Attachment_I _II_and_III-Amendment-5Mar16.docx

ATTACHMENT A1

MRE TEST PLAN EXAMPLE/FORMAT

Contained in this document are three sample sections from a Material Readiness Evaluation (MRE) Test Plan. The sample sections enclosed are used for the Full Power Run, Auxiliary Systems Inspections, and Thermography Analysis.

Other sections that are contained in a typical test plan are: Air Compressors, Anchor Windlass, Boilers, Deck Machinery, Electrical Insulation and Resistance, Emergency Generator, Distilling Plants, Habilability, Hull Survey, Environmental Pollution Control, Pumps, Refrigeration, SSDG’s, Steering Gear, and Structural Survey.

Description Pages

Full Power Run 2 - 12

Auxiliary Systems Inspections 13 - 22

Thermography Analysis 23 - 26

THE FOLLOWING FULL POWER TRIAL TEST PROCEDURE HAS BEEN PREPARED IN ACCORDANCE WITH COMMANDING OFFICER MILITARY SEALIFT COMMAND (COMSC) INSTRUCTION 9094.1B ENTITLED "FULL POWER TRIAL REQUIREMENTS FOR MSC SHIPS".

TEST PROCEDURES

PRE-TRIAL PREPARATION

PRIOR TO CONDUCTING FULL POWER TRIALS, THE FOLLOWING PREPARATIONS SHOULD BE MADE:

A. ALL PROPULSION PLANT MACHINERY SAFETY DEVICES (OVERSPEEDS, LIMITS, ALARMS, ETC.) SHOULD BE CHECKED AGAINST DESIGN SETTINGS AND/OR VERIFIED THAT THEY HAVE BEEN TESTED TO THE REQUIREMENTS OF APPLICABLE REGULATORY BODIES.

B. A LIST SHOULD BE MADE OF ALL SAFETY DEVICES WHICH ARE OVERDUE FOR INSPECTION OR WHICH HAVE TESTED UNSATISFACTORILY.

C. ALL CRITICAL INSTRUMENTATION SHOULD BE CALIBRATED. A LIST SHOULD BE PREPARED IDENTIFYING ALL CRITICAL INSTRUMENTS, THEIR LOCATION AND THEIR LAST DATE OF CALIBRATION.

MACHINERY WARM-UP

THE SHIP'S PROPULSION MACHINERY SHOULD BE LINED-UP TO PROVIDE ALL NORMAL SERVICES WHILE UNDERGOING FULL POWER TRIALS. MACHINERY DESIGN PRESSURES, TEMPERATURES AND OTHER LIMITATIONS SHALL NOT BE EXCEEDED. MACHINERY NOT MAINTAINING OR TENDING TO EXCEED DESIGN PARAMETERS SHALL BE NOTED IN THE ENGINE ROOM LOG AND THE FULL POWER TRIAL REPORT. PRIOR TO FULL POWER TRIALS, THE PROPULSION PLANT SHOULD BE OPERATED AT A HIGH PARTIAL LOAD POWER LEVEL FOR A MINIMUM OF TWO HOURS TO THOROUGHLY WARM UP MACHINERY AND STABILIZE OPERATING TEMPERATURES.

PROPULSION FULL POWER TRIAL

A. FOLLOWING MACHINERY WARM-UP, THE SHIP'S PROPULSION PLANT SHALL BE GRADUALLY INCREASED TO FULL SHAFT HORSEPOWER AS LISTED IN COMSCINST 9094.1B. POWER DEVELOPMENT SHALL BE DETERMINED USING A CALIBRATED SHAFT HORSEPOWER METER AND/OR BY THE ENGINE MANUFACTURER'S NOMOGRAPHS AND BRAKE SPECIFIC FUEL CONSUMPTION CURVES.

B. ONCE LISTED FULL POWER HAS BEEN ACHIEVED, A MINIMUM PERIOD OF 30 MINUTES SHALL BE PROVIDED FOR PROPULSION PLANT STABILIZATION PRIOR TO COMMENCEMENT OF THE PROPULSION FULL POWER TRIAL.

MATERIAL READINESS EVALUATION

SHIP & HULL NUMBER

INSPECTION/TEST PROCEDURES

C. THE PROPULSION FULL POWER TRIAL SHALL BE CONDUCTED FOR A MINIMUM OF FOUR (4) HOURS. DURING THIS TIME ALL VITAL PROPULSION PLANT PERFORMANCE RELATED OPERATIONAL DATA AND SPECIFIC BRIDGE DATA SHALL BE RECORDED HOURLY.

NOTE: UNDER NO CIRCUMSTANCES SHALL THE REQUIREMENTS OF COMSCINST 9094.1B RELIEVE THE MASTERS AND CHIEF ENGINEERS OF THE RESPONSIBILITY OF OPERATING THEIR SHIPS IN A SAFE AND EFFICIENT MANNER AND OF EXERCISING GOOD JUDGMENT WHEN ENCOUNTERING ADVERSE WEATHER, EXCESSIVE SEA CONDITIONS, VIBRATION OR SIMILAR CONDITIONS.

N00033-13-R-8035 Shipboard Inspection Program

Attachment A-1: MRE TEST PLAN

Attachment A-1

INSPECTION/TEST PROCEDURES (CONT) INSPECTOR ________________________________________

RECORD THE FOLLOWING OPERATIONAL DATA DURING THE FULL POWER RUN:

OPERATION DESIGN START 1 HR 2 HR 3 HR END

JACKET WATER

PISTON COOLING WATER

SHIP & HULL NUMBER

INSPECTION/TEST PROCEDURES (CONT) INSPECTOR ________________________________________

RECORD THE FOLLOWING OPERATIONAL DATA DURING THE FULL POWER RUN:

PARAMETER DESIGN START 1 HR 2 HR 3 HR END

FUEL VALVE COOLING WATER

TURBO & EXHAUST VALVE WATER

INSPECTION/TEST PROCEDURES (CONT) INSPECTOR ________________________________________

PARAMETER DESIGN START 1 HR 2 HR 3 HR END

COOLING SEA WATER

SEA WATER TEMP., F 50

SW TEMP. INTO JW CLR, F

SW TEMP OUT JW CLR, F

SW TEMP. INTO PCW CLR, F

SW TEMP. OUT PCW CLR, F

SW TEMP. INTO LO CLR, F

SW TEMP OUT LO CLR, F

PRESSURE

LUBE OIL

PRESS. TO CROSS HEADS,PSIG 45 - 58

BEARINGS, PSIG 25 - 36

FUEL OIL

PRESSURE AFTER FILTER 60 - 80

TRUST BEARING TEMP. FWD,F

THRUST BEARING TEMP. AFT,F

AIR PRESSURE

CONTROL AIR PRESSURE, PSIG

STARTING AIR PRESSURE, PSIG

SHIP & HULL NUMBER

INSPECTION/TEST PROCEDURES (CONT) INSPECTOR ____________________________________

PARAMETER DESIGN START 1 HR 2 HR 3 HR 4 HR

MAIN BEARING TEMPERATURES,F

INSPECTION/TEST PROCEDURES (CONT) INSPECTOR ________________________________________

PARAMETER DESIGN START 1 HR 2 HR 3 HR END

SCAVENGING TRUNK PRESS,"Hg 22.3

NO. 1 TURBO-BLOWER

BEARING OIL TEMP,F

AIR INTERCOOLER,F

NO. 2 TURBO-BLOWER

BEARING OIL TEMP,F

AIR INTERCOOLER,F

INSPECTION/TEST PROCEDURES (CONT) INSPECTOR ________________________________________

PARAMETER DESIGN START 1 HR 2 HR 3 HR 4 HR

NO. 3 TURBO-BLOWER

BEARING OIL TEMP,F

AIR INTERCOOLER,F

COMPRESSION PRESSURES (TAKEN ONCE AT FULL POWER)

CYLINDER NUMBER

MEASUREMENT 1 2 3 4 5 6 7 8

INDICATED MEAN PRESSURE*

(137.5 PSI)

MAXIMUM PRESSURE

(1060 - 1120 PSI)

COMPRESSION PRESSURE

(645 - 695 PSI)

INDICATED HORSEPOWER*

* IF AVAILABLE

1. SHIP & HULL NUMBER

4. IDENT

5. LOCATION

7. INSPECTOR

NAME PLATE/DESIGN DATA

MAIN ENGINE

INSPECTION/TEST PROCEDURES

TEST THE FOLLOWING ALARMS AND TRIPS:

DESIGN OBSERVED

LOW JACKET WATER PRESSURE TRIP

LOW PISTON WATER PRESSURE ALARM 50

LOW PISTON WATER PRESSURE TRIP

* NOTE: THE M.E. PUMPS AUTO SWITCHOVERS WILL NOT OPERATE IF THE RESET BUTTON ON THE CENTER SECTION OF THE MAIN SWITCHBOARD IS NOT PRESSED AFTER ANY LOSS OF POWER.

4. IDENT

7. INSPECTOR

NAME PLATE/DESIGN DATA

INSPECTION/TEST PROCEDURES

1. CONDUCT VISUAL INSPECTION, RECORD RUNNING TEMPERATURE.

THRUST BEARING READING HOURLY

COMMENTS:

7. INSPECTOR

INSPECTION/TEST PROCEDURES

1. CONDUCT VISUAL INSPECTION FOR DETERIORATION, CORROSION, AND MIS-ALIGNED SENSORS, CABLES, INSTRUMENTATION, RESILIENT MOUNTS, CONTACTORS AND LATCH MECHANISMS.

2. CHECK OPERATION OF ALL SIGNAL LAMPS.

3. OBSERVE OPERATION AND RESPONSE TIME.

4. CHECK SHIFTING OF CONTROL BETWEEN CONTROL SPACES.

5. LEVEL ALARMS - TEMPORARILY FILL OR DRAIN A LEVEL SENSOR. WHERE THIS IS NOT POSSIBLE, REMOVE THE FLOAT SWITCH FROM IT'S RESERVOIR AND SLIDE THE FLOAT UP AND ON IT'S STEM.

6. TEMPERATURE ALARMS - TEMPORARILY PLACE THE SENSOR CAPILLARY BULB IN AN ELECTRIC DEEP FRYER WITH OIL, AND SLOWLY INCREASE THE TEMPERATURE TO THE ALARM SET POINT. USING A PORTABLE PYROMETER, OBSERVE AND RECORD THE ACTUAL SET POINT.

7. PRESSURE ALARMS - SENSOR SHOULD BE TEMPORARILY CONNECTED TO A COMPRESSED AIR BOTTLE OR LINE WITH A PRESSURE GAUGE AND REGULATING VALVE. THE PRESSURE SHOULD BE INCREASED OR DECREASED TO THE ALARM SET POINT AND THE ACTUAL SET POINT PRESSURE SHOULD BE OBSERVED AND RECORDED.

8. MISCELLANEOUS INDICATORS - OTHER INDICATORS AND ALARMS SHOULD BE OBSERVED BY ACTUALLY CAUSING THE MALFUNCTION OR INDICATION TO OCCUR IF NOT DETRIMENTAL TO ANY EQUIPMENT. SIMULATIONS SHOULD TEST AS MANY COMPONENTS IN THE ALARM SYSTEM AS POSSIBLE.

VARIOUS

AREAS COVERED BY MEMO: INSPECTOR___________________________________

AS LISTED

PERSONNEL REQUIRED:

A. ONE ENGINEERING SURVEYOR

INSTRUMENTATION/EQUIPMENT REQUIRED:

A. NONE

TEST PROCEDURES

A. VISUALLY EXAMINE/INSPECT THE LISTED SYSTEMS PIPING, VALVES, FLANGES AND OTHER COMPONENTS FOR SIGNS OF LEAKAGE, DAMAGE, DETERIORATION OR IMPROPER OPERATION. SPECIAL ATTENTION SHOULD BE PAID TO THE FOLLOWING COMPONENTS IN PARTICULAR:

ANY MISSING SAFETY RELATED ITEMS SUCH AS LAGGING, FLANGE SHIELDS, STRAINER SHIELDS AND CONTAINMENTS SHOULD BE NOTED AND BROUGHT TO THE IMMEDIATE ATTENTION OF WATCH PERSONNEL. ALL DEFICIENCIES ARE TO BE NOTED ON THE COMMENT SHEET (LAST PAGE) LISTING THE MRE NO., DETAILED LOCATION AND DESCRIPTIVE SUMMARY OF DEFECT. CONCURRENT EXAMINATIONS OF ADJACENTLY PIPED SYSTEMS ARE ENCOURAGED.

SYSTEMS INSPECTION

INSPECTION/TEST PROCEDURES (CONT)

MRE NO. EQUIPMENT

261 - PIPING AND MISC. FUEL OIL SERVICE

262 - PIPING AND ACC, MAIN LUBE OIL

342 - * GENERATOR SUPPORT SYSTEMS

521 - FIREMAIN AND FLUSHING PIPING SYSTEM

524 - PIPING, AUXILIARY SALT WATER

529 - DRAINAGE AND BALLASTING

533 - * WATER, POTABLE SERVICE SYSTEM

542 - AVIATION AND GENERAL PURPOSE FUELS

543 - * LUBE OIL FILL, TRANSFER, PURIFICATION

559 - * UPTAKES, BAFFLES AND INNER CASING

* SEE ATTACHED SHEETS

SYSTEMS INSPECTION

INSPECTION/TEST PROCEDURES (CONT)

MRE NO. DEFICIENCY

SYSTEMS INSPECTION

INSPECTION/TEST PROCEDURES (CONT)

MRE NO. DEFICIENCY

4. IDENT

6. TECH MANUAL

7. INSPECTOR

INSPECTION/TEST PROCEDURES

NO. 1 NO. 2 NO. 3 NO. 4

APL: N990ARRZ01 N990ARRZ11 N990ARRZ12 N990ARRZ17

MFG:

MFG DWG:

MFG ID:

CAP:

HEAT RATE:

HEAT SURF:

CHECK HEATER FOR TEMPERATURE, DEFORMATION, CAPACITY OF RELIEF VALVE AND TEMPERATURE CONTROL EQUIPMENT.

4. IDENT

5. LOCATION

7. INSPECTOR

NAME PLATE/DESIGN DATA

GEAR MOTOR

INSPECTION/TEST PROCEDURES

1. INSPECT FOR DAMAGE, DETERIORATION, MISSING OR INOPERATIVE COMPONENTS, UNUSUAL NOISE, VIBRATION AND TEMPERATURES.

2. OBSERVE ENGAGING AND DISENGAGING OPERATIONS.

3. OBSERVE AND RECORD THE FOLLOWING DATA.

DESIGN ACTUAL

MOTOR SERIAL # _____

MOTOR RESISTANCE

MEGGER READING ( F) _____

4. IDENT

5. LOCATION

7. INSPECTOR

INSPECTION/TEST PROCEDURES

1. INSPECT PROPULSION SHAFTING FOR CORROSION, CRACKS, EXCESSIVE ECCENTRICITY AND INTERFERENCE WITH OTHER OBJECTS.

2. INSPECT COUPLINGS FOR BOLTING.

3. OBSERVE DURING FULL POWER RUN.

4. INSPECT STERN TUBE SEAL ASSEMBLY FOR LEAKS, CORROSION, VIBRATION AND DAMAGE.

A. INFLATABLE SEAL

B. PACKING GLAND AND CASTING

C. STERN TUBE PACKING GLAND

4. IDENT

5. LOCATION

7. INSPECTOR

INSPECTION/TEST PROCEDURES

1. INSPECT INNER CASING UPTAKES FOR DAMAGE, PITTING, DETERIORATION AND TYPE OF INSULATION.

2. TEST FLAPPER VALVE FOR OPERATION AND FULL TRAVEL.

3. INSPECT SPARK ARRESTOR/MUFFLER FOR INTACTNESS, DAMAGE AND DETERIORATION.

4. INSPECT SOOT POTS AND DRAINS AND TEST OPERATE VALVES.

4. IDENT

6. TECH MANUAL

7. INSPECTOR

NAME PLATE/DESIGN DATA

PURIFIER MOTOR

INSPECTION/TEST PROCEDURES

1. INSPECT FOR DAMAGE, DETERIORATION, MISSING OR INOPERATIVE COMPONENTS, UNUSUAL NOISE, VIBRATION AND TEMPERATURES.

2. OBSERVE ENGAGING AND DISENGAGING OPERATIONS.

3. OBSERVE AND RECORD THE FOLLOWING DATA.

DISCH. PRESSURE

INLET TEMPERATURE, F

1. SHIP & HULL NUMBER

4. IDENT

6. TECH MANUAL

7. INSPECTOR

INSPECTION/TEST PROCEDURES

1. INSPECT PIPING, FLANGES AND VALVES FOR DAMAGE, DETERIORATION AND LEAKAGE.

SHIP & HULL NUMBER

AREAS COVERED BY MEMO: INSPECTOR___________________________________

PERSONNEL REQUIRED:

INSTRUMENTATION/EQUIPMENT REQUIRED:

INSPECTION/TEST PROCEDURES

A. CONDUCT THERMOGRAPHIC INSPECTION OF EQUIPMENT LISTED IN THE FOLLOWING SHEETS.

B. INSPECT MOTOR CONTROLLERS, SWITCHBOARDS AND DISTRIBUTION PANELS FOR CLEANLINESS AND OVERALL CONDITION OF WIRING, BUS BAR MOUNTINGS AND INSULATION.

SHIP & HULL NUMBER

THERMOGRAPHIC INSPECTION

INSPECTION/PROCEDURES

EQUIPMENT SPACE REMARKS

SHIP & HULL NUMBER

THERMOGRAPHIC INSPECTION

INSPECTION/PROCEDURES

EQUIPMENT SPACE REMARKS

SHIP & HULL NUMBER

THERMOGRAPHIC INSPECTION

INSPECTION/PROCEDURES

EQUIPMENT SPACE REMARKS

Attachment A-1

ATTACHMENT A2

SMART TEST PLAN EXAMPLE/FORMAT

SHIP & HULL NUMBER

TEST MEMO

STEERING SYSTEM

SWBS TEST #

56110

REVISION: 1

DATE: JANUARY, 1999

COMSC APPROVAL:

PRESINSURV APPROVAL:

PERSONNEL REQUIRED:

A. ONE ENGINEERING SURVEYOR

B. LICENSED SHIP'S ENGINEER

C. SHIP'S ELECTRICIAN

D. THERMOGRAPHIC INSPECTOR

REFERENCES:

ABS 5.15.14

ABS 5.15.1

INSTRUMENTATION/EQUIPMENT REQUIRED:

A. STOP WATCH

B. AMP PROBE

INSPECTOR:

PRE-UNDERWAY REQUIREMENTS:

GENERAL - THERE MUST BE NO CONDITIONS PRESENT WHICH, IN THE DISCRETION OF THE SENIOR INSPECTOR, PRESENT SIGNIFICANT FIRE OR PERSONNEL HAZARDS. THE SHIP SHALL BE FREE FROM FUEL LEAKS AND PROPERLY SECURED FOR SEA. THERE MUST BE NO CONDITION WHICH WOULD RESULT IN THE USCG ISSUING A "NO-SAIL" FORM 835. THERE MUST BE NO C-4 CASREPS. THERE MUST NOT BE AN ACCUMULATION OF C-3 CASREPS WHICH WOULD RENDER THE SHIP UNRELIABLE OR UNSAFE.

INSPECTION/TEST PROCEDURES:

IN PORT / PRE-UNDERWAY CHECKS:

1. TEST ALL INSTALLED INSTRUMENTATION AND ALARMS: (REF. ABS 5.15.14)

2. TEST THE INTERNAL RELIEF VALVE FOR EACH UNIT.

3. TEST HAND PUMP AND/OR NFU OPERATION OF THE HYDRAULIC SYSTEM, AS APPLICABLE.

4. PERFORM A TIMED SWING RATE TEST OF EACH UNIT (SIMILAR TO TM 56100 "AT SEA", ITEM #2).

5. VERIFY THAT THE UNIT CAN ACHIEVE THE MAXIMUM STATED RUDDER TRAVEL.

6. CHECK FOR RUDDER FOLLOW-UP ERROR.

COMMENTS: ________________________________________________________________________________________________________________________________________________________________________________

SHIP MATERIAL ASSESSMENT & READINESS TESTING

STEERING SYSTEM

56110

INSPECTION/TEST PROCEDURES (CONT)

AT SEA:

1. AT THE COMPLETION OF THE FULL POWER TRIAL. PERFORM AHEAD STEERING GEAR OPERATIONAL TESTS AS FOLLOWS: (REF. ABS 5.15.1)

A. THE VESSEL MUST BE RUNNING AHEAD AT THE MAXIMUM CONTINUOUS RATED SHAFT RPM (AT THE SUMMER LOAD WATERLINE BUT NOT LESS THAN 11 KNOTS).

B. STEERING GEAR MOTOR CONTROLLERS SHALL BE OPENED PRIOR TO THE TEST TO FACILITATE MOTOR AMPERAGE READINGS AND THERMOGRAPHIC INSPECTION.

C. ESTABLISH COMMUNICATION BETWEEN THE BRIDGE AND THE LOCAL STEERING GEAR CONTROL PLATFORM.

2. WHEN THE BRIDGE DETERMINES IT IS CLEAR FOR MANEUVERS THE FOLLOWING RUDDER ORDERS SHALL BE CARRIED OUT AND RESPONSE TIMES RECORDED:

- MIDSHIP TO 35o RIGHT RUDDER

- 35o RIGHT RUDDER TO 35o LEFT RUDDER (TIME FROM 30oR TO 30oL)

- 35o LEFT RUDDER TO 35o RIGHT RUDDER (TIME FROM 30oL TO 30oR)

- 35o RIGHT RUDDER TO MIDSHIPS

3. PERFORM AHEAD BLOCKING VALVE / BLOCKING VALVE FUNCTION TESTS:

A. SECURE POWER TO THE STANDBY STEERING UNIT.

B. ORDER 20o RIGHT RUDDER.

C. WHEN THE RUDDER REACHES 20o RIGHT AND THE STEERING SYSTEM PRESSURE IS STEADY, SECURE POWER TO THE ONLINE STEERING UNIT BY PLACING THE REMOTE/ LOCAL SELECTOR SWITCH IN THE "OFF" POSITION. LEAVE THE POWER OFF FOR 10 SECONDS AND OBSERVE THE RUDDER FOR MOVEMENT.

D. RE-ENERGIZE THE STEERING UNIT AND ORDER 20o LEFT RUDDER.

E. WHEN THE RUDDER REACHES 20o LEFT AND THE STEERING SYSTEM PRESSURE IS STEADY, SECURE POWER TO THE ONLINE STEERING UNIT BY PLACING THE REMOTE/ LOCAL SELECTOR SWITCH IN THE "OFF" POSITION. LEAVE THE POWER OFF FOR 10 SECONDS AND OBSERVE THE RUDDER FOR MOVEMENT.

F. RE-ENERGIZE THE STEERING UNIT AND ORDER RUDDER AMIDSHIP.

4. UPON TEST COMPLETION OF THE ON-LINE STEERING GEAR UNIT, THE BRIDGE SHALL CHANGE OVER TO THE OTHER STEERING GEAR UNIT AND REPEAT STEPS 2 AND 3.

5. DURING THIS TEST ALL PERTINENT DATA ON THE ENCLOSED "STEERING GEAR TEST DATA SHEET" SHALL BE RECORDED.

SHIP MATERIAL ASSESSMENT & READINESS TESTING

STEERING SYSTEM

56110

INSPECTION/TEST PROCEDURES (CONT)

6. THE STEERING GEAR MUST BE CAPABLE OF PUTTING THE RUDDER FROM 30o ON EITHER SIDE TO 30o ON THE OTHER SIDE IN NOT MORE THAN 26 SECONDS - EQUAL TO A RUDDER TRAVEL RATE NOT LESS THAN 2.3 DEGREES/SECOND.

7. AFTER THE SHIP HAS CONDUCTED THE QUICK REVERSAL DEMONSTRATION, PERFORM ASTERN STEERING GEAR OPERATIONAL TEST AS FOLLOWS:

A. THE VESSEL MUST BE OPERATING ASTERN AT FULL POWER SHAFT RPM WITH STERN WAY ON THE SHIP.

B. ESTABLISH COMMUNICATION BETWEEN THE BRIDGE AND THE LOCAL STEERING GEAR CONTROL PLATFORM.

8. WHEN THE BRIDGE DETERMINES IT IS CLEAR FOR MANEUVERS THE FOLLOWING RUDDER ORDERS SHALL BE CARRIED OUT:

- MIDSHIPS TO 35o RIGHT RUDDER

- 35o RIGHT RUDDER TO 35o LEFT RUDDER

- 35o LEFT RUDDER TO 35o RIGHT RUDDER

- 35o RIGHT RUDDER TO MIDSHIPS

9. OBSERVE PROPER OPERATION OF STEERING GEAR UNIT AND NOTE ANY UNUSUAL NOISES OR LIFTING RELIEF VALVES. IF THE RUDDER GOES OVER AND FAILS TO RESPOND TO RUDDER COMMANDS, DETERMINE THE MAXIMUM ASTERN RPM AT WHICH THE STEERING GEAR MAINTAINS CONTROL OF THE RUDDER.

10. CONDUCT VISUAL INSPECTION OF RUDDERSTOCK AND CROSSHEAD FOR CRACKING, DAMAGE AND DETERIORATION. INSPECT PACKING GLAND FOR INTACTNESS AND EXCESSIVE LEAKAGE.

N00033-13-R-8035 Shipboard Inspection Program Attachment A-2: SMART TEST PLAN

Attachment A-2

ATTACHMENT A3

SAMPLE TASK 1: SMART inspection of the USNS OVERTHEHORIZON (T-EST 001)

The purpose of this task is to plan, prepare, provide resources and test equipment and conduct the SMART inspection for the vessel, and prepare the report.

Specific Tasks:

1. USNS OVERTHEHORIZON (T-EST 001): Support shall include conducting main propulsion (MP) and auxiliary (AX) machinery inspection test plans, shipboard safety inspection test plans, infra-red survey of the ship’s switchboards, load centers and power panels, and temporary installation of a shaft torque meter to measure torque, shaft RPMs and calculate shaft horsepower. The Contractor shall provide a total of five (5) people to support this inspection, including: One Engineer to set up the shaft torque meter(s) and to assist with MP/AX inspections. A second Engineer to assist with MP/AX inspections. One engine/marine surveyor/safety specialist to assist with Safety inspections. One Engineer/Marine Surveyor to assist the SMART Coordinator and to capture test plan changes, and one thermographer.

2. Pre-SMART Meeting: The Contractor shall attend a meeting at the MSC Norfolk location to discuss preparations and expectations for supporting the USNS OVERTHEHORIZON (T-EST 001) SMART inspection.

3. The Contractor shall assemble all existing test plans for the scheduled SMART from the SMART Team Coordinator.

a. The Contractor shall validate through SAMM and ShipClip that all test plans are linked to the current machinery and equipment onboard.

b. As directed by the SMART Team Coordinator, the Contractor shall update test plans based on comments from the ship (relayed via the SMART Team Coordinator) and/or via discrepancies noted by the Contractor’s comparison of test plans to equipment noted in SAMM and ShipClip. These changes shall be maintained/tracked on the change log discussed in paragraph 2.1.6.3 below.

c. The Contractor shall provide all ship specific test plans to the SMART Coordinator no later than 30 days before the scheduled SMART start date.

4. The Contractor shall provide the services of a Thermographer to accomplish an infra-red survey of all switchboards, power panels, lighting panels and group control centers. The Contractor shall develop an Infra-red Survey Report as follows:

a. The Contractor shall provide a comprehensive report of each load center, power panel and switchboard element inspected and findings.

b. The report shall provide an infra-red and normal picture of each hotspot found. The report page shall show pictures, identify the element, provide a descriptive rating of the severity of the finding, and the recommended corrective actions.

c. The Thermographer shall notify the ship’s Chief Engineer and the SMART Team Coordinator immediately when hot spots considered to require immediate attention are discovered.

5. The Contractor shall provide one (1) engineer to provide and temporarily install a shaft torque meter(s) to measure and record shaft torque, horsepower, and RPMs during the underway full power run. This engineer shall assist the SMART team in MP/AX inspections. A second engineer shall assist with MP/AX inspection support or other inspection areas as assigned by the SMART Coordinator.

a. The Contractor shall develop a Full Power Shaft Horsepower Report containing raw data as collected from the full power run and calculated shaft horsepower attained during this time period.

6. The Contractor shall provide one (1) engineer/marine surveyor/safety specialist to assist the SMART team by carrying out all Safety test plans, and providing SMART inspection findings to the SMART Team Coordinator.

7. The Contractor shall provide one (1) engineer/surveyor to support the SMART Coordinator in red-lining and updating test plans based upon input provided by SMEs during the actual SMART.

a. Engineer shall work with all SMEs during the SMART inspection to capture recommended updates, observing the test plan issues to fully understand suggested changes. Engineer will develop a listing of suggested changes for review by the SMART Coordinator and SMART Team Naval Officers prior to completion of the SMART inspection.

b. Engineer shall research all changes to determine applicability to other ships in the Class with 2 weeks of the end of the SMART Inspection and notify the SMART Coordinator of findings.

c. Upon approval by the SMART Coordinator, engineer shall update all applicable test plans. Engineer shall maintain a log of test plan updates including date of update, SME that identified initial discrepancy, applicability and date of authorization. This log shall be maintained for all MSC ships.

d. The Contractor shall develop a Trip Report from USNS OVERTHEHORIZON (T-EST 001) SMART attendees recording observations, questions, and suggestions concerning the conduction of the SMART inspection.

The Contractor shall develop the final SMART report in electronic format. A CDROM copy of the final inspection files will be provided by the SMART Team Coordinator at the completion of the inspection. The Contractor shall consolidate all inputs including inspection data, pictures, and attached documents into the report format. The SMART Team Coordinator shall provide the contractor the final database of SMART inspection findings, attachments and final assessments within 10 days of completion of the SMART.

SAMPLE TASK 2: Root Cause Analysis on the USNS OVERTHEHORIZON (T-EST 001)

The purpose of the task is to accomplish a root cause failure investigation and analysis of a connecting rod bolt failure on SSDG #1, using industry RCA practices such as the “5 Whys”, and provide a report detailing findings and recommendations.

Specific Tasks:

1. Support shall include assembling a technical team with diesel engine expertise to attend the ship, observe the engine in as-is state and during disassembly, interview crew, discuss findings with OEM technical representatives, collect engine log data and failed parts.

2. Arrange with the MSC TPOC to send failed parts back to a material failure analysis laboratory.

3. Map out root casual factors and contributing factors.

4. Provide interim and final reports on findings, observations and root causes. Provide recommendations to avoid repeat failures.

SAMPLE TASK 3: SMART/SIP test plan development for a new ship class

USNS OVERTHEHORIZON (T-EST 001) is set to deliver to MSC in 60 days. The ship will accomplish Operational Test and Evaluation over the next 6 months, followed by Final Contract Trials. Task will require the Contractor to develop comprehensive shipboard equipment and system test and evaluation plans to be utilized to demonstrate the capabilities of the ship for Final Contract Trials.

Specific Tasks:

1) Review fleet introduction manuals, technical documentation and other Government Furnished Information and develop a draft index of shipboard test and evaluation plans.

2) Develop a POAM to research, establish test and evaluation criteria, and write test and evaluation plans for the ship.

a. Discuss resource requirements

b. Discuss significant milestones

3) Determine evaluation criteria.

4) Discuss methods to validate test and evaluation plans

5) Provide project management, coordination and administration support for the Final Contract Trial event.

6) Support post-FCT event to identify issues and update test and evaluation plans for future SMART or SIP inspections.

SAMPLE TASK 4: Re-engine study onboard the USNS OVERTHEHORIZON (T-EST 001)

Task will require the Contractor to accomplish a study for re-engineing the main propulsion engines.

Specific Tasks:

1) Develop a POAM for the task. Highlight key milestones.

2) Review operation, maintenance and repair history for the engines. Identify specific issues necessitating engine replacement. Discuss upgrade/modification options in lieu of replacement.

3) Discuss latest technologies, regulatory requirements and other factors influencing options.

4) Discuss full spectrum of options and identify ROM lead time and machinery acquisition costs for each option.

5) Provide recommendations, cost/benefit analysis and publish the report.

N00033-13-R-8035 Shipboard Inspection Program

Attachment A-3: SAMPLE TASKS

6) Prepare presentations as directed by the MSC POC to disseminate the main points from the study.

Attachment A-3