the Construction or Testing phases.

The Contractor shall provide Safe for Workers labels, in accordance with the OSHA regulations stated in 29 CFR 1915.11-12, for all confined and enclosed spaces prior to permitting entrance for work or inspection. This procedure shall be reflected in the Contractor’s Safety Plan. See Contract Section H, Paragraph H07.

Entry shall not be permitted to any confined or enclosed space that does not have a current Safe for Workers label.

LAUNCHING

The Contractor shall be responsible for the satisfactory launching of the vessel at the time and date selected and mutually agreed upon by the Contractor and the COR. The Contractor shall ensure that the vessel is suitable for launching, including completion of hull structure, and finalization of all components that would be difficult to perform while in the water.

The Contractor shall provide a written notice to the COR no less than 14 calendar days prior to the launching. Prior to launching, all painting of exterior hull surfaces must be completed in accordance with the requirements of Contract Paragraph C406. The hull interior and exterior surfaces shall be thoroughly inspected by an authorized Government representative to verify compliance with the requirements of the specification. The vessel shall not be launched until the hull painting has been approved by the COR and the paint manufacturer’s on-site representative. The Contractor shall schedule no less than 5 days between hull inspection and launch to allow any new paint on the hull interior and exterior to cure properly.

Following the launching, the Contractor shall provide the Government with a Launching Report, which shall include, at a minimum, draft and freeboard readings at the port and starboard forward, midship, and aft locations, an estimated percentage of the vessel complete, and the time and date of the launch. After launching, all tanks and voids shall be inspected for damage and leaks, and their conditions shall be recorded as part of the Launching Report. This report shall be provided as 924-E02 Launching Report and shall be submitted to the COR for review and approval no later than 2 working days after the launching of the vessel.

Upon completion of Level 5 testing, including approval of test results by the COR, the Contractor shall perform underwater inspection of the vessel to inspect for damage prior to delivery. Alternatively, the Contractor may choose to drydock the vessel in lieu of performing the underwater inspection. The Contractor shall inspect the vessel in conjunction with the COR for damage. If damage is discovered, the contractor shall be responsible for completing any repairs (including re-drydocking as required), shall clean the vessel, and repair damaged coatings as required. All damage to the hull, hopper, and appendages shall be repaired as directed.

Upon completion of repairs, the hull exterior and appendages shall be cleaned, and all damaged paint surfaces touched up with original coatings to present a smooth, unbroken surface. Paint and coatings shall be in accordance with the requirements in Section C, Paragraph C406. The Contractor shall re-launch the vessel upon acceptance of the drydock repairs by the COR.

QUALITY CONTROL AND INSPECTION

A. GENERAL

After Notice To Proceed with Phase I “PLANNING & SCHEDULING”, the Contractor shall develop a Contractor Quality Control (CQC) and Inspection Program for the work required in this Contract. This program, which consists of two sub-programs, shall provide for review and quality control of the “Engineering and Scheduling” submittals, regular inspection and testing of the construction work in progress, and the preparation and maintenance of documentation and records.

The first sub-program, CQC of the engineering phase, must be submitted within 120 calendar days after the Notice To Proceed with the Phase I “PLANNING & SCHEDULING” phase of the Contract.

The second sub-program, CQC of the construction phase, must be submitted and accepted in the “ENGINEERING” phase of the Contract. The Notice To Proceed with Phase III “CONSTRUCT & TEST”, will not be issued until this document is accepted.

The documentation and records of the ENGINEERING Phase CQC and Inspection Program shall:

Define the review and correction process for all “Planning & Scheduling” and “Design” phase submittals.

Include a defined process of internal review and correction, including timing, of any sub-contractor’s submittals prior to submission to the government for review.

Include a defined process for incorporating comments and resubmission for re-review or record (depending on government review action) including timing.

Incorporate the use of comment review spreadsheets and comment discussion meetings, as outlined in Contract Paragraph H05.

The documentation and records of the CONSTRUCT & TEST CQC and Inspection Program shall:

Define Contractor tests and inspections to be accomplished for each work item of the Contract. Such tests and inspections shall be keyed to the appropriate level of testing and contract paragraph requirements.

Be commensurate with the complexity of the work in the specification and adequate to assure the Contractor that the product or subproduct offered conforms to the requirements of the Contract.

Be available to the Government Representative at all times and contain recorded data of all Contractor conducted inspections and tests conducted to date. All Quality Control reports, including those of subcontractors and regulatory agencies, will be maintained and included in the Test Report(s) and Booklets of Contract Paragraph E05.A.3.

List by name and title, the Contractor’s representatives who are authorized to witness or perform and sign for each test and inspection. These individuals shall be considered Authorized Contractor Representatives.

Ensure that responsible authorized personnel shall inspect the work in progress and all completed work, conduct necessary tests and record the data required. An Authorized Contractor Representative shall sign the records attesting to the validity of the information.

Include a defined process and timeline for repair and reinspection.

Contractor certified inspection is an integral part of all work, therefore the COR will consider the entire Contract incomplete if Contractor documentation and records signed by the Contractor’s Authorized Representative are not complete.

B. SUBCONTRACTORS

Work subcontracted and/or performed away from the shipyard shall be covered by this inspection system. The prime Contractor cannot delegate the authority to witness or perform, and sign for tests and inspections conducted away from the shipyard, without approval of the COR.

If the subcontractor has an established Quality Control program with designated organization and personnel, the prime Contractor may designate an appropriate individual in that organization as his authorized representative. Such designation shall clearly indicate that the individual is an employee of a subcontractor, and his appointment shall be subject to the approval of the COR.

C. TESTING

When any workmanship, material, or apparatus fails to pass any test or inspection, it shall be fully retested only after all known faults have been eliminated. Where directed by the COR, such failed material or apparatus shall be completely removed from the work and renewed. Any defects in workmanship or material shall be remedied by the Contractor at no additional cost to the Government, except where work was performed on material furnished by the Government.

D. ABS ONSITE INSPECTION

The Contractor shall coordinate ABS Onsite Inspection activities in accordance with the requirements of the ABS Guide for Hull Survey for New Construction, and as agreed in the Construction Survey Plan required by Contract Paragraph C004. As part of the inspection program, the Contractor shall maintain a record of all inspection interactions with ABS, which shall include the scheduled inspection date(s), actual inspection date(s), and signature blocks for the ABS Inspector and Contractor, and notes for what inspection(s) were conducted. This report shall be kept current and upon request be made available to the COR. All ABS inspection-related documentation shall be included in the applicable Test Booklet as described in E05.A.3.d.

FACILITIES FOR PERSONNEL

The Contractor shall provide a set of at least three rented office trailers at the shipyard for use by a Government staff of approximately ten (10) personnel. Trailers may be adjoining. Trailers shall include a conference space. Trailers shall be within close proximity of the vessel construction. Should the trailers be located greater than ¼ mile from the vessel construction site, the Contractor shall provide the Government with two identical means of powered transportation (golf cart, utility vehicle, etc.), each capable of seating at least two people, for the duration of the project. The trailers shall all have lockable doors, and Government staff shall be provided keys by the Contractor upon arriving on site. There shall be at minimum three (3) sets of keys for Government use for each trailer.

The trailers shall have electric power, and be air conditioned, heated, ventilated, well maintained, and well secured. The trailers shall be equipped with:

· High-speed internet & Wi-Fi

· 6 workstations with storage drawers

· 10 surge protectors

· 1 free standing large white board

· 1 conference table (sits ten personnel) in standalone conference space

· 16 ergonomic conference room chairs (including the ten required for conference table above)

· 2 waist height cabinets for storage and to house microwave/ coffee machine

· 6 ergonomic rolling chairs for workstations

· 5 folding chairs

· Two (2) commercial telephones (with speaker phone capability) with commercial phone service nation-wide during entire contract.

· Two restrooms, suitable for both female and male staff – The contractor shall be responsible for the supply of all toiletries and sewage service.

· Potable water for restrooms

· One Commercial-grade laundry pair (Washer and dryer), including all necessary water services, venting, and power supply.

· One potable water cooler. Shipyard is responsible for water cooler service during the contract.

· One full-size refrigerator with ice maker, or one full-size refrigerator with a standalone ice maker provided separately by the Contractor.

· One microwave

· One industrial coffee maker and pot

· One high-speed printer with Bluetooth capability, capable of printing 11”x17” page size

· One standalone photocopier. Shipyard is responsible for photocopier service during the contract.

· Two wall mounted 72” HD TVs with supporting ancillary HDMI cords and wall mount to allow for presentations. One TV to be mounted in “open” area and one TV to be mounted in stand-alone conference space. The conference room TV setup shall be configured to allow for presentations to be made from the conference table, through provision of sufficiently long HDMI cords or other means of connecting a computer to the TV.

· Conference room teleconference equipment to include speakers, camera, and commercial phone service

· One free standing closet with office supplies (i.e., printer paper, pens, staples, etc.) The shipyard shall supply the Government Office with paper print products and various office supplies as needed during the contract.

· The space and facilities shall be suitable for both male and female staff.

· Custodial service for cleaning and garbage removal shall be provided by the contractor. Trash receptacles shall be provided by the contractor.

· 1 cork board for posting required documentation available to open area. Size should be a minimum of 68” x 40”.

· Six computer monitors, with ancillary cords, to be used for the entirety of the contract.

· Project office signage per USACE Sign Standards Manual (EP 310-1-6a, Section 16) requirements, including the following requirements:

· Approx. overall dimensions: 48” x 72”

· Made from aluminum

· Weather resistant

· Includes a rendering of the completed vessel

· Lists the names of the Contractor and Designer of Record

· Foundation/bracing per EP 310-1-6a (Construction Project Identification Sign).

· Design shall be submitted to the COR for review and approval prior to fabrication.

Government Representatives attending the construction may bring with them communication equipment, cameras, and various items of test equipment. All Government representatives shall be granted picture capturing ability of all construction, testing, and delivery activities. The Contractor shall permit unencumbered ingress and egress to and from the shipyard and vessel with such equipment.

The Contractor shall furnish an up-to-date paper set of drawings for exclusive use of USACE personnel while in the shipyard. Paper set of drawings shall be sized at 11”x17” at a minimum but will be determined dependent on details of requested drawings. The Contractor shall ensure that these drawings reflect any changes made to the drawings throughout the construction. Updates to printed drawings shall be provided to USACE personnel as requested.

In addition, the Contractor shall also furnish ten (10) parking spaces within the shipyard, in safe locations and accessible to the assigned office space.

TRIALS, TESTS AND DEMONSTRATIONS

GENERAL REQUIREMENTS

Levels of Testing The Contractor shall perform tests on all equipment, machinery, and systems; individually and integrated as a whole. The tests shall be performed as necessary to demonstrate satisfactory compliance with the Specification requirements contained in Section C, “DESCRIPTION/SPECIFICATION/WORK STATEMENT,” of this Contract.

The Contractor shall perform seven levels of testing as follows:

All demonstrations, tests, and trials shall be performed as specified herein and as specified in Section C of the Contract. The Contractor shall furnish all labor, materials, tools, and test equipment as necessary and perform the testing, trials, and demonstrations specified. This shall include the required services of vendors, subcontractors, and consultants as necessary.

The Contractor shall successfully complete all parts of the prior level of testing including any repairs and retesting required, before moving on to subsequent levels.

The COR shall be notified in writing at least 14 calendar days in advance of the date set for each testing level of the vessel.

All systems and equipment shall be inspected and tested to verify proper installation and workmanship; demonstrate full functionality of all features, controls, monitoring and alarm points; and to verify the performance in accordance with the approved design, During Phase II, NLT 120 calendar days prior to the first FAT test, the Contractor shall provide a summary of all testing to be completed across levels, including a list of equipment and systems to be tested and the phase(s)/levels they are to be tested in. All tests required by ABS, USCG, SOLAS, and equipment manufacturers shall be included. This list shall be submitted as 924-E05-TESTING OVERVIEW.

The Contractor shall utilize the SNAME Technical and Research Bulletins 3-39: Guide for Shop and Installation Tests (2018), and Bulletin 3-47: Guide for Sea Trials (2015) as a guide for the development and execution of the tests, trials, and demonstrations. For equipment and systems not specifically identified in the regulatory body requirements, SNAME Guides, or as tests below in this section, the Contractor shall employ a testing methodology consistent with the SNAME Guides for the respective testing.

Levels of testing and certain details of testing requirements have been described by the Government throughout this Contract Section; however, it is possible, due to conditions at the Contractor’s facility and other factors, these requirements may not be achievable as currently stated. In this event, the Contractor shall provide alternative arrangements for obtaining the testing requirements per the objectives of the individual trials. This may be achieved through alternative locations, procedures, or timelines. The Contractor shall provide a memorandum on the alternative arrangements, including identification of the reason the trial cannot occur as stated, and the proposed solution. Memorandum(s) shall be titled 924-E05-MOD-CXXX EQUIPMENT OR SYSTEM NAME and shall be submitted to the COR for review and approval no less than 120 days prior to the scheduled start of the applicable Level of testing.

Consumables, Operating Fluids, and Test Equipment The Contractor shall furnish all fuel oil, hydraulic oil, lubricating oil, gear oil, engine anti-freeze, treatment chemicals, degreasing agents, gases, potable water and any other consumables required to perform the tests and demonstrations, and as required in Contract Section C.

The Contractor shall provide all equipment necessary to execute the complete testing program. Where required to suit the needs of equipment OEMs or other Test Procedures, the Contractor shall provide sufficient internet access at all points on the vessel. The vessel’s satellite internet system shall not be used by the Contractor for execution of the testing program, with the exception of testing of the internet system itself and its associated components.

The Contractor shall provide fuel as necessary for delivery. Two fuel samples and a fuel test report shall be provided to the COR. Upon final delivery, the Government will make payment to the Contractor for the quantity of fuel remaining in the vessel fuel tanks. For payment, the fuel amount in the tanks shall be determined by sounding the tanks and developing the tank amounts from the tank capacity tables. The per gallon fuel cost for payment shall be identical to the cost paid by the Contractor for the fuel fill. The Contractor shall provide the fuel fill invoice to document the cost per gallon.

Test Documentation For each Level of testing, the Contractor shall prepare Test Agendas, Test Procedures, Test Reports, and Testing Booklets as described below.

At a high level, the purpose of the test documentation described below is to ensure that the following information are captured for record purposes:

Type of inspection or test (e.g., visual, mechanical, functional, liquid penetrant, radiographic), accept/reject criteria, and a statement as to whether the inspection was satisfactory or unsatisfactory.

Number and type of deficiencies of material, design, or workmanship found in the product or subproduct inspected and corrective action taken to correct the deficiencies and, for repetitive deficiencies, to preclude recurrence.

Date and signature of the Authorized Contractor Representative who witnessed or performed the test or inspection.

Level 3, Level 4, and Level 5 testing shall not commence without written approval of the Test Procedure(s) from the COR.

Dredging Trials will require coordination of permits for dredging activities between USACE and the Contractor. The Contractor shall propose their intended site for dredging trials at least 1 year in advance of the scheduled trial date to ensure adequate time for the Government to secure the necessary dredging permits.

Test Agenda(s) The Contractor shall prepare a separate Test Agenda for each Level of Tests and Trials. Each Agenda shall be a complete, detailed schedule of all tests, trials, and demonstrations specified in this contract paragraph and/or required by Regulatory Bodies for that Level of testing. The Test Agenda(s) shall be arranged by day, not date, and shall list the specific tests, trials, and demonstrations, and the sequence in which these will be performed. A separate Test Agenda shall be provided for testing the launch vessel for obtaining the Subchapter T COI.

It is understood that preparation of a detailed schedule for Level 1 Testing may not be practical. The Contractor shall schedule the Level 1 Test and Trial activities to the best of their ability. At a minimum, the schedule shall delineate the progression of Level 1 testing and the order in which the various tests will occur.

The Agenda for Level 4 Testing shall state where the open water trials will take place, along with any launch points for personnel pickup as applicable.

The Agenda for Level 5 Testing shall state where the dredging trials will take place, along with any launch points as applicable.

The Agenda for each Level of Testing shall be submitted to the COR for review and approval no less than 120 calendar days prior to the scheduled date of the first test in that level.

Test Procedures The Contractor shall prepare Test Procedures for all tests and trials conducted under Levels 0 through 6 of this contract paragraphs. Test Procedures shall adhere to all manufacturer testing requirements and shall demonstrate the successful construction of the dredge per the requirements in Contract Section C.

The Test Procedures shall describe the actual test procedures and data to be recorded. The procedures shall be in accordance with the “start-up” procedures for the equipment, as delineated in the operating manuals furnished for the equipment by the manufacturer. The Contractor shall incorporate demonstrations of all applicable controls, monitoring, instruments, and alarms, into each system’s Builder’s Dock Trials, Dock Trials, Open Water Trials, Dredging Trials, and Final Acceptance Demonstrations sections of the Test Procedures. Procedures shall be arranged such that data to be recorded in time intervals is presented in tabular format so that data trends can be easily recognized.

Each Test Procedure shall (as applicable):

· List the major equipment

· Include a space for nameplate data, make, model, and serial number of equipment, etc.

· List the characteristics of equipment (i.e. impeller size, motor size hp and amp., flow capacity, line pull capacity, cfm, etc.)

· Reference the manufacturer’s manual(s) used to format the test procedure

· Describe instrumentation for each test

· Describe the test methodology and activities

· List the Pass/Fail limits

· List the expected results

· Include a space for the actual results

· Include a space for the ambient conditions

· Include signature blocks for Contractor Representative, Government Representative, Regulatory Body Representative, and any required Manufacturer’s Representative witness signatures, times and dates

· Include a space for writing comments The Test Procedures shall be formatted on 8½-inch by 11-inch sheets, single side. Each page shall include the Marine Design Center project number (i.e. 3389) and hull number (924) at the top. Test Procedures shall be submitted electronically to the COR for review and approval in accordance with the following schedule. Note that the Test Procedures for Levels 2 through 6 shall each be delivered as one combined submittal, while Procedures for Levels 0 and 1 may be submitted individually as required to suit the Contractor’s test schedule.

The Procedures shall be arranged by system and equipment. Equipment and systems shall be organized by their respective WBS number as specified in Section C. Where Test Procedures are submitted for individual pieces of equipment or systems for approval, they shall be titled 924-E05-CXXX EQUIPMENT OR SYSTEM NAME – Level X Test Procedure. Multiple systems may be tested within a single Procedure, however all applicable WBS numbers shall be clearly identified on the Procedure. Combination of system testing is dependent on written approval from the COR and shall be clearly identified in the applicable Test Agenda.

Test Reports The Contractor shall populate all provided data fields of each Test Procedure. Upon completion of testing and the appropriate signature fields on the Procedure, the document is considered an official record and shall be submitted to the COR as a Test Report. Test results shall be reported to the COR in the following manner:

· Within two working days of the completion of any tests, a copy of the Report for that specific test shall be provided to the COR for review.

· Upon completion of any level of testing, the COR shall be notified that the specific level of testing has been completed. All Test Reports shall be filed in the appropriate Test Booklet as described below.

· Test Reports shall be titled 924-E05-CXXX EQUIPMENT OR SYSTEM NAME – Level X Test Report.

Test reports shall include certificates/reports documenting the calibration data of all instrumentation used in the test, as applicable.

Test Booklets The Contractor shall provide one Test Booklet for each Level of Testing. The Test Booklet shall contain the Test Agenda, Test Procedures, and Test Reports for the applicable level of Testing. The Test Booklet shall be maintained regularly and shall exist both electronically as a compilation of scanned PDF files, and as a printed 3-ring binder maintained by the Contractor. Each Test Booklet, with all prior test results, must always be current, and shall be available for review at the request of the COR at any time. At the conclusion of each Level of Testing, the final version of each Test Booklet shall be bound in three ring binders with dividers, and two printed copies shall be submitted to the COR for review along with a completed electronic version in .pdf file format. The Government’s copy of the Test Booklet may consist of photocopies of each test document and is not required to contain original signatures. Test Booklets shall be provided and maintained in the following manner:

· The Test Agenda provided as part of the Test Booklet shall indicate both the scheduled test date and the actual date on which testing occurred.

· The Procedures and Reports shall be arranged by system and equipment, with all documentation for a specific system or piece of equipment recorded under the respective heading.

· Equipment and systems shall be organized by their respective WBS number as specified in Section C.

· Upon approval of each Test Procedure, a copy of the approved procedure shall be placed in the Test Booklet along with its associated review letter.

· With completion of each test, each signed and completed Test Report shall be placed in a Test Booklet.

· Results of all vendors’ tests shall be filed with the applicable test section. The Test Booklet shall be submitted for review and approved by the COR within two working days of the conclusion of each level of testing. Review and approval of the Test Booklet by the Contractor and the COR is a precondition of moving to the next level of testing.

· Test Booklets shall be titled 924-E05 – Level X – Test Booklet Deficiencies All deficiencies at each level of testing shall be corrected and successfully retested prior to moving to the next level of testing. Final Acceptance of the vessel will only be made following remedy of all deficiencies.

The successful completion of all tests, trials, demonstrations and remedied deficiencies, shall be determined solely by the COR.

Safety Requirements Throughout the testing and trials phase, the atmosphere in spaces being prepared for, and preserved by, paints and tank coatings dissolved in highly volatile, toxic, and flammable solvents (29 CFR 1915.35(b)), shall be tested frequently and shall be in accordance with the U.S. Occupational Safety and Health Agency Standards regulations stated in CFR 1915.31-36. Within 24 hours of any inspection, and before any representative of the U.S. Government boards the vessel for such duties, each compartment or space to be inspected shall be certified “SAFE FOR WORKERS” by an National Fire Protection Associations (NFPA) certified Marine Chemist. This means that in the compartment or space so designated:

· The oxygen content of the atmosphere is at least 19.5 percent and below 22 percent by volume;

· The concentration of flammable vapors is below 10 percent of the lower explosive limit (LEL);

· Toxic materials in the atmosphere are within permissible concentrations;

· Any residues or materials associated with any work in the space shall not produce uncontrolled release of toxic materials under existing atmospheric conditions while maintained as directed on the Marine Chemist’s certificate.

The vessel will not be inspected and accepted by the Government without an NFPA Marine Chemist certificate for each hull compartment designated “SAFE FOR WORKERS.” The Contractor’s competent person(s) shall maintain the certificate(s) daily as required. If a certificate is not maintained in accordance with the space requirements, or the conditions in the space change, the Marine Chemist shall be required to re-certify the space and issue a new certificate.

FACTORY ACCEPTANCE TESTS (FAT) (LEVEL 0) – PHASE II & III

The Contractor shall notify the COR NLT 30 days prior to the scheduled date of any FAT, to ensure adequate time for the Government to secure travel to attend the FAT in-person at their discretion. All equipment required by ABS, USCG and SOLAS, including diesel engines, generator sets, IMACS system, propulsion equipment, and cranes, required to have FAT shall be documented in the Test Procedures and Reports. FAT tests performed at the manufacturer’s facility for dredging equipment shall be documented in the Test Procedures and Reports. Satisfactory FAT Test Reports shall be provided.

1. Diesel Engine FAT – Prior to being installed on its skid and paired with its alternator, each Deisel Engine (including emergency generator) shall be tested on a dynamometer to ensure it can produce 110% rated power and the fuel rate of the main engines shall be compared to the original factory performance specifications. This comparison shall be made for the entire operating range of the engines using instrumentation to acquire real-time fuel rate and engine output.

2. Generator Set FAT – Operate each generator set (including emergency generator) at 1/4, 1/2, 3/4 and full loads in 15 minute intervals. Contract-required frequency and voltage stability and response requirements shall be tested at each load level. The Genset shall be tested at 110% rated load (with the use of a load bank) for 2 hours. Generator Sets shall be operated in isochronous mode for the testing. Additionally, the generator set shall be tested in accordance with its ABS approved DVTP and any other Regulatory Body requirements.

3. IMACS FAT – The entire control system as described in C780 (less the actual sensors and driven equipment) shall be connected and tested at the factory. All alarms, failovers, sequences, user interfaces, etc. shall be tested “virtually” using signal generators, computer simulations, or similar to prove the system operates as intended. All functionality required by the FMEA and DVTP shall also be demonstrated by simulation, and all redundancy by actually shutting down the redundant pieces of the system.

4. Non-nuclear density meters - Non-nuclear density meters shall be tested at the factory by the OEM. As part of the FAT Procedure, the OEM shall describe the methodology for calibration and accuracy validation of the non-nuclear density meter, for review and approval by the COR.

PRE-TRIAL TESTS (LEVEL 1) - PHASE III

The Pre-trial tests are designed to ensure proper construction, and installation of all equipment, shaft alignment, piping, and electrical systems, tanks, and exterior and interior bulkheads.

Testing of the vessel’s hull and construction shall be in accordance with the ABS Guide for Hull Survey for New Construction. As noted elsewhere in this Contract, all submittals made by the Contractor to ABS shall also be forwarded to the Government. Specifically, all schedules, procedures, reports, and other documentation related to vessel survey by ABS shall be submitted to the COR. The Contractor shall provide notification to the COR no less than 48 hours in advance of any ABS inspection call-out to allow the Government to attend at their discretion. All meetings and official correspondence related to ABS construction survey shall include representatives from the Government.

All piping, piping appurtenances and applicable equipment shall be tested according to the requirements of ABS. If not specified by ABS, the Contractor shall propose a testing policy to be reviewed and approved by the COR based on the SNAME guidance cited above, including Shop Testing prior to installation in the vessel as applicable.

The Contractor’s Pre-Trial Test program shall include specific inspection call-outs for closure of any and all vessel tanks and voids. The COR shall be present for final inspection of all tanks and voids. The Contractor shall provide notification to the COR no less than 72 hours prior to any tank or void close-out inspection.

In order to satisfy the requirements of Contract Paragraph C514, the Contractor is required to calibrate the control system and sensors for the proportional opening of the hopper doors. As such, the Contractor will be required to measure the distance of the doors below the hull against that reported in the Dredging Control System and re-calibrate the system as-required to ensure agreement. The Contractor may choose to accomplish this test while the vessel is still on land prior to launch if the associated systems are sufficiently installed. Alternatively, this test may be performed at a later stage of in-water testing at the Contractor’s discretion. The Contractor’s methodology for testing and calibration of the door opening system shall be clearly documented in the appropriate Test Procedure.

Pre-trial tests shall be performed during the course of construction and prior to the beginning of Level 2 testing (Builder’s Dock Trials).

The COR shall be notified at least 48 hours in advance of any such testing and may, at his/her discretion, send a Government representative to witness any or all tests. The Contractor shall coordinate with ABS and USCG to ensure that they are present for all tests required to be witnessed for Class. The Contractor shall also coordinate with equipment manufacturers to undergo commissioning, initial start-up, and shutdown. Testing items shall be performed by the manufacturer’s representative with assistance from the Contractor (such as providing access to equipment, running machinery per representative request, and supply of consumables to run tests).

Documentation of all pre-test inspections shall be in accordance with the requirements of Contract Paragraph E03 (Quality Control and Inspection) and shall be provided as part of the applicable Test Booklet per Contract Paragraph E05.A.3.d. All deficiencies, including cracks, leaks, and grounds detected in new circuits, or poor workmanship shall be corrected prior to commencement of the Builder’s Dock Trials.

BUILDER’S DOCK TRIALS (LEVEL 2) - PHASE III

Builder’s Dock Trials are a preliminary “run‑through” of all required Dock Trials (Level 3) by the Contractor. The intent of this testing is to provide both the Contractor and the COR reasonable assurance that all equipment and systems have been thoroughly prepared and are ready for formal testing in Dock Trials (Level 3).

For the vessel, Builder’s Dock Trials shall be conducted at the Contractor’s facility listed in Section B of the Contract. The COR shall be notified, in writing, at least 14 calendar days prior to the scheduled commencement date of Builder’s Dock Trials. All testing documentation required by Contract Paragraph E05.A.3 must be current prior to commencing Builder’s Dock Trials.

The contractor shall perform the same tests as will be performed in the Level 3 dock trials. The trials shall be of sufficient scope and duration to ensure that all machinery and equipment is operable. and all systems are complete.

DOCK TRIALS (LEVEL 3) - PHASE IV

1. General Dock Trials are the operability tests the Contractor must perform in the presence of the Government Representative to demonstrate the proper installation, performance, operation, control, and performance of all outfitting, furnishings, equipment, machinery, and systems installed as part of this Contract.

In addition, each test or demonstration shall include control, monitoring, instrumentation and alarm operation as applicable.

Prior to the start of Dock Trials, all construction and installations must be complete (except for final cleaning and touch‑up painting), and all Level 0, Level 1 and Level 2 testing must be successfully completed and documented.

The Commencement of Dock Trials shall not be sooner than seven full calendar days after COR acceptance of the Builder’s Dock Trials (Level 2) results. The COR shall be notified immediately of any condition which would delay the commencement of Dock Trials.

As part of testing described above, tests and trials shall be conducted in the presence of vendor representatives for the following equipment at minimum:

· C180 – Preliminary Noise survey

· C404 – Anti-Fouling System

· C405 – Cathodic Protection System(s)

· C445 – Rescue and life boats

· C446 – Launch

· C455 – Deck crane(s)

· C456 – Winches, hoists, windlass and davits

· C502 – Dredge Piping System (including collection & distribution)

· C504/C506 – Dredge pumps and drives

· C508 – Dragarm Handling System

· C510 – Trunnion & Dragarm

· C511 – Draghead & TED

· C514 – Hopper Door System (including proportional opening capability)

· C516 – Hopper Overflow System

· C517/C519 – Hopper Flushing System

· C518/C519 – Jetting systems, pumps and drives

· C522 – Swell Compensator

· C524 – Dredging Control System

· C525 – Dredge Gate Valves

· C602 – Diesel engines

· C604 – Reduction Gears

· C605 – Propulsion Drive System

· C606 – Propulsors

· C608 – Propulsion Controls

· C620 – Bow thruster and variable speed motor drives

· C640 – Box Coolers (as applicable)

· C655 – Hydraulic System

· C660 – Ballast Water Treatment System (as applicable)

· C662 – Oily Water Separator (as applicable)

· C665 – Potable water

· C667 – Black water, greywater

· C677 – Fire Extinguishing System(s)

· C678 – Fire detection & alarm System

· C685 – HVAC Systems

· C687 – Refrigeration System

· C705 – AC Electrical System

· C706 – DC Electrical SystemC733 – Electrical Power Plant

· C740 – Switchboards and Power Control

· C765 – Communication Systems

· C770 – Navigation Systems

· C780 – Control, monitoring and alarm systems In order to move from dock trials to sea trials, the entire IMACS system shall have been tested, including each sensor and alarm, and there shall be no “active alarms” in the system including alarms that have been acknowledged but not cleared.

In addition to the testing described above, the Contractor shall complete the Stability Test of the vessel during Dock Trials, as required by Contract Paragraph C115.

The cost to have vendor representatives on-site during testing shall be the responsibility of the Contractor.

The tests shall be conducted in accordance with the Agenda and Procedures.

The Contractor shall indicate on the Test Procedures which tests will be performed using the vessel’s electrical power plant and which tests will be performed using shore power.

The success of all tests and the existence of any deficiencies shall be determined by the COR. Deficiencies discovered during the Dock Trials shall be remedied and retested prior to start of Open Water Trials (Level 4), which shall be planned to start no sooner than 7 calendar days after the end of the original Dock Trial completion date.

2. Specific Dock Trials and Demonstrations (Level 3) - Phase III In addition to satisfying the overall testing of the vessel’s systems and equipment as identified in E05.A.1 above, the Contractor shall ensure that the following test requirements are included in the Level 3 trials for their respective systems. Dock tests (Level 3) shall include dredge pump tests to verify installation, but not to the extent as during the open water trials (Level 4).

C445 and C446 – Rescue and Launch Vessels The Contractor shall test the operation and deployment of the launch and rescue vessels. Testing for all vessels shall include speed tests, a one (1) hour endurance test, verification of all required safety equipment per CFR Rules, and verification of loading capacities. The launch shall also be tested for safe deployment and retrieval with the davits located on the dredge. The Contractor shall ensure that the Subchapter T Certificate of Inspection is obtained prior to delivery of the dredge. All testing shall be performed to ensure that the launch is built and can receive CFR Subchapter T Certificate of Inspection. If this certificate is intended to be obtained during this test, the Contractor shall ensure that proper representatives are present including regulatory bodies and the COR or their chosen representatives.

C504 – Dredge Pumps and Drives – Endurance The Contractor shall test the endurance operation of the dredge pumps and drives for a minimum of four (4) hours at 100% load, or as close as possible while pumping water, without overheating the equipment. The Contractor shall provide orifices or other suitable means to throttle the discharge to obtain this loading. The Contractor shall take measures, such as partial opening of hopper doors, to ensure that the hopper is not filled during the test. The Contractor shall record the suction and discharge pressures, motor RPMs, and pressures and temperatures of all relevant equipment and fluids in the applicable Test Report. Pumps shall continue to be operated at full flow until four (4) hours of operation have been completed without issue in the pumps or their auxiliary systems.

C504 – Dredge Pumps and Drives – Performance The Contractor shall conduct tests as necessary to verify the performance one dredge pump against the published clear-water pump curves provided as part of the Phase II design data. This shall be done at the rated full load speed of the pump drive as well as any other design operating points. The objective of this performance trial shall be to develop a maximum vacuum characteristic of the dredge pumps. This shall result in the development of a NPSH curve showing the flow and head of the system, with a line showing the limit of the pump at 5% cavitation.

The Contractor shall provide orifices or other suitable means to throttle the discharge at not less than three (3) different pressures. Use of the gate valves installed in the system to throttle flow is not acceptable. Discharge rates shall be recorded for all pressures in the applicable Test Report.

This test may be omitted if the pump supplier can furnish certified pump performance curves based on previous testing of an identically constructed prototype pump. This shall be provided to the COR for review and approval no later than 60 days prior to beginning Level 3 testing. If test is sought to be omitted, the Contractor shall clearly highlight this in their submission of the Test Agenda and Procedures(s). Regardless of omission of testing, the Contractor shall provide a maximum vacuum characteristic of the dredge pump as described above.

C514 - Hopper Doors The Contractor shall fill the hopper to the maximum overflow position with water. This level shall be measured at five (5) points along both the starboard and port sides of the hopper, and at five (5) points along both the forward and aft sides of the hopper, for a total of 20 points. The Contractor shall record the water level reduction every two hours over a 12-hour period at each of the previous 20 points. The Contractor shall ensure that the average reduction is not greater than 1 foot measured at even list and trim (or as close to even trim as practical). All data shall be recorded in the appropriate Test Report and submitted for review in accordance with the requirements prescribed in Contract Paragraph E05.A.3.c.

C733 – Electrical Power Plant – Load Bank Testing All of the dredge’s power generation plant shall be load bank tested. An authorized representative from the plant’s manufacturer and Regulatory Bodies (as applicable) shall be present for the load bank test and shall sign off on the completion of the test. Operate each plant at 1/4, 1/2, 3/4 and design full loads (90%) in 15-minute intervals, 100% rated load (with the use of a load bank) for 2 hours, and 110% rated load (with the use of a load bank) for 15 minutes. All equipment parameters shall be recorded at 5-minute intervals for the partial and full load periods, and at 15-minute intervals for the 100% and 110% load period. All data shall be recorded in the appropriate Test Report and submitted for review in accordance with the requirements prescribed in Contract Paragraph E05.A.3.c.

Demonstrate the abilities of the electrical system including parallel operations (including paralleling and bump-less transfer to/from shore power) and reverse power protection trips.

Operate the electrical power plant in parallel at 1/4, 1/2, 3/4 and 100% of the combined rated load (with the use of a load bank) in 15-minute intervals in all possible engine operating scenarios (for instance Genset A and B, A and C, B and C, and A,B,C), Record all equipment parameters at 5-minute intervals. in the appropriate Test Report.

Demonstrate the power management system operations and emergency start operations and its ability to keep the plant online in the event a Genset trips offline. This should be done in each possible engine operating scenario as described above.

If the arrangements of the electrical power plant are better tested through Open Water Trials due to cooling availability, the Contractor shall identify which plant components are to be tested during that level of testing as part of their Test Agenda and Procedure(s).

C740 – Switchboard and Power Control The Contractor shall demonstrate the successful operation of the electrical system, including ability to run equipment from both shore power and electrical power plant. The tests shall also include demonstration of the Power Management System as described in Contract Section C Paragraph C740.

OPEN WATER TRIALS (LEVEL 4) - PHASE IV

1. General After all items on the schedule of Dock Tests (Level 3) have been satisfactorily completed and any deficiencies corrected to the satisfaction of the COR, the Contractor shall commence a program of Open Water Trials. NOTE: Any work performed after pre-trial tests that is negatively affected by other work must be retested. Open Water Trials (Level 4) shall include dredge pump tests to verify installation, to a greater extent than the Dock Tests (Level 3). The open water trial schedule (submitted as part of the Test Agenda) shall cover the entire trial program with approximate time of day for each event.

Prior to the start of Open Water Trials, the Contractor shall host a meeting at their facility with all intended participants of the trials. This shall include at minimum Regulatory Bodies, Government representatives, vendor representatives, dredge equipment manufacturer, and Contractor representatives. The meeting shall serve to discuss trial logistics including the intended agenda, access to accommodations and facilities, and identification of roles of all representatives. The Contractor shall submit Minutes of the Open Water Trials Meeting to the COR as a record of all discussions and agreements made during the meeting. The Contractor shall be responsible for the operation of the dredge during all Open Water Trials, including dredging operations. The Contractor shall also be responsible for all provisioning during the trials, including provisions for Regulatory and Government representatives.

The Contractor’s personnel shall operate the vessel and shall make all observations and record all data in the appropriate Test Reports.