Attachment_14_-_NAVSEA_SS80-AG-MAN-010P-9290_REV_A.pdf

SYSTEM CERTIFICATION PROCEDURES

AND CRITERIA MANUAL FOR

DEEP SUBMERGENCE SYSTEMS

THIS DOCUMENT SUPERSEDES: NAVSEA P-9290

DISTRIBUTION STATEMENT A:

Approved for Public Release; Distribution is Unlimited

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

SS800-AG-MAN-010/P-9290

REVISION A

0910-LP-018-2840 3 NOVEMBER 1998

CHANGE 2 - 7 MAY 2014

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SS800-AG-MAN-010/P-9290

LIST OF EFFECTIVE PAGES

Date of Original pages is: 3 November 1998

Original 116

Total Number of pages in this publication is 374 consisting of the following:

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TABLE OF CONTENTS

Chapter 1: General Information ............................................................ 1-1

1.1 Introduction ........................................................................................................ 1-1

1.2 Background ....................................................................................................... 1-1

1.2.1 History ......................................................................................................... 1-1

1.2.2 Lessons Learned ......................................................................................... 1-2

1.3 Certification Definitions ...................................................................................... 1-3

1.3.1 Deep Submergence System ....................................................................... 1-3

1.3.2 Deep Submergence System Personnel ...................................................... 1-3

1.3.3 Scope of Certification .................................................................................. 1-3

1.3.4 Certification Program Plan .......................................................................... 1-4

1.3.5 Scope of Certification Notebook .................................................................. 1-4

1.3.6 Surveys ....................................................................................................... 1-4

1.3.7 Objective Quality Evidence ......................................................................... 1-4

1.3.8 Certification Survey Plan ............................................................................. 1-5

1.3.9 Certification Package .................................................................................. 1-5

1.3.10 Certification ............................................................................................... 1-5

1.3.11 Authorization for Manned Use ................................................................... 1-5

1.3.12 Letter of Certification ................................................................................. 1-5

1.3.13 Initial Certification ...................................................................................... 1-6

1.3.14 Sustaining Certification ............................................................................. 1-6

1.3.15 Prohibition Against Manned Operations .................................................... 1-6

1.3.16 Suspension of Certification ........................................................................ 1-6

1.3.17 Letter of Suspension of Certification ......................................................... 1-6

1.3.18 Reinstatement of Certification (Re-Certification) ....................................... 1-7

1.3.19 Functional Audits ....................................................................................... 1-7

1.3.20 Technical Assistance Review (Tech Assist) .............................................. 1-7

1.4 Principal Participants ......................................................................................... 1-7

1.5 Deep Submergence Systems Oversight Board (DSSOB) ................................. 1-8

1.6 Basis for Initial DSS Certification ....................................................................... 1-9

1.7 DSS Certification Process ................................................................................. 1-9

1.8 Documentation Hierarchy .................................................................................. 1-9

CHANGE 2 ii

Chapter 2: The System Certification Process ..................................... 2-1

2.1 Introduction ........................................................................................................ 2-1

2.2 Application for Initial Certification ....................................................................... 2-1

2.2.1 Plan of Action and Milestones ..................................................................... 2-2

2.2.2 System Safety Program Plan ...................................................................... 2-2

2.2.3 Proposed Certification Program Plan (CPP) ............................................... 2-6

2.2.4 Proposed Scope of Certification .................................................................. 2-7

2.2.4.1 Scope of Certification ............................................................................ 2-8

2.2.4.2 Scope of Certification Notebook ............................................................ 2-9

2.2.4.3 Memorandum of Understanding ............................................................ 2-9

2.2.5 Certification Survey Plan ........................................................................... 2-10

2.3 Approval of System SOC Documents .............................................................. 2-10

2.4 Departure From Specification .......................................................................... 2-10

2.4.1 Processing Departures From Specification ............................................... 2-11

2.4.2 DFS Administrative Control and Records .................................................. 2-12

2.5 Technical Certification Requirements .............................................................. 2-14

2.6 Certification Package ....................................................................................... 2-14

2.7 Internal Certification Survey ............................................................................. 2-14

2.8 SCA Surveys ................................................................................................... 2-14

2.9 Operational Demonstration .............................................................................. 2-15

2.10 Issuance of Certification ................................................................................ 2-15

2.11 Sustaining Certification .................................................................................. 2-16

2.12 Modifications .................................................................................................. 2-16

2.13 Suspension of Certification ............................................................................ 2-16

2.14 Functional Audits ........................................................................................... 2-17

2.15 Process For Changing The Manual ............................................................... 2-17

2.15.1 Change Submittal .................................................................................... 2-17

2.15.2 Change Status Accounting ...................................................................... 2-17

2.15.3 Manual Distribution ................................................................................. 2-18

Chapter 3: Requirements for Certification ........................................... 3-1

3.1 Introduction ........................................................................................................ 3-1

3.2 Design and Configuration Management ............................................................ 3-1

3.2.1 Summary Description of the DSS ................................................................ 3-2 iii CHANGE 2

3.2.2 Design Parameters ..................................................................................... 3-2

3.2.3 Subsystem Descriptions .............................................................................. 3-3

3.2.4 Design Analysis and Calculations ............................................................... 3-4

3.2.4.1 Design Calculations ............................................................................... 3-4

3.2.4.2 Stress Analysis ...................................................................................... 3-5

3.2.5 Drawings ..................................................................................................... 3-6

3.2.6 Operability and Maintainability .................................................................... 3-7

3.2.7 Justification of Materials .............................................................................. 3-7

3.2.8 Toxic and Flammable Materials .................................................................. 3-7

3.2.9 Atmosphere Analysis .................................................................................. 3-8

3.2.10 Vacuum in Manned and Floodable Spaces ............................................... 3-9

3.2.11 System Safety Program ............................................................................ 3-9

3.3 Material Control ................................................................................................. 3-9

3.3.1 Definition of Material SOC Control Divisions ............................................. 3-10

3.3.1.1 Material Control Division A .................................................................. 3-10

3.3.1.2 Material Control Division B .................................................................. 3-10

3.3.1.3 Material Control Division C .................................................................. 3-11

3.3.2 Material Procurement ................................................................................ 3-11

3.3.3 Material Marking and Traceability ............................................................. 3-11

3.3.3.1 MCD A Material Marking and Traceability ........................................... 3-11

3.3.3.2 MCD B Material Marking and Traceability ........................................... 3-12

3.3.3.3 MCD C Material Marking and Traceability ........................................... 3-12

3.3.4 Receipt Inspection ..................................................................................... 3-12

3.3.4.1 MCD A Receipt Inspection .................................................................. 3-12

3.3.4.2 MCD B Receipt Inspection .................................................................. 3-13

3.3.4.3 MCD C Receipt Inspection .................................................................. 3-14

3.3.5 Verification of Completion of Required Testing ......................................... 3-14

3.3.6 Installation Verification .............................................................................. 3-14

3.3.6.1 Installation Verification Requirement for MCD A, B and C Material ..... 3-14

3.3.7 Material Transfer ....................................................................................... 3-14

3.3.7.1 Material Certification Maintained ......................................................... 3-14

3.3.7.2 Material Certification Lapsed (DSS/Ship In Inactivation Availability) ... 3-15

3.3.7.3 Material Recertification Required ......................................................... 3-17

3.4 Fabrication Process Control ............................................................................ 3-17

CHANGE 2 iv

3.4.1 Work Procedures ...................................................................................... 3-18

3.4.2 Welding Procedures .................................................................................. 3-18

3.4.3 Brazing Procedures ................................................................................... 3-19

3.4.4 Pipe Bending Procedures ......................................................................... 3-19

3.4.5 Cleaning Procedures ................................................................................. 3-19

3.5 Quality Assurance............................................................................................ 3-20

3.5.1 Design and Drawing Control ..................................................................... 3-21

3.5.2 Fabrication and Manufacturing Control ..................................................... 3-21

3.5.3 Testing and Inspection Control .................................................................. 3-22

3.5.4 Calibration ................................................................................................. 3-22

3.5.5 Audits ........................................................................................................ 3-23

3.6 Test Performance ............................................................................................ 3-23

3.6.1 Development Tests ................................................................................... 3-23

3.6.2 Quality Assurance Tests ........................................................................... 3-24

3.6.3 System Operation, Integration and Proof Tests ........................................ 3-24

3.6.3.1 Proof, Builder's Pre-Trial or Pre-Sea Trial Tests .................................. 3-24

3.6.3.2 Structural Testing ................................................................................ 3-24

3.6.3.3 Fluid System Testing ........................................................................... 3-24

3.6.3.4 Cleanliness Testing ............................................................................. 3-25

3.6.3.5 Electrical Testing ................................................................................. 3-25

3.6.3.6 Inclination Testing ................................................................................ 3-27

3.6.3.7 Access to Vital Equipment ................................................................... 3-27

3.7 Operational Demonstration and Trials Stage (Builder’s Trials or Sea Trials) ... 3-27

3.7.1 Certification/Re-Certification Dive ............................................................. 3-30

3.7.2 Emergency Surfacing ................................................................................ 3-31

3.7.3 Test Dive Deficiencies ............................................................................... 3-31

3.7.4 Manned Use of One Atmosphere DSSs in Pursuit of Certification (or Reinstatement of Certification) ............................................................................ 3-32

3.8 Operating and Emergency/Casualty Procedures ............................................. 3-33

3.8.1 Operating Manual ...................................................................................... 3-34

3.9 Maintenance Procedures ................................................................................. 3-35

3.9.1 Maintenance Requirement Card ............................................................... 3-35

3.9.2 SOC Planned Maintenance Documentation .............................................. 3-36

3.10 Record Retention Requirements ................................................................... 3-37 v CHANGE 2

Chapter 4: On-Site Certification Survey ............................................... 4-1

4.1 Introduction ........................................................................................................ 4-1

4.2 Types of Surveys ............................................................................................... 4-1

4.2.1 Initial Certification Survey ............................................................................ 4-1

4.2.2 Sustaining Certification Survey ................................................................... 4-1

4.2.2.1 Sustaining Certification Survey Periodicity ............................................ 4-2

4.2.3 Reinstatement of Certification Survey ......................................................... 4-2

4.2.4 End-Of-Availability Survey ........................................................................... 4-2

4.2.5 Internal Surveys .......................................................................................... 4-2

4.2.5.1 Internal Survey Periodicity ..................................................................... 4-3

4.3 Preparation For Survey ...................................................................................... 4-3

4.3.1 Scheduling of SCA Surveys ........................................................................ 4-3

4.3.1.1 Work Completion Requirements ............................................................ 4-3

4.3.1.2 Maintenance Requirement Status ......................................................... 4-4

4.3.1.3 Testing Procedure Status ...................................................................... 4-4

4.3.1.4 Departure Status ................................................................................... 4-4

4.3.1.5 Certification Survey Plan ....................................................................... 4-6

4.3.1.6 Personnel .............................................................................................. 4-6

4.4 Survey Team Personnel .................................................................................... 4-6

4.5 Certification Survey Cards ................................................................................. 4-6

4.6 Survey Guidelines ............................................................................................. 4-8

4.7 Operational Demonstration ................................................................................ 4-8

Chapter 5: Sustaining Certification ...................................................... 5-1

5.1 Introduction ........................................................................................................ 5-1

5.2 Qualification Policy ............................................................................................ 5-1

5.3 Responsibilities .................................................................................................. 5-1

5.3.1 Program Manager and SCA Responsibilities .............................................. 5-2

5.3.2 Sustaining Activity Responsibilities ............................................................. 5-2

5.3.3 Industrial Facility/Supervising Authority Responsibilities ............................. 5-3

5.4 Sustaining Certification Control Procedures ...................................................... 5-4

5.4.1 Re-entry Control .......................................................................................... 5-4

5.4.2 Work Procedures ........................................................................................ 5-4

5.4.3 Planned Maintenance Procedures .............................................................. 5-5

CHANGE 2 vi

5.4.4 Temporary Modifications ............................................................................. 5-6

5.5 Test and Trials Stage ......................................................................................... 5-7

5.6 Sustaining Certification Survey .......................................................................... 5-7

5.7 Operating Limits ................................................................................................ 5-7

5.8 Continuation of Certification ............................................................................... 5-7

APPENDIX A: Categorization of SOC Materials and Components ... A-1

A.1 INTRODUCTION ............................................................................................... A-1 A.2 CATEGORY 1 MATERIALS .............................................................................. A-1 A.3 CATEGORY 2 MATERIALS .............................................................................. A-4

A.3.1 Structural Materials ..................................................................................... A-4 A.4 CATEGORY 3 MATERIALS .............................................................................. A-5

A.4.1 Pressure Hull/Vessel and Other Structural Materials .................................. A-6 A.5 VIEWING WINDOW MATERIALS ..................................................................... A-7 A.6 FLOTATION MATERIALS ................................................................................. A-7 A.7 HYDRAULIC SYSTEM FLUIDS ........................................................................ A-8 A.8 ELECTRICAL/ELECTRONIC SYSTEM MATERIALS ....................................... A-8

A.9 FAIRING AND MISCELLANEOUS NONSTRUCTURAL MATERIALS .............. A-9

A.10 LIFE SUPPORT SYSTEM MATERIALS ......................................................... A-9

APPENDIX B: Design Factors for Deep Submergence Systems ...... B-1

B.1 INTRODUCTION ............................................................................................... B-1 B.2 STRUCTURAL DESIGN CONSIDERATIONS .................................................. B-1

B.2.1 Fatigue ........................................................................................................ B-2 B.2.2 Fracture Toughness .................................................................................... B-3

B.3 DESIGN STRENGTH PARAMETERS OF EXTERNALLY LOADED PRESSURE

HULLS/VESSELS, HARD STRUCTURES ............................................................... B-4

B.3.1 Inelastic Stability ......................................................................................... B-5 B.3.2 Elastic Stability ............................................................................................ B-5 B.3.3 Stress Analysis ........................................................................................... B-5 B.3.4 Verification of Calculated Collapse Pressure .............................................. B-6

B.3.4.1 Testing Procedures/Test Instrumentation ............................................. B-7 B.3.5 Verification of As-Built Strength (Proof Test) .............................................. B-7

B.3.5.1 Proof Testing Procedures/Instrumentation ............................................ B-8 vii CHANGE 2

B.4 DESIGN STRENGTH PARAMETERS OF INTERNALLY LOADED PRESSURE

VESSELS/HARD STRUCTURES ............................................................................. B-8

B.4.1 Stress Analysis ........................................................................................... B-9 B.4.2 Verification of Calculated Design Operating Pressure ................................ B-9

B.4.2.1 Testing Procedures/Test Instrumentation ........................................... B-10

B.5 MISCELLANEOUS PRESSURE VESSELS AND HARD STRUCTURES ....... B-10

B.6 DESIGN OF PENETRATIONS INTO AND THROUGH THE PRESSURE HULL

ENVELOPE ............................................................................................................ B-10

B.6.1 Piping Penetrations ................................................................................... B-11 B.6.2 Electrical Penetrations .............................................................................. B-11 B.6.3 Viewports .................................................................................................. B-11 B.6.4 Hatches/Closures ..................................................................................... B-12 B.6.5 Seals ......................................................................................................... B-12

B.7 MATERIAL SELECTION ................................................................................. B-13 B.7.1 Corrosion Resistance ............................................................................... B-13

B.7.1.1 Electrolytic Corrosion .......................................................................... B-13 B.7.1.2 Stress Corrosion ................................................................................. B-14

B.7.2 Toxicity...................................................................................................... B-14 B.7.3 Flammability .............................................................................................. B-14

B.8 FABRICATION ................................................................................................ B-15 B.8.1 Fabrication, Welding and Brazing ............................................................. B-15 B.8.2 Threaded Fasteners ................................................................................. B-15 B.8.3 Locking Devices for Mechanical Fasteners............................................... B-16 B.8.4 Protective Finishes ................................................................................... B-16

B.9 NAVAL ARCHITECTURE DESIGN ................................................................. B-16 B.9.1 Stability and Equilibrium ........................................................................... B-16

B.9.1.1 Inclining Experiments and Trim Dives for Submersibles and Submerged Habitats ............................................................................................................ B-17

B.9.2 Additional Conditions ................................................................................ B-18 B.10 DESIGN OF PIPING SYSTEMS ................................................................... B-18

B.10.1 Piping System Flexibility ......................................................................... B-19 B.10.2 Piping Systems Component Structural Design Consideration ................ B-20

B.10.2.1 Categories of Stress .......................................................................... B-21 B.10.3 Design of Piping Systems and Components ........................................... B-22 B.10.4 Hoses and Umbilical (Deck Shelters, Etc.) ............................................. B-23

CHANGE 2 viii

B.10.5 Special Considerations for Oxygen Systems .......................................... B-24 B.10.6 Piping System Design Verification .......................................................... B-25 B.10.7 Relief Valves ........................................................................................... B-25

B.11 DESIGN OF ELECTRICAL SYSTEMS ......................................................... B-25 B.11.1 Power Requirements .............................................................................. B-25

B.11.1.1 Batteries ............................................................................................ B-25 B.11.2 Wiring Methods ....................................................................................... B-25 B.11.3 Ungrounded System ............................................................................... B-27 B.11.4 Fault Current Protection .......................................................................... B-27 B.11.5 Electrical Shock Hazards ........................................................................ B-27 B.11.6 Insulation Considerations ........................................................................ B-28 B.11.7 Electrical Connectors and Penetrators ................................................... B-28

B.11.7.1 Electrical Connectors ........................................................................ B-28 B.11.7.2 Electrical Penetrators ........................................................................ B-29 B.11.7.3 Electrical Hull Penetrator Protection .................................................. B-29

B.11.8 Lighting Systems .................................................................................... B-29 B.11.9 Instrumentation ....................................................................................... B-29 B.11.10 Communication Systems ...................................................................... B-30 B.11.11 Heating Systems ................................................................................... B-30

B.12 PROPULSION SYSTEM ............................................................................... B-30 B.13 HUMAN ENGINEERING ............................................................................... B-30

B.13.1 Sound Levels .......................................................................................... B-30 B.13.2 Thermal Control ...................................................................................... B-31

B.14 LIFE SUPPORT SYSTEM ............................................................................. B-31 B.14.1 Life Support System Design Specification .............................................. B-32

B.14.1.1 Closed Circuit Life Support Design Specification .............................. B-32 B.14.1.2 Open Circuit Life Support Design Specification................................. B-33

B.14.2 Breathing Gas System General Design Considerations ......................... B-33 B.14.3 Breathing Gas Equipment Considerations .............................................. B-35

B.14.3.1 Breathing Gas Compressors ............................................................. B-35 B.14.3.2 Stored Breathing Gas Supply ............................................................ B-36 B.14.3.3 Carbon Dioxide Removal .................................................................. B-37 B.14.3.4 Breathing Gas Relief Valves ............................................................. B-38 B.14.3.5 Instrumentation ................................................................................. B-38 ix CHANGE 2

B.15 OPERATIONAL CONTROL SYSTEMS ........................................................ B-40 B.15.1 Control Power Supply ............................................................................. B-40 B.15.2 Control Actuators .................................................................................... B-41

B.16 FIRE PROTECTION SYSTEM ...................................................................... B-42 B.17 NAVIGATION SYSTEMS .............................................................................. B-42 B.18 FOOD AND WATER SUPPLY ...................................................................... B-42 B.19 WASTE SYSTEMS ....................................................................................... B-42 B.20 RESCUE/RETRIEVAL SYSTEMS ................................................................ B-43 B.21 HANDLING SYSTEMS .................................................................................. B-43

APPENDIX C: Testing Parameters for Permanently or Temporarily Mounted External Implodable and Explodable Items C-1

C.1 INTRODUCTION .............................................................................................. C-1 C.2 DEFINITIONS .................................................................................................. C-3

C.3 DETERMINATION OF WHETHER OR NOT AN EXPLODABLE OR

IMPLODABLE IS CRITICAL OR NONCRITICAL .................................................... C-4

C.4 TESTING REQUIRED FOR NONCRITICAL IMPLODABLE/EXPLODABLE

VOLUMES ............................................................................................................... C-5

C.5 TESTING NECESSARY FOR CRITICAL IMPLODABLE VOLUMES .............. C-5

C.6 TESTING NECESSARY FOR CRITICAL EXPLODABLE VOLUMES .............. C-6

C.7 TEST RECORD OQE REQUIRED FOR CRITICAL IMPLODABLE AND

EXPLODABLE VOLUMES ...................................................................................... C-6

APPENDIX D: Testing Parameters for Explodable Items due to Decompression ............................................................. D-1

D.1 INTRODUCTION .............................................................................................. D-1 D.2 DESCRIPTION AND ORIENTATION ............................................................... D-1 D.3 TEST PROCEDURE ........................................................................................ D-1 D.4 POROUS OR VENTED COMPONENTS ......................................................... D-2

APPENDIX E: DSS Breathing Gas and Atmospheric Requirements E-1

E.1 INTRODUCTION ............................................................................................... E-1 E.2 BREATHING GAS CONSUMPTION ................................................................. E-1 E.3 SURFACE BREATHING AIR REQUIREMENTS .............................................. E-2

E.3.1 Surface Oxygen Requirements ................................................................... E-3 E.3.2 Carbon Dioxide Production and Toxic Effects ............................................. E-5

CHANGE 2 x

E.3.3 Carbon Dioxide Removal ............................................................................ E-6 E.3.4 Carbon Dioxide Levels ................................................................................ E-7

E.4 ATMOSPHERIC CONTAMINANTS .................................................................. E-8 E.5 CARBON MONOXIDE LEVELS ........................................................................ E-8 E.6 DECOMPRESSION CONSIDERATIONS ......................................................... E-8 E.7 BREATHING GAS ALGORITHMS .................................................................... E-9

E.7.1 Conversion Factors ..................................................................................... E-9 E.7.2 Steady Oxygen Production and Removal Process ................................... E-10 E.7.3 Carbon Dioxide Buildup With No Removal Process ................................. E-10 E.7.4 Steady Contaminant Introduction And Removal Process ......................... E-10 E.7.5 No Contaminant Introduction But Constant Removal Process .................. E-11 E.7.6 Expected Contamination From a Volatile Solvent ..................................... E-11

APPENDIX F: General Guidelines for Control of Atmospheric Contaminants in Manned DSS ..................................... F-1

F.1 INTRODUCTION ............................................................................................... F-1

F.2 DSS FACTORS EFFECTING ATMOSPHERE CONTROL ............................... F-1

F.2.1 Mission Duration ......................................................................................... F-1 F.2.2 Atmospheric Pressure ................................................................................. F-2 F.2.3 Material Density .......................................................................................... F-3 F.2.4 Atmospheric Temperature ........................................................................... F-3 F.2.5 Atmospheric Control Equipment ................................................................. F-3 F.2.6 Cleanliness ................................................................................................. F-3

F.3 CONTROLLING AND MONITORING CONTAMINANTS .................................. F-3 F.3.1 Background ................................................................................................. F-3 F.3.2 Controlling Personnel Contaminants ........................................................... F-4 F.3.3 Controlling and Monitoring Breathing Gas Purity ........................................ F-5 F.3.4 Controlling and Monitoring Gaseous Contaminants in Breathing Gas Systems ................................................................................................................ F-6 F.3.5 Monitoring Gaseous Contaminants in the DSS ........................................... F-7

F.3.5.1 Unmanned DSS Atmospheric Testing ................................................... F-7 F.3.5.2 Manned DSS Atmospheric Testing ....................................................... F-9

F.4 CONTROLLING AND MONITORING NON-METALLIC MATERIAL ................. F-9

F.4.1 Non-Metallic Material List .......................................................................... F-10 F.4.2 Non-Metallic Material Off-Gas Testing ...................................................... F-10 xi CHANGE 2

F.4.3 Non-Metallic Material Off-Gas Test Report ............................................... F-11 F.4.4 Non-Metallic Material Qualification ............................................................ F-12

F.4.4.1 Initial Qualification Process ................................................................. F-13 F.4.4.2 Vendor Qualified Materials .................................................................. F-13 F.4.4.3 Lot Sampled Materials ......................................................................... F-14

F.5 IDENTIFYING CONTAMINANTS .................................................................... F-14 F.5.1 Physical Nature of Contaminants .............................................................. F-15 F.5.2 Medical Effects of Contaminants ............................................................... F-16 F.5.3 Target Compound Lists ............................................................................. F-18 F.5.4 Target Compound List Approval ............................................................... F-19 F.5.5 Breathing Gas System and Manned Space Off-Gas Test Report ............. F-20

F.6 EVALUATING OFF-GAS AND ATMOSPHERIC ANALYSIS RESULTS ......... F-20

F.7 LABORATORIES PERFORMING ANALYSES ............................................... F-21 F.8 FLAMMABILITY TESTING .............................................................................. F-28

F.8.1 Flammability Test Equipment .................................................................... F-29 F.8.2 Material Sample Test Documentation Requirements ................................ F-30 F.8.3 Alternate Procedure for Complete Assemblies ......................................... F-30

APPENDIX G: General Guidelines for Cleaning Breathing Gas Systems ......................................................................... G-1

G.1 INTRODUCTION ............................................................................................. G-1 G.2 REFERENCES ................................................................................................ G-1

G.2.1 Military Standards ...................................................................................... G-1 G.2.2 Commercial Specifications ........................................................................ G-1 G.2.3 Other ......................................................................................................... G-1

G.3 SYSTEM AND COMPONENT CLEANLINESS CONCERNS .......................... G-2

G.4 CLEANING METHODS AND MATERIALS ...................................................... G-3

G.4.1 Approved Cleaning Agents ........................................................................ G-3 G.4.2 Cleaning Processes .................................................................................. G-3 G.4.3 Commercial Oxygen Cleaning Specifications ............................................ G-4

G.5 POST CLEANING GAS ANALYSIS ................................................................. G-4 G.6 MAINTAINING THE SYSTEM IN A CLEAN CONDITION ................................ G-4

G.6.1 Providing a Clean Gas .............................................................................. G-4 G.6.2 Maintaining Cleanliness During Maintenance and Repairs ....................... G-5

CHANGE 2 xii

APPENDIX H: Design Guidelines for DSS Handling Systems .......... H-1

H.1 INTRODUCTION .............................................................................................. H-1 H.2 DEFINITIONS .................................................................................................. H-1 H.3 DESIGN CRITERIA AND GUIDELINES .......................................................... H-2

H.3.1 Equipment Design Criteria ......................................................................... H-2 H.3.1.1 Types of Loads .................................................................................... H-3 H.3.1.2 Environmental Considerations ............................................................. H-3

H.3.1.2.1 Sea State ....................................................................................... H-4 H.3.1.2.2 Air and Water Temperature ........................................................... H-4 H.3.1.2.3 Precipitation ................................................................................... H-4 H.3.1.2.4 Wind Velocity ................................................................................. H-4 H.3.1.2.5 Ocean Currents ............................................................................. H-4 H.3.1.2.6 Corrosion ....................................................................................... H-5

H.3.1.3 System Considerations ........................................................................ H-5 H.3.2 Human Engineering and Operational Design Considerations .................... H-5

H.3.2.1 Emergency Conditions and Reduced Operating Capability ................. H-6 H.4 DESIGN AND TESTING REQUIREMENTS .................................................... H-6

H.4.1 Load Bearing Component Requirements .................................................. H-7 H.4.1.1 Load Bearing Component Design ........................................................ H-7

H.4.1.1.1 Design Factors of Safety ............................................................... H-7 H.4.1.2 Submission of Drawings and Calculations for Load Bearing Components .......................................................................................................................... H-9 H.4.1.3 System Testing for Load Bearing Components.................................. H-10

H.4.2 Hydraulic and Pneumatic System Requirements ..................................... H-14 H.4.2.1 System Design ................................................................................... H-14 H.4.2.2 System Testing .................................................................................. H-15

H.4.2.2.1 Hydrostatic Testing Requirements ............................................... H-15 H.4.2.2.2 System Tightness Testing Requirements .................................... H-16 H.4.2.2.3 Maintenance Testing Requirements ............................................ H-17

H.4.2.3 Relief and Counter-Balance Valves ................................................... H-18 H.4.2.4 Cleaning, Flushing, and Preservation ................................................ H-19

H.4.3 Electrical Power Requirements and Controls .......................................... H-19 H.4.3.1 System Design ................................................................................... H-19 H.4.3.2 System Testing .................................................................................. H-20 xiii CHANGE 2

H.4.3.2.1 Maintenance Testing Requirements ............................................ H-20 H.5 CERTIFICATION REQUIREMENTS .............................................................. H-21

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

APPENDIX I: Re-Entry Control Procedures ........................................ I-1

I.1 INTRODUCTION ................................................................................................. I-1 I.1.1 Work Procedures .......................................................................................... I-1

I.2 RE-ENTRY CONTROL IMPLEMENTATION RESPONSIBILITIES ..................... I-2

I.3 REC CLOSEOUT ................................................................................................ I-3

I.3.1 REC Closeout via Deep Dive Test Forms or DFSs ....................................... I-3 I.3.2 REC Closeout with Incomplete Work ............................................................ I-3 I.3.3 Deep Dive DFS and Test Form Depth Restrictions ....................................... I-4

I.4 RE-ENTRY CONTROL FORM AND INSTRUCTION MATRIX ............................ I-5 I.5 RE-ENTRY CONTROL LOG ............................................................................... I-5

I.6 RE-ENTRY CONTROL RECORD RETENTION REQUIREMENTS .................... I-6

I.7 EXCEPTIONS TO RE-ENTRY CONTROL .......................................................... I-6

APPENDIX J: DSS Pipe and Piping Components Pressure Testing Requirements ................................................................. J-1

J.1 INTRODUCTION ............................................................................................... J-1 J.2 RESTRICTIONS ................................................................................................ J-1 J.3 DEFINITIONS .................................................................................................... J-1 J.4 TEST PRESSURE TOLERANCES .................................................................... J-3 J.5 TEST PRESSURE DURATION ......................................................................... J-3 J.6 HYDROSTATIC TESTING REQUIREMENTS ................................................... J-3 J.7 JOINT TIGHTNESS TESTING REQUIREMENTS ............................................. J-4 J.8 SEAT TIGHTNESS TESTING REQUIREMENTS .............................................. J-5 J.9 PRESSURE DROP TESTING REQUIREMENTS ............................................. J-6 J.10 OBJECTIVE QUALITY EVIDENCE ................................................................. J-6

APPENDIX K: Certification Survey Plan ............................................. K-1

K.1 INTRODUCTION ............................................................................................... K-1 K.2 CERTIFICATION SURVEY PLAN DEVELOPMENT ......................................... K-1

CHANGE 2 xiv

K.2.1 Proposed Certification Survey Plan ............................................................ K-2 K.2.2 Certification Survey Plan Review ................................................................ K-2

K.3 CERTIFICATION SURVEY PLAN FORMAT AND CONTENT ..........................