Section C-2 Technical Requirements Testing.docx

Attachment C-2: TECHNICAL REQUIREMENTS: TESTING 175 WLM MMA ATON CRANE, INTEGRATED CONTROLS, & CENTRAL HYDRAULIC SYSTEM

Department of Homeland Security (DHS)

United States Coast Guard (USCG)

175 (WLM) MAJOR MAINTENANCE AVAILABILITY (MMA)

Attachment C-2

TECHNICAL REQUIREMENTS:

TESTING

ATON CRANE, INTEGRATED CONTROLS, & CENTRAL HYDRAULIC SYSTEM SETS

15 June 2022

Table of Contents

1. General System Test Requirements

1.1. Test Plans

1.1.1. Plans shall include a description and the pass/fail criteria for each test.

1.1.2. Test Plans shall be submitted for:

1.1.2.1. First Article Testing

1.1.2.2. Factory (Production) Testing

1.1.2.3. Shipboard Testing

1.2. The Contractor shall work with the Coast Guard to identify critical or highly stressed weld joints. These joints shall be masked or not painted for post load testing NDT and then painted.

1.3. The Contractor shall notify the Contracting Officer of all tests at least 14 calendar days prior to the event. The Contractor shall retain records of all tests and submit them to the Contracting Officer, and provide a copy to the Quality Assurance Inspector. A report of the tests shall be submitted which shall include a description of the test setup and procedure, photographs from two adjacent sides, documentation of weights used, logs of times for start and finish, and any measurements taken during the test.

1.4. The Contractor shall provide a Test Stand for conducting all ATON Crane and Integrated Controls First Article and Factory weight and performance tests.

1.4.1. The Test Stand shall provide structural support for the crane in both tilted (10-degree list, 5 degree trim) and horizontal configurations.

1.4.2. For every test conducted, the Contractor shall utilize the same Central Hydraulic System (CHS) that will be delivered with the ATON Crane & Integrated Controls as a shipset. CHS shall be capable of supplying 160 gpm at 2500 psi, and maintaining the fluid within acceptable temperature boundaries of 120-degree F to 140-degree F during testing.

1.4.3. The Contractor shall provide a temporary booth for the Buoy Deck Control chair, console and operator during testing. The booth need not be weather tight, but shall provide shelter from rain, snow, sun and inclement weather during testing.

1.4.4. When ambient testing temperatures are below 40 degrees F, space heating shall be provided for the operator and controls.

1.4.5. For safety, the Contractor shall provide an E-Stop device for the test stand CHS within reach of the operator in the temporary booth.

1.4.6. The test stand, CHS and booth shall be maintained by the Contractor during the duration of this contract, but are not deliverables to the Coast Guard.

2. First Article, Factory, & Shipboard Testing Requirements

2.1. The crane system and supporting Central Hydraulic System shall not require adjustment or biasing of pressure settings, control limits or counterbalance valves, and the system shall not operate in an unacceptable overload condition. Winch capability to repeat-reeve cleanly and correctly shall be demonstrated as part of First Article Testing and Production Unit Testing.

2.2. PLC based control of the CHS shall be demonstrated.

2.3. Hydrostatic tests and the setting of relief valves shall not occur prior to all other tests, nor shall they be reset after testing.

2.4. No Load Test

2.4.1. Equipment shall be visually inspected and shall be given a No-Load test prior to all other operational or weight testing.

2.4.2. Without a load on the cane, move the crane slowly through the full range of motions. The main and Aux hooks shall be raised and lowered slowly through the extent of their respective range. Verify the brakes are working properly in both directions. Verify the 2-block inhibitor works properly on each line, main and Aux.

2.4.3. The No-Load test shall demonstrate that equipment functions in the direction intended, that all controls, safety provisions, limits and interlocks are functional.

2.4.4. The crane control interlocks, limits, and alarm related functions of the PLC based ICCS shall be demonstrated.

2.4.5. The crane collision avoidance system shall be programmed with different avoidance locations and demonstrated.

2.5. After completion of the crane specific tests, all buoy deck equipment control features of the PLC Control System shall be demonstrated.

2.6. The ability of the operator, sitting in the Buoy Deck Control Booth chair, to multi-task and easily operate shall be demonstrated. Operation of the following shall be included:

· Both the crane and a cross-deck winch simultaneously.

· Multiple cross-deck winches simultaneously.

· A rising sheave chain stopper, the chain winch and the level wind arm simultaneously.

· A cross-deck winch and rising sheave chain stopper simultaneously.

· The Contractor shall provide mock-up test load devices to permit demonstration of the buoy deck controls and display features.

· The ability to roll motors in both directions at various speeds, the ability to move cylinders in both directions at various speeds, interlock features, and the ability to display load cell readings shall be demonstrated.

· Mock-ups of the various buoy deck devices themselves are not required.

2.7. Hardware in the loop (HIL) simulation may be utilized during first article and production testing.

2.8. The system under test (SUT) shall include:

· PLC Control System

· The Buoy Deck Crane Operator’s Chair and control console

· The operator HMI and display

· The tethered controller

· All sensors and actuators not listed in this section

2.9. SUT items shall not be simulated. All hardware supplied by the Contractor shall be used during testing.

2.10. The plant simulation shall include:

· All sensors and actuators listed throughout the specification.

· Installation Testing Prerequisite Requirements.

· Hardware in the loop testing shall allow for the simulation of load and deck equipment conditions which will generate alerts/limits.

· The control system shall be fully connected to the equipment intended, and the buoy deck machinery shall be functionally demonstrated from the Buoy Deck Control Booth Visual Inspection and No-Load Tests.

· The system shall be visually inspected. All rigging shall be properly installed, and all accessories and safety devices shall be installed.

· The ability to power up and power down operations shall be demonstrated. All proper indicators shall be lit.

· All visual displays shall be functional.

· All accumulators shall be charged and operational.

· Load lifting and lowering features shall be functional.

· Boom and jib raising and lowering features shall be functional.

· Slewing features and brakes shall be functional in both directions.

· All operator interfaces and displays shall be functional.

· All other crane features shall be functional.

· All safety equipment shall be functional.

· Anti-2-block switches, encoders and all other system sensors shall be functional.

· All features and accessories on the CHSs shall be functional.

· All buoy deck controls shall be functional.

3. First Article Testing The following tests shall be performed on the first shipset of equipment constructed under this contract. After successful completion of the No-Load tests, weight tests shall be conducted in the order shown, going from heaviest (static) to lightest (100% WLL). All tests shall be conducted with the crane mounted on a test platform that has been tilted to simulate 10 degrees list and 5 degrees trim defined as worst loading arrangement.

3.1. Static Load Test

3.1.1. The crane structure shall be static load tested to 220% of the Working Load Limit of the crane. (2.2 x 20k = 44,000 lbs). This shall apply to the first production unit (SUT) only. Follow on units shall be static load tested to 200% of the working load limit.

3.1.2. The load shall be externally applied to the structure of the crane, exclusive of the rigging; the load shall be slowly applied and slowly removed under controlled conditions.

3.1.3. The position of the boom tip shall be triangulated with laser beams. Deflection measurements (in each of 3 axes) based on the coordinate basis of the crane shall be recorded.

3.1.4. Upon load release, the crane structure shall return to the original position with no permanent deformities or deflections.

3.2. Modified Static / Brake Test

3.2.1. The rigging and brake systems shall be static load tested to 150% of the WLL of the main and auxiliary rigging systems, (30,000 lbs and 13,500 lbs) by attaching the load and tensioning the rigging, setting the brakes, and limited lifting (grunt) of the test load by luffing.

3.2.2. The test load shall be held suspended for 10 minutes, without drifting or creeping. The test load shall be slowly removed by luffing down.

3.3. Dynamic Overload Testing

3.3.1. The crane shall be dynamically tested to 125% of the WLL of the main and auxiliary rigging systems (25,000 lbs and 11,250 lbs), by hoisting, luffing, and slewing the test load 180 degrees over the complete range of motion of the crane, subject to test weight interferences with structure.

3.3.2. The load shall be moved at slow to medium (unspecified) speed.

3.3.3. Lift and lower the test weights repeatedly for at least 10 minutes using the winches. The load shall be stopped and held at several locations. Winch action should be smooth and uniform, and not indicate problems.

3.3.4. Exercise the boom cylinders and slewing gear by moving the test load over the complete range of motion for at least 10 minutes. Cylinder and slewing actions shall be smooth and uniform, and not indicate problems.

3.4. Rated Load Testing

3.4.1. The crane shall be tested at rated load of the main and auxiliary rigging systems (20,000 lbs and 9,000 lbs) by hoisting, luffing, and slewing the test load 180 degrees over the complete range of motion of the crane subject to test weight interferences with structure.

3.4.2. The test weight shall be moved continuously for at least 10 minutes.

3.4.3. The following speeds shall be measured and recorded to establish baseline speeds for diagnostic comparison. Speeds do not include acceleration and deceleration at the beginning and end of movement. Speeds shall be recorded at least 6 times each and averaged, in both directions.

3.4.3.1. Load lifts and lower speeds (feet per second).

3.4.3.2. Boom luff and lower speeds (cylinder feet per second).

3.4.3.3. Jib luff and lower speeds (cylinder feet per second).

3.4.3.4. Slewing port and starboard (degrees per second).

3.5. Central Hydraulic System Testing

Testing and inspections shall include as a minimum but not be limited to the following:

3.5.1. Testing shall be conducted with the system completely assembled.

3.5.2. CHS assembly shall be operated for a burn-in period and adjustment period of not less than one (1) hour. Operating temperatures and other instrumentation readings of the system shall be monitored and recorded at 15 minute intervals. A test load shall be attached to ensure the capacity requirements are met.

3.5.3. Operation at the rated pressure and capacity for eight (8) hours. Operating temperatures, oil pressures, and other instrumentation readings shall be monitored and recorded at 30 minute intervals. All measurements must fall within the manufacturer’s normal operating range.

3.5.4. All system protections and interlocks shall be tested to verify proper operation.

3.5.5. The vibration level shall be measured and recorded at the system design pressure and capacity during the eight (8) hour test.

3.5.6. Airborne noise levels shall be measured and recorded at the system design pressure and capacity during the eight (8) hour test.

3.6. Mission Testing

3.6.1. Chain Stopper

The approximate position of the mechanical chain stoppers on the cutter shall be identified at the testing facility, in relation to the crane pedestal. The ability to raise buoy chain (or equivalent) in 30 foot lift segments at that position, and lay the chain over 45 degrees shall be demonstrated five times.

3.6.2. Lubrication

The Contractor shall validate the instructions for lubrication of the crane by performing the recommended maintenance, in accordance with the technical publication, for the Quality Assurance Inspector. All points of lubrication on the crane shall be addressed.

3.6.3. Adjustments

The Contractor shall validate the instructions for equipment adjustments by performing the recommended maintenance, in accordance with the technical publication, for the Quality Assurance Inspector. All adjustments shall be addressed.

3.6.4. Control System Testing

3.6.4.1. The control system operator interface shall be the primary control input for first article testing.

3.6.4.2. The tethered controller shall be the auxiliary control input for first article testing.

3.6.4.3. The operator display shall be the system output display for first article testing.

3.6.5. Monitoring and Display

3.6.5.1. The monitoring and display capabilities of the ICCS shall be completely tested. Extra sensors with separate readouts shall be provided to verify system readings.

3.6.5.2. The crane shall be moved through its entire range for each operation. Each evolution shall be stopped at 3 random points and data shall be gathered from the operator display and extra sensor.

3.6.5.3. The deck equipment monitoring and display capabilities shall be demonstrated using HIL simulation.

3.6.6. Control

3.6.6.1. The complete control capabilities of the crane system shall be demonstrated from the primary and auxiliary controllers.

3.6.6.2. The control capabilities of the deck equipment shall be demonstrated using HIL simulation. Output signals shall be compared to expected values.

3.6.7. Limits and Alerts

3.6.7.1. The Contractor shall demonstrate all system limits using both the primary and secondary control sources.

3.6.7.2. Each limit shall be tested 3 times and the error shall be measured.

3.6.7.3. Each alert shall be actuated and observed at the control booth 3 times. The reading at the operator display as well as the extra sensors shall be recorded. The error shall be measured.

3.6.8. Collision Avoidance

3.6.8.1. The collision avoidance zone shall be set prior to all tests using the operator interface.

3.6.8.2. The collision avoidance limits and alerts shall be demonstrated from 3 different directions. Directions shall include slewing from both sides and lowering the boom into the restricted area.

3.6.8.3. The override function shall then be demonstrated.

3.6.8.4. The zone shall then be reset to a different configuration and retested as described above.

3.6.9. Emergency Stop

The emergency stop function shall be demonstrated from both the main and auxiliary control sources.

4. Factory Testing The following factory tests shall be performed on the all remaining shipsets of equipment constructed under this contract. After completion of the No-Load tests, weight tests shall be conducted in the order show, going from heaviest (static) to lightest (100% WLL). All tests shall be conducted with the crane mounted on a test platform that has been tilted to simulate 10 degrees list and 5 degrees trim.

4.1. No Load Test

4.1.1. Without a load on the cane, move the crane slowly through the full range of motions. The main and Aux hooks shall be raised and lowered slowly through the extent of their respective range. Verify the brakes are working properly in both directions. Verify the 2-block inhibitor works properly on each line, main and Aux.

4.1.2. The ability to slew and park over the bow to the electronic and structural stops shall be demonstrated, both port and starboard.

4.1.3. The ability to override the collision avoidance system and slew beyond set limits shall be demonstrated.

4.2. Static Load Test

Test in accordance with section 3.1.

4.3. Modified Static / Brake Test

Test in accordance with section 3.2.

4.4. Dynamic Overload Test

Test in accordance with section 3.3

4.5. Rated Load Testing

Test in accordance with section 3.4

4.6. Collision Avoidance Testing

Test in accordance with section 3.6.8

4.7. Central Hydraulic System Factory Testing

4.7.1. Testing shall be conducted with the system completely assembled.

4.7.2. Operation at the rated pressure and capacity for four (4) hours. Operating temperatures, oil pressures, and other instrumentation readings shall be monitored and recorded at 30 minute intervals. All measurements must fall well within the manufacturer’s normal operating range.

4.7.3. Factory Test reports, including a description of test setup and procedure, photographs from two adjacent sides, logs of times for start and finish and any measurements taken during the test, must be provided for each system tested.

5. Shipboard Testing and Demonstration

5.1. The Contractor must develop a Shipboard Test Plan for use by the installing activity for Shipboard Testing.

5.1.1. The Shipboard Test Plan shall fully address all features and capabilities of the equipment and must fully demonstrate the proper installation and operation of the equipment, including the below sections.

5.1.2. A Shipboard Testing and Demonstration test plan shall be submitted as part of the Data for Provisioning.

5.1.3. The crane will, after installation, be static and dynamically tested.

5.1.4. The following installation tests and demonstrations shall be performed on the all shipsets of equipment constructed under this contract.

5.1.5. Weight tests of the installed crane shall be completed.

5.1.6. The equipment having been contractually “tested” at the factory, the capabilities of the equipment shall be demonstrated, showing that the original capabilities have not degraded as part of the shipping and installation processes.

5.1.7. After completion of the Visual Inspection and No-Load tests, weight tests shall be conducted in the order show, going from heaviest (static) to lightest (100% WLL).

5.1.8. The Government will provide the labor and equipment for performance of the installation tests. Installation testing support by the Contractor shall be provided as a part of the Field Services.

5.2. Initial bearing alignment readings shall be obtained by the Contractor’s service agent as part of completion of the crane installation process onboard the cutter. Readings shall be documented in the Commissioning Report, issued to the Contracting Officer and COR.

5.3. Static Load Test

5.3.1. The crane structure shall be static load tested to 200% of the Working Load Limit of the crane. (2.0 x 20k = 40,000 lbs).

5.3.2. As a prerequisite to Static load testing the Cutter Stability Report shall be reviewed to verify adequate stability for vessel due to the moments applied by testing. The crane shall be oriented in the worst loading arrangement, subject to stability of the cutter. The load shall be externally applied to the structure of the crane, exclusive of the rigging; the load shall be slowly applied and slowly removed under controlled conditions.

5.3.3. Upon load release, the crane structure shall return to the original position with no obvious permanent deformities or deflections (as verified by the technical representative with contractor supplied test hardware).

5.4. Modified Static / Brake Test

5.4.1. Test in accordance with section 3.2.

5.4.2. The contractor shall provide test hardware required to evaluate deflections under load at critical points (as defined by the technical representative).

5.4.3. The contractor shall conduct post test inspections on the crane (visual and NDT) to check for deflections (none allowed) and over stress conditions resulting from testing (none allowed). All post test instrumentation for the crane shall be provided by the contractor. Certification of current calibration shall be available.

5.5. Dynamic Testing

5.5.1. As a prerequisite to dynamic testing the Cutter Stability Report shall be reviewed to verify adequate stability for vessel due to the moments applied by testing.

5.5.2. Test in accordance with section 3.3 by hoisting, luffing, and slewing the test load at least 180 degrees between the Buoy Port Service Areas, and over the buoy deck) over varying elevations of the crane.

5.6. Rated Load Testing

Test in accordance with section 3.4.

5.7. Collision Avoidance Testing

5.7.1. The collision avoidance zone shall be set prior to all tests using the operator interface.

5.7.2. The collision avoidance limits and alerts shall be demonstrated from 3 different directions. Directions shall include slewing from both sides and lowering the boom into the restricted area.

5.7.3. The override function shall then be demonstrated.

5.7.4. The zone shall then be reset to a different configuration and retested as described above.

5.8. Central Hydraulic System Shipboard Testing

Shipboard testing must include the testing requirements of SFLC Standard Specification 5000 Auxiliary Machine Systems (appendix C) and include the following but not limited to:

5.8.1. Operation of the system at full rated pressure for a minimum of four (4) hours with all instrumentation readings taken at 30 minute intervals.

5.8.2. Demonstration of all control functions.

5.8.3. Demonstration of all safety devices, emergency stops, and interlock devices.

5.8.4. Demonstration of all sensing and monitoring devices.

5.8.5. Inspection for the presence of foreign material and excessive wear particles.

5.8.6. Test report data sheets to be used for documenting the test of the installed system.