Attachment_13_-_SS521-AA-MAN-010_REV_2.pdf

SS521-AA-MAN-010 REVISION 2

0910-LP-103-3916

U.S. NAVY

DIVING AND MANNED

HYPERBARIC SYSTEMS

SAFETY CERTIFICATION

MANUAL

THIS DOCUMENT SUPERCEDES: SS521-AA-MAN-010 Rev 1 dated 19 May 2004

DISTRIBUTION STATEMENT A: THIS DOCUMENT HAS BEEN APPROVED FOR PUBLIC

RELEASE AND SALE; ITS DISTRIBUTION IS UNLIMITIED.

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

1 NOV 2006

THIS PAGE INTENTIONALLY LEFT BLANK

SS521-AA-MAN-010

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Diving is an inherently dangerous occupation, performed in a hostile environment. The sole purpose of the US Navy Diving and Hyperbaric Systems Safety Certification Program is to make this occupation as safe as possible for the men and women who put their lives on the line, every day, in the service of their country.

Through the System Certification Programs, it is our mission to provide a final independent review of diving and hyperbaric system design, fabrication, testing, repair, maintenance and operation.

This revision represents the second major change to the Certification Manual in less than three years. The primary focus of this revision is to remove most of the technical requirements from this manual and refer those readers seeking technical requirements for the design, construction, test, repair and maintenance of diving and manned hyperbaric systems to the appropriate NAVSEA and NAVFAC technical documents. The appropriate technical requirements for shore/shore-based fixed diving and manned hyperbaric installations are contained in UFC 4-159-01N Design:

Hyperbaric Facilities Manual (formerly NAVFAC DM-39) and NAVFAC MO-406:

Hyperbaric Facilities Maintenance Manual. The appropriate technical requirements for all other Navy diving and manned hyperbaric systems, including shipboard and portable systems, are now found in NAVSEA TS500-AU-SPN-010: U.S. Navy General Specifications for the Design, Construction and Repair of Diving and Hyperbaric Equipment (Diving GENSPECS). The three remaining appendices in this manual are:

Design Guidelines For Diver Handling Systems; Re-Entry Control Procedures; and Objective Quality Evidence. Our goal for this manual revision is to separate the system certification requirements that we are responsible for developing and maintaining from the diving and hyperbaric systems technical requirements for which the respective NAVSEA and NAVFAC technical authorities are responsible. The retention of the Divers Handling Systems technical requirements in this revision of the Certification Manual is due to the fact that the NAVSEA Diving Programs Division is not responsible for weight handling systems. Although in the near future, this appendix is expected to migrate into the Diving GENSPECS.

Questions and comments regarding the content of this manual, or the certification process in general, should be submitted by e-mail to NAVSEA at 00C4@supsalv.org. For specific shore-based system issues, submit questions and comments to NAVFAC at hypercert@navy.mil.

JAMES W. WRIGHT ROBERT L. WARREN

System Certification Authority System Certification Authority Naval Facilities Engineering Command Naval Sea Systems Command i

TABLE OF CONTENTS

CHAPTER 1 – GENERAL INFORMATION

1-1 Introduction ........................................................................................................1-1 1-2 Standard Navy Syntax Summary.......................................................................1-3 1-3 Purpose .............................................................................................................1-4 1-4 Scope and Applicability......................................................................................1-4 1-5 Class Certification of Diver Worn Equipment .....................................................1-5 1-6 System Certification Procedure .........................................................................1-5

CHAPTER 2 – THE SYSTEM CERTIFICATION PROCESS

2-1 Introduction ........................................................................................................2-1 2-2 Application for System Certification ...................................................................2-1 2-2.1 Scope of Certification (SOC)..............................................................................2-3 2-2.2 Milestone Event Schedule (MES) ......................................................................2-5 2-2.3 Initial Certification(s) Pre-Survey Outline Booklet (PSOB).................................2-7 2-2.4 Recertification/Continuance of Certification Pre-Survey Outline Booklet

(PSOB) ..............................................................................................................2-9 2-2.5 Supplemental Certification Documentation......................................................2-10 2-2.5.1 Certification Scope Notebook .....................................................................2-10 2-2.5.2 Mission Configuration Matrix ......................................................................2-11 2-3 Negotiation.......................................................................................................2-11 2-4 Submission of Supporting Documentation.......................................................2-12 2-5 Review and Approval of Supporting Documentation........................................2-13 2-6 On-Site Survey ................................................................................................2-13 2-6.1 Survey Team Personnel ..................................................................................2-14 2-6.2 Objective Quality Evidence (OQE)...................................................................2-14 2-6.3 Survey Coverage .............................................................................................2-14 2-6.4 Preparation for Survey.....................................................................................2-15 2-6.5 Survey Guidelines............................................................................................2-16 2-6.6 On-Site Material Surveys/Audits at Fabrication Facilities.................................2-16 2-7 System Certification Survey Cards ..................................................................2-17 2-8 Examples of Common System Certification Survey Cards ..............................2-20 2-9 Operational Demonstration ..............................................................................2-22 2-10 Issuance of Certificate .....................................................................................2-23 2-11 Tenure of Certification......................................................................................2-23 2-11.1 Termination or Suspension of System Certification .........................................2-23 2-11.1.1 Termination of Certification.........................................................................2-23 2-11.1.2 Suspension of Certification.........................................................................2-23 2-11.1.3 Conditions for Termination or Suspension..................................................2-24 2-11.2 Sustaining System Certification .......................................................................2-24 2-11.2.1 Design Changes and Alterations ................................................................2-24 2-11.2.2 Repairs and Maintenance...........................................................................2-25 2-11.2.3 Periodic Inspection and Operations............................................................2-25 2-11.2.4 Operating Limits .........................................................................................2-26 ii

2-11.2.5 Unusual Situations......................................................................................2-26 2-11.3 Continuation of System Certification................................................................2-26 2-11.4 Recertification ..................................................................................................2-26 2-11.5 Extension of Certification .................................................................................2-26 2-12 Transfer of System Custody ............................................................................2-27 2-12.1 Temporary Transfer of Custody .......................................................................2-27 2-12.2 Permanent Transfer of Custody.......................................................................2-28 2-13 Responsibility for Certification Costs................................................................2-29 2-14 Disposition of Diving Equipment ......................................................................2-29

CHAPTER 3 –INITIAL CERTIFICATION

3-1 Introduction ........................................................................................................3-1 3-2 Design Review Information ................................................................................3-1 3-2.1 System Scope of Certification (SOC).................................................................3-2 3-2.2 Milestone Event Schedule (MES) ......................................................................3-3 3-2.3 Pre-Survey Outline Booklet (PSOB) ..................................................................3-3 3-2.4 Summary Description of the Diving System.......................................................3-3 3-2.5 Subsystem Descriptions ....................................................................................3-3 3-2.6 Design Parameters ............................................................................................3-3 3-2.7 Design Analysis .................................................................................................3-4 3-2.7.1 Design Calculations......................................................................................3-5 3-2.7.2 Stress Analysis .............................................................................................3-5 3-2.7.3 Design Verification........................................................................................3-7 3-2.8 System Drawings...............................................................................................3-7 3-2.9 Operability and Maintainability Criteria and Procedures ....................................3-8 3-2.9.1 Operability Analysis ......................................................................................3-8 3-2.9.2 Maintainability Analysis ................................................................................3-8 3-2.9.3 Operating and Emergency Procedures ........................................................3-8 3-2.9.4 Maintenance Procedures..............................................................................3-9 3-2.10 Justification of Materials.....................................................................................3-9 3-2.11 Toxic and Flammable Materials Data ..............................................................3-10 3-2.12 Hyperbaric Chamber Vacuum Data .................................................................3-10 3-2.13 Hazard Analysis...............................................................................................3-11 3-3 Fabrication and Assembly................................................................................3-11 3-3.1 Controlled Work Procedures............................................................................3-12 3-3.2 Process Instructions.........................................................................................3-13 3-3.3 Welding Procedures ........................................................................................3-13 3-3.4 Brazing Procedures .........................................................................................3-14 3-3.5 Tube Flaring and Flanging Procedures............................................................3-14 3-3.6 Assembly Procedures......................................................................................3-14 3-3.7 Cleaning Procedures .......................................................................................3-15 3-3.8 Quality Assurance Procedures/Inspections for Contractual Work....................3-15 3-3.9 Personnel Qualifications ..................................................................................3-15 3-3.10 PVHO Pressure Vessel Documentation...........................................................3-15 3-4 Quality Assurance Program.............................................................................3-16 3-4.1 Configuration Management, Document and Drawing Control..........................3-17 iii

3-4.2 Material Control ...............................................................................................3-17 3-4.3 Fabrication and Manufacturing Control ............................................................3-18 3-4.4 Cleanliness Control..........................................................................................3-18 3-4.5 Testing and Inspection Control ........................................................................3-19 3-4.6 Atmosphere Analysis .......................................................................................3-20 3-4.7 Re-Entry Control (REC) ...................................................................................3-20 3-5 System Testing Program .................................................................................3-20 3-5.1 Test Categories ...............................................................................................3-21 3-5.2 General Requirements for Test Procedures ....................................................3-22 3-5.3 Electrical Testing .............................................................................................3-23 3-6 Operating and Emergency Procedures (OPs and EPs)...................................3-25 3-6.1 Specific Emergency Procedures......................................................................3-25 3-7 Maintenance Program......................................................................................3-26 3-8 Operating and Maintenance Manual................................................................3-27 3-9 Granting Initial Certification..............................................................................3-29

CHAPTER 4 – RESPONSIBILITIES OF THE ACQUISITION MANAGER

4-1 Introduction ........................................................................................................4-1 4-2 System Certification Requirements in Contracts................................................4-1 4-2.1 Contract Data Requirements List (CDRL)..........................................................4-2 4-2.2 Data Item Description (DID)...............................................................................4-2 4-2.3 Certification Requirements When Using Commercial Contracts........................4-2 4-2.4 Material Specifications.......................................................................................4-2 4-2.5 Performance and Procedure Specifications.......................................................4-3 4-2.6 Quality Assurance (QA) .....................................................................................4-3 4-3 Document Control..............................................................................................4-3 4-4 Preparation of Certification Application..............................................................4-3 4-5 Configuration Management (CM) Plan...............................................................4-3 4-6 Technical Design Reviews.................................................................................4-4 4-7 Associated Documents ......................................................................................4-5

CHAPTER 5 – REPAIR AND OVERHAUL

5-1 Introduction ........................................................................................................5-1 5-2 Certification Status During Repair or Overhaul ..................................................5-2 5-3 Pre-Overhaul Requirements ..............................................................................5-3 5-3.1 Overhaul of Shore-Based Systems....................................................................5-4 5-4 Document Control..............................................................................................5-5 5-5 Procedures ........................................................................................................5-6 5-6 Quality Assurance (QA) .....................................................................................5-6 5-7 Re-Entry Control (REC) .....................................................................................5-6 5-8 Retest Requirements .........................................................................................5-6 5-9 Technical Requirements ....................................................................................5-7 iv

CHAPTER 6 – CERTIFICATION REQUIREMENTS FOR DIVER WORN EQUIPMENT

6-1 Introduction ........................................................................................................6-1 6-2 Class Certification of Diver Worn Equipment .....................................................6-2 6-2.1 Responsibilities of the Acquisition Manager/Applicant.......................................6-2 6-2.2 Responsibilities of the User Commands ............................................................6-3 6-3 Operational Demonstration ................................................................................6-4 6-4 Continuation of Class Certification.....................................................................6-4 6-5 Custody Control of Diver Worn Equipment ........................................................6-5 v

LIST OF APPENDICES

APPENDIX-A - RE-ENTRY CONTROL PROCEDURES

A-1 Standardization of Re-Entry Control Procedures ...........................................................A-1 A-2 Acronyms ......................................................................................................................A-1 A-3 Introduction....................................................................................................................A-2 A-4 Re-Entry Control Program Resources............................................................................A-3 A-5 Re-Entry Control Responsibilities ..................................................................................A-4 A-5.1 DLSS Re-Entry Control Maintenance Technician.........................................................A-4 A-5.2 DLSS Re-Entry Control Supervisor ..............................................................................A-4 A-5.3 Senior Diving Supervisor .............................................................................................A-4 A-5.4 Diving Officer ...............................................................................................................A-5 A-5.5 Commanding Officer....................................................................................................A-5 A-5.6 Contracting Out Work Within the SOC.........................................................................A-5 A-6 Approach to Re-Entry Control Process and Unique Considerations...............................A-5 A-6.1 Revision.......................................................................................................................A-6 A-6.2 Rework ........................................................................................................................A-6 A-6.3 Planned Maintenance ..................................................................................................A-6 A-6.4 Repair Parts Control ....................................................................................................A-7 A-6.5 Component Handling and Cleanliness .........................................................................A-7 A-6.6 Re-Entry Control Review .............................................................................................A-7 A-6.6.1 Approval ..................................................................................................................A-8 A-6.6.2 Close Out.................................................................................................................A-8 A-6.7 Objective Quality Evidence ..........................................................................................A-8 A-7 Re-Entry Control Documentation ...................................................................................A-8 A-7.1 Forms Application ........................................................................................................A-9 A-7.1.1 Re-Entry Control Log (Figure 1) .................................................................................A-9 A-7.1.2 Re-Entry Control Form (Figure 2)...............................................................................A-9 A-7.1.3 Re-Entry Control Continuation Page (Figure 3)..........................................................A-9 A-7.1.4 Re-Entry Control Continuation Page Rework (Figure 4).............................................A-9 A-7.1.5 Test and Inspection Report (Figure 5)........................................................................A-9 A-7.1.6 Controlled Assembly Report (Figure 6) ....................................................................A-10 A-7.1.7 Test and Inspection Report, Joint Tightness Test (Figure 7) ....................................A-10 A-7.1.8 Test and Inspection Report, Valve Seat Tightness Test (Figure 8)...........................A-10 A-7.1.9 Test and Inspection Report, Hydrostatic/Pneumatic Test (Figure 9).........................A-10 A-7.1.10 Test and Inspection Report, System Drop Test (Figure 10)....................................A-10 A-7.1.11 Departure From Specifications Log (Figure 11)......................................................A-10 A-7.1.12 Request for Departure From Specifications Report (Figure 12)..............................A-10 A-7.2 Forms ........................................................................................................................A-11 A-7.3 Disposition of Re-Entry Control and Supporting Documentation ................................A-11 A-8 Electrical/Electronic Components ................................................................................A-12 A-8.1 Purpose .....................................................................................................................A-12 A-8.2 General......................................................................................................................A-12 A-8.3 Quality Characteristics of Electrical Maintenance.......................................................A-12 A-9 Qualifications and Training ..........................................................................................A-13 A-9.1 Qualification Requirements........................................................................................A-13 A-9.2 Qualification Records.................................................................................................A-13 vi

A-9.3 Training And Continued Education ............................................................................A-13 A-10 On-Site Surveys ..........................................................................................................A-14 A-11 Reference Publications................................................................................................A-14 A-12 Military Standards/Specifications .................................................................................A-15 A-12.1 Compressed Gas Association....................................................................................A-15 A-12.2 NAVFAC Manuals......................................................................................................A-16 A-12.3 NAVSEA Manuals......................................................................................................A-16

APPENDIX-B - OBJECTIVE QUALITY EVIDENCE

B-1 Introduction......................................................................................................................B-1 B-2 Pre-Fabrication OQE .......................................................................................................B-1 B-3 Fabrication OQE..............................................................................................................B-2 B-4 Post-Fabrication OQE......................................................................................................B-2

APPENDIX-C - DESIGN GUIDELINES FOR DIVER HANDLING SYTEMS

C-1 Introduction................................................................................................................... C-1 C-2 Definitions..................................................................................................................... C-1 C-3 Design Criteria and Guidelines ..................................................................................... C-3 C-3.1 Equipment Design Criteria .......................................................................................... C-3 C-3.1.1 Types of Loads ....................................................................................................... C-3 C-3.1.2 Environmental Considerations ................................................................................ C-4 C-3.1.2.1 Sea State.............................................................................................................. C-4 C-3.1.2.2 Air and Water Temperature................................................................................... C-4 C-3.1.2.3 Precipitation .......................................................................................................... C-4 C-3.1.2.4 Wind Velocity ........................................................................................................ C-5 C-3.1.2.5 Ocean Currents..................................................................................................... C-5 C-3.1.2.6 Corrosion .............................................................................................................. C-5 C-3.1.3 System Considerations ........................................................................................... C-5 C-3.2 Human Engineering and Operational Design Considerations...................................... C-6 C-3.2.1 Emergency Conditions and Reduced Operating Capability ..................................... C-6 C-4 Design and Testing Requirements................................................................................ C-7 C-4.1 Load Bearing Component Requirements .................................................................... C-7 C-4.1.1 Load Bearing Component Design ........................................................................... C-7 C-4.1.1.1 Design Factors of Safety....................................................................................... C-8 C-4.1.2 Submission of Drawings and Calculations for Load Bearing Components .............. C-9 C-4.1.3 Divers Handling System Pre-Mission Control ........................................................C-10 C-4.1.4 System Testing for Load Bearing Components ..................................................... C-11 C-4.2 Hydraulic and Pneumatic System Requirements ...................................................... C-13 C-4.2.1 System Design...................................................................................................... C-13 C-4.2.2 System Testing ..................................................................................................... C-15 C-4.2.2.1 Hydrostatic Testing Requirements ...................................................................... C-16 C-4.2.2.2 System Tightness Testing Requirements............................................................ C-16 C-4.2.2.3 Maintenance Testing Requirements.................................................................... C-17 C-4.2.3 Relief and Counter-Balance Valves....................................................................... C-18 C-4.2.4 Cleaning, Flushing, and Preservation.................................................................... C-19 C-4.3 Electrical Power Requirements and Controls ............................................................ C-19 C-4.3.1 System Design...................................................................................................... C-19 C-4.3.2 System Testing ..................................................................................................... C-20 C-4.3.2.1 Maintenance Testing Requirements.................................................................... C-20 C-5 Certification Requirements.......................................................................................... C-21 vii

C-5.1 Initial and Sustaining Certification Requirements ...................................................... C-21 C-5.2 Certification Surveys................................................................................................. C-25 C-5.3 Suspension of Certification ....................................................................................... C-26 viii

LIST OF FIGURES

FIGURE AND TITLE PAGE NO.

2-1 Major Certification Events 2-2

2-2 Certification Milestone Event Schedule 2-6

2-3 Certification Scope Identification 2-11

2-4 Mission Configuration Matrix 2-12

2-5 System Certification Survey Card 2-19

C-1 Control Work Package, Test and Inspection Report, and Diver Portable Handling System Annual Survey Plan

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LIST OF TABLES

TABLE AND TITLE PAGE NO.

B-1 Acceptance Criteria for Joint Tightness, Extended Tightness, and Drop Tests

B-6

C-1 Factors of Safety for Rigging C-9

C-2 Maintenance Testing Requirements - Load Bearing Components

C-14

C-3 Maintenance Testing Requirements - Hydraulic Systems C-17

C-4 Maintenance Testing Requirements - Electrical Systems C-20 x

LIST OF ABBREVIATIONS AND ACRONYMS

ABS American Bureau of Shipping AHP Air, High Pressure ALP Air, Low Pressure ANSI American National Standards Institute ANU Authorized for Navy Use ASME American Society of Mechanical Engineers ata Atmospheres, Absolute atm Atmospheres BIBS Built In Breathing System CDRL Contract Data Requirements List CFR Code of Federal Regulations CGA Compressed Gas Association CM Configuration Management CO Carbon Monoxide CO2 Carbon Dioxide COC Certificate of Compliance DC Direct Current DFARS Defense Federal Acquisition Regulations Supplement DFS Departure From Specification DID Data Item Description DLSS Divers’ Life Support System DOD Department of Defense DOT Department of Transportation DRMO Defense Reutilization and Marketing Office EP Emergency Procedure EXH Exhaust FADS Fly Away Dive System FAR Failure Analysis Report FARC Fly Away Recompression Chamber FAT Factory Acceptance Test FMGS Flyaway Mixed Gas System GSO General Specifications for Overhaul of Surface Ships HAZCAT Hazard Category Level HP High Pressure HPU Hydraulic Power Unit IR Insulation Resistance LSS Life Support System LWDS Light Weight Dive System MAWP Maximum Allowable Working Pressure MCM Mission Configuration Matrix MES Milestone Event Schedule MCR Manual Change Request MILSTRIP Military Standard Requisitioning and Issuing Procedures xi

MOA Memorandum of Agreement MOP Maximum Operating Pressure MOT Manned Operational Tests MRC Maintenance Requirement Card MT Magnetic Particle Inspection NAVFAC Naval Facilities Engineering Command NAVSEA Naval Sea Systems Command NAVOSH Navy Occupational System and Health NDT Nondestructive Testing NEDU Navy Experimental Diving Unit NFESC Naval Facilities Engineering Service Center Ni-Cu Nickel-Copper NSTM Naval Ships’ Technical Manual O2 Oxygen O&M Operating and Maintenance OAS Obstacle Avoidance System OPEVAL Operational Evaluation OPNAV Office of the Chief of Naval Operations OP Operating Procedure OQE Objective Quality Evidence PFT Prototype/First article Testing PIT Pre-installation Tests PMS Preventive Maintenance System POT Pre-operational Tests psia Pounds per Square Inch, Absolute psid Pounds per Square Inch, Differential psig Pounds per Square Inch, Guage PSOB Pre-Survey Outline Booklet PT Liquid Penetrant Inspection PTFE Polytetrafluoroethylene PVHO Pressure Vessels for Human Occupancy QA Quality Assurance REC Re-entry Control SAR SHIPALT Record SCA System Certification Authority scfm Standard Cubic Feet per Minute SCSC System Certification Survey Cards SCUBA Self-contained Underwater Breathing Apparatus SEADL NAVSEA Data List SECNAV Secretary of the Navy SHIPALT Ship Alteration SIT System Integration Test SNDL Standard Navy Double Lock SOC Scope of Certification SOT System Operational Test STP Standard Temperature and Pressure xii

TL Transfer Lock TR Time Required TRCS Transportable Recompression Chamber Systems UBA Underwater Breathing Apparatus UL Underwriters Laboratories USN United States Navy UT Ultrasonic Testing

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APPENDIX C

DESIGN GUIDELINES FOR DIVER HANDLING SYSTEMS

C-1 Introduction

Diver Handling Systems include any weight handling systems that are used to launch and recover divers through the air/sea interface from a support ship. Inspection and load testing requirements apply to diver handling operations and should not be used for general crane applications. The user should use Naval Ships’ Technical Manual Chapter 589, Cranes, for general crane requirements. Diver Handling Systems may consist of a simple block and tackle arrangement, using a davit and capstan to raise and lower a diver stage, or may consist of a complex A-frame system that is used to launch and recover manned tethered underwater vehicles, such as the Pressurized Rescue Module (PRM). It is therefore prudent for the Acquisition Manager to discuss the certification requirements that are specific to the handling system with the SCA.

a. This appendix contains certification parameters for handling systems employed in the launch and recovery of manned Diving Systems from support ships.

The methods of design and fabrication are discussed, and their required verification OQE is identified. Preventive maintenance documentation, which is influenced by, and evolved from the basic design concepts as well as operational documentation, is also outlined.

b. Diving System handling equipment to be certified under these requirements includes, but is not limited to, cranes, booms, davits, and A-frames; plus their associated winching and rigging components. Hydraulic, electrical, and pneumatic subsystems are also considered part of the handling system.

c. All critical items, as defined in paragraph C-2.b, shall be included in the SOC. The SOC will also contain all items necessary to ensure compliance with the objective and intent of certification as described in Chapter 1.

d. Weight handling components are typically included within the SOC for the Diving System. When the weight handling system is portable, it must be included within the SOC for each diving system it will be used to support.

C-2 Definitions

a. Added Mass Effect. The mass of water particles surrounding an object immersed in water that is accelerated with the object as the object is accelerated through the water. When a body is accelerated in a fluid, it behaves as though its mass is greater than it actually is due to the effect of the surrounding fluid. This additional mass must be added to the actual body mass to account for the change in inertia.

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b. Critical Item. Any item within a system, equipment, or component whose failure would endanger the occupants of the Diving System. These failures may include uncontrolled dropping, shifting, or other sudden movement of the Diving System when it is supported by the handling system.

c. Design Load. The maximum force due to the rated load plus some or all of the following: (1) added mass effects, (2) entrained water, (3) any external payloads,

(4) drag or wind loads, and (5) dynamic loads which are derived with the aid of the dynamic load factor.

d. Dynamic Load. The load imposed on a system due to accelerations of gravity and ship motion. It is dependent upon the magnitude and frequency of ship motions, ship attitude, and the location of the handling system on the ship.

e. Dynamic Load Factor. A calculated number given in acceleration units, g, where 1g is the acceleration of gravity. The force exerted by the system on its supports is determined by multiplying the dynamic load factor by the weight of the system.

f. Fail-safe. Components within the handling system that are designed to prevent uncontrolled dropping, shifting, or sudden movement of the Diving System during a hydraulic or electrical system failure or component/equipment malfunction.

g. Handling System. The mechanical, electrical, structural equipment and rigging used on board a support ship to launch and recover divers or a manned Diving System.

(1) Load Bearing. Those components of the handling system that support the loads resulting from launching and recovering of a manned Diving System.

(2) Load Controlling. Those components of the handling system that position, restrain, or control the movement of a manned Diving System. Towing is excluded from the SOC.

h. Operational Load. The maximum weight that will be lifted during diver handling operations. This is normally the weight of the stage plus three fully dressed divers.

i. Rated Load. The maximum weight that may be lifted by the assembled handling system at its rated speed and under parameters specified in the equipment specifications (e.g., hydraulic pressures, electrical current, electrical voltages, etc.).

j. Rigging. Running rigging consists of the rope (wire rope or synthetic line) and end fittings intended to handle the Diving System that passes over sheaves or through rollers. Standing rigging is rope that is stationary and provides mechanical support to the handling system.

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k. Static Test Load. A weight equal to 200 percent of the Operational Load of the handling system. It is used to physically verify the structural integrity of the handling system, and the adequacy of its brakes and fail-safe components.

l. Support Ship. Any platform used to transport, launch, and retrieve a Diving System. Ships, boats, vessels, barges, and submarines are included in this definition. An example of a submarine support platform is one modified to carry a Dry Deck Shelter for operations with Swimmer Delivery Vehicles.

C-3 Design Criteria and Guidelines

C-3.1 Equipment Design Criteria

This section provides guidelines and criteria for the design and analysis of Diver Handling System components and associated structures within the SOC. Alternatively, the Acquisition Manager may elect to impose commercial design criteria administered by the American Bureau of Shipping (ABS). If the ABS Rules are used, the Acquisition Manager must obtain initial certification for the handling system from ABS. Once ABS certification is obtained, the Acquisition Manager shall use ABS to conduct periodic surveys. When ABS is used to certify the handling system, the Acquisition Manager shall include the SCA in all design reviews to ensure that all issues concerning interfacing with the diving system are accounted for. The Acquisition Manager is cautioned that after commercial certification to commercial standards has been achieved, it may not be possible to revert to using the criteria in this manual to recertify the system under U.S. Navy requirements.

C-3.1.1 Types of Loads

The initial step in designing any handling system is to determine the design load that the system will encounter. The design load is derived from a combination of forces under worst-case operating conditions. Components should be sized according to the greatest design load, or combination of loadings that will be encountered. The following loads and forces should be considered when designing Diver Handling Systems:

a. Asymmetric loads. When sizing structural members for handling systems that employ more than one load carrying member to support their payload, consideration should be given to factors which might cause asymmetric loading. Such factors affecting the Diving System that would result in asymmetric loading include, but are not limited to, the following: external water, free surface effects in the internal tanks, a shift in ballast, and external payloads.

b. Dynamic loads. In addition to the load generated by lifting the normal rated capacity of the handling system, dynamic forces due to wave induced motions on the support vessel must also be considered. Analysis should be conducted in accordance with DOD-STD-1399, Section 301A or equivalent, unless support vessel motions are known. If support vessel motions have been measured at sea, or have been determined through the application of proven computer programs, the results can be used in lieu of DOD-STD-1399, Section 301A.

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c. Dead loads. The minimum dead load consists of the weight of the structural parts of the Diver Handling System and materials permanently attached to the structure.

d. Wind Forces. The wind loads on the projected area of the handling system structure and on the Diving System, appropriate to the design conditions, are to be considered.

e. Maximum Forces. Structural members are to be sized using the appropriate loads and factors of safety. The general requirements in applying factors of safety to all U.S. Navy weight handling systems that perform manned lifts are presented in paragraph C-4.1.1.1 and Table C-1.

C-3.1.2 Environmental Considerations

Diver Handling Systems are subjected to extremely harsh and powerful environmental factors that significantly impact the operational and maintenance characteristics of the system. Environmental factors which should be considered in the system design parameters are sea state, air temperature, water temperature, precipitation (rain and snow), ice, wind velocity, currents, and the corrosive affects of the salt water environment.

C-3.1.2.1 Sea State

For the operational sea state specified, the uppermost value for the wave heights of the significant wave or the 1/10th highest wave should be taken as the design wave.

The period of maximum energy of the sea spectrum should be chosen as the design period.

C-3.1.2.2 Air and Water Temperature

The maximum and minimum design operating temperatures of both the air and water must be taken into account during handling system design. This is particularly important for hydraulic systems where hydraulic fluid may become too viscous in extreme cold or lose its lubricating properties in extreme heat. Additionally, extremely cold air temperatures may affect the ductility of some metals and render structural members unsafe if not adequately designed.

C-3.1.2.3 Precipitation

The effect of rain, snow, sleet and ice can be dramatic on topside equipment not designed for it. Electrical connectors, junction boxes and motors that are not rated for harsh outside environments often fail in shipboard service. All pivoting or sliding load bearing surfaces should either be sealed from the weather or be designed to permit thorough inspections and be provided with an adequate number of lubrication fittings.

Waterproof grease is required for these applications. Also, steels must have a protective coating of paint designed for a salt air environment.

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C-3.1.2.4 Wind Velocity

Side loads may be induced in the handling system by high winds. This loading may be significant if either the Diving System or the handling system itself has a large surface area. The prudent designer will account for possible wind related effects in the system design.

C-3.1.2.5 Ocean Currents

In the same manner that wind affects the handling system topside, ocean currents affect any submerged components of the Diving System. Drag effects caused by ocean currents may be significant depending on the geometry of the Diving System and/or any submerged portions of the handling system. Drag effects must be taken into account in the design of the handling system.

C-3.1.2.6 Corrosion

Each component should be carefully reviewed for its susceptibility to corrosion, with special attention given to those components immersed in salt water. Furthermore, care should be taken to avoid galvanic corrosion when several different kinds of metals are in physical contact. Galvanic series charts or tables should be consulted when utilizing dissimilar metals.

C-3.1.3 System Considerations

The operation of the handling system is an integral part of the total Diving System, and as such, is limited by the coordination of personnel on deck and interface of the Diving System, handling system, and support vessel. For safe and efficient launch and recovery evolutions, the following items must be considered when developing a Diver Handling System:

a. Positive Control. The motion of the Diving System during launch and recovery operations must be under positive control at all times.

b. Fail-Safe. A provision designed to automatically stop or safely control any motion when a hydraulic or electrical failure occurs. The Diver Handling System shall be provided with interlocks, safety devices, and protective devices so that it will be fail-safe.

c. Motion effects. The physical location of the handling system on board the support ship should be such that the effects of the ship’s motions on the Diving System during handling evolutions are minimized.

d. Weight. The weight of the Diver Handling System should be minimized to limit the weight added to the support vessel and the adverse effects on its sea keeping ability.

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e. Shock mitigation. Dynamic motions of the support ship at-sea can cause shock loads to the Diving System and its personnel through the handling system.

Motion compensating devices shall be considered to minimize these shock loads.

C-3.2 Human Engineering and Operational Design Considerations

Diver Handling Systems are designed to transport personnel in a restricted and hazardous environment under the direct supervision and control of support personnel.

A human engineering evaluation should be conducted to ensure the ability of support personnel to control and supervise the safe and coordinated movement of the Diving System. The following are some critical areas that should be addressed in the evaluation:

a. Hazardous exposure. Due to the nature of handling system operations, some evolutions will be inherently hazardous. However, hazards should be eliminated whenever possible. There should be a minimum of support personnel exposed to hazardous operations during handling evolutions. There should be minimal diver/swimmer involvement during launch and recovery of the Diving System.

b. Coordination and control. Safe and timely operation of handling systems requires precise control and coordination of all personnel involved. The system arrangement should facilitate simplicity and require minimal supervision to attain this goal.

c. Communication. In addition, there must be clear communications between Diving System handling support personnel, the support ship personnel responsible for maneuvering the ship and the Diving Supervisor.

d. Monitoring equipment status. Control and support personnel responsible for the operation of the handling system should have access to monitoring devices to enable them to evaluate the status of the equipment. This is to ensure the system is operating within its capability limits (e.g., speed, load, pressure, temperature, etc.).

These factors, along with the observed sea state, can then be evaluated to determine their effect on the operating parameters of the Diving System.

e. Manning. Minimizing the number of personnel required to operate and maintain the system should be considered.

C-3.2.1 Emergency Conditions and Reduced Operating Capability

The Diver Handling System shall be designed to minimize the effects of component failures. To identify and define the failures, and to determine how to resolve them, a hazard analysis shall be performed in accordance with MIL-STD-882, System Safety Program Requirements, or an approved industrial standard. The system hazard analysis can also be used to evaluate the system’s capability to continue to operate and safely recover Diving System personnel. All handling system components shall be operable in sea states specified by the mission profile. In the event of a control console failure, an alternate or backup means of system operation is required.

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C-4 Design and Testing Requirements

a. NAVSEA design and testing requirements of Diver Handling Systems shall be met as stated in this section.