Attachment_4b_-_Welding_Tasks_Electrical_Isolation_Tech_Refresh.pdf

ELECTRICAL ISOLATION PROCEDURE FOR

WELDING, SANDBLASTING, AND PAINTING TASKS

TECH REFRESH

IMPROVED NAVY LIGHTERAGE SYSTEM (INLS)

Revision 0

NSWCCD-SSES

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS (OPERATIONAL, MAINTENANCE AND TRAINING) (8 November 2011).

PUBLISHED BY DIRECTION OF

NAVFAC EXPEDITIONARY PROGRAMS OFFICE (NEPO)

5 June 2014

REVISION HISTORY

Revision Date Edited By Description

0 5 June 2014 Ghanshyam Dhamelia NSWCCD Code 955 Royce Cearley

SSA

Initial Release.

FOREWORD

SAFETY SUMMARY

TABLE OF CONTENTS

Section Page No.

1. Causeway Ferry Power Module / Warping Tug .................................................................... 1-1

1.1. Procedure: Step By Step Instructions ..................................................................... 1-1

2. Beach Module

2.1. Procedure: Step By Step Instructions ..................................................................... 2-1

3. Checklist

3.1. Causeway Ferry Power Module / Warping Tug ...................................................... 3-1

3.2. Beach Module .......................................................................................................... 3-5

FOREWORD

Purpose- The purpose of this document is to provide qualified personnel procedures required for preparing an INLS craft for any task that requires welding onto a crafts structure. This document shall also be implemented when performing large sandblasting and spray painting tasks.

Organization- This document consists of three chapters; chapters 1 and 2 contain procedures and chapter 3 contains procedure checklists.

Document Evaluation- All errors, omissions, discrepancies, and suggestions for improvement to this procedure shall be reported to:

Alan Tibbetts NAVSEA Philadelphia INLS Mechanical and Electrical ISEA

1000 KITTY HAWK AVENUE

PHILADELPHIA, PA 19112

Office 215-897-7873 Cell 215-205-0287 E-MAIL: alan.tibbetts@navy.mil

SAFETY SUMMARY

GENERAL SAFETY PRECAUTIONS

Basic Safety- All personnel shall follow the general safety instructions provided in OPNAVINST 5100.19 C1 and the basic electrical safety instructions provided in OPNAVINST 5100.19 B7 while working with any electrical system.

Tag-out Procedures- Before any personnel may work on an electrical system, the appropriate tag-out procedures shall be followed. These procedures must be in accordance with current craft procedures and Navy regulations provided in

OPNAVINST 5100.19 C9.

Do Not Repair or adjust alone- Under no circumstances should the repair or adjustment of energized equipment be attempted alone. The immediate presence of someone capable of rendering aid is necessary. Before making an adjustment, be sure to protect against grounding. If possible, adjustments should be made with one hand, with the other hand free and clear of equipment. Even when power has been removed from equipment circuits, dangerous potentials may still exist due to retention of charges by capacitors. Circuits must be grounded and all capacitors discharged prior to attempting repairs.

Test Equipment- Make certain test equipment is in good condition. If a test meter must be held, ground the case of the meter before starting measurement; do not touch live equipment or personnel working on live equipment while holding a test meter. Some types of measuring devices should not be grounded; these devices should not be held when taking measurements.

Resuscitation- Personnel working with or near high voltages should be familiar with modern methods of resuscitation.

Navigation Hazards- Much of the equipment covered in this document is vital for the safe operation of the vessel. Before securing any navigation equipment, verify with the responsible officer that the equipment is not needed and will not be needed during the time it will be down.

1-1

1. Causeway Ferry Power Module / Warping Tug

1.1. Procedure: Step By Step Instructions

1. Follow Lockout / Tagout procedures IAW Command policy. If a tag is required, de-energize all incoming sources of power, and tag DANGER DO NOT OPERATE.

Test equipment with multi-meter to ensure that voltage has been isolated. Until electrical isolation has been proven and is verified, assume that power is on and use applicable precautions.

2. If connected to shore power disconnect and Tag, and ensure the craft is grounded. If connected to the Containerized Crew Shelter disconnect the CCS from the system and attach a ground to the shelter externally (See Figure 1-1):

Figure 1-1:

Containerized Crew Shelter

1-2

3. A checklist is included in section 3.1 to ensure completion of all items in steps 4-10.

4. Locate and open all breakers in the following panels (see fig.1-2 for reference):

a. Switchboard

b. PP2-6-1 (LRIP) / PP2-6-2 (FRP)

c. LC2-6-7 (LRIP) / LC2-6-5 (FRP)

d. LP01-9-1

e. PP2-9-2

f. LP2-7-1

g. LP01-9-3

h. LP2-6-3 (LRIP) / LP2-6-1 (FRP)

i. LP2-6-9 (LRIP) / LP2-6-3 (FRP)

j. LP2-6-5 (LRIP Only)

k. LP1-7-1

Figure 1-2:

Panel LP1-7-1

1-3

5. Locate and open the following breakers:

a. All breakers in the UPS.

b. All breakers in the 24V distribution panel (fig. 1-3).

Figure 1-3:

24V Distribution Panel

6. Locate and disconnect all PC cables in the MCC, CP and LOS. Also remove the “Ground” and “KE” wires from the Ground Fault Monitor in SPU 1.

Figure 1-4:

MCC (PC) CP (PC) LOS (PC) Ground Fault Monitor

1-4

7. Locate the Dief enclosures mounted to the side of SSDG #1 and #2. Locate and disconnect the 3 pin harness on top, and the 12, and 40 pin harnesses on the sides of the Deif enclosure.

3 Pin (Top) 12 Pin (Left side) 40 Pin (Right side)

Figure 1-5:

Deif Harness Location

8. Locate and disconnect the four (4) harnesses from the MPDE ECM units on engines

#1 and #2. Also disconnect four (4) harness assemblies from the bottom of the MPDE LCP for engines #1 and #2.

Figure 1-6:

ECM and LCP Harness Location

1-5

9. Locate and open the battery disconnects then disconnect both the Positive and Negative output terminal battery cables for the following:

a. Inverter (Emergency House Batteries)

b. MCS UPS

c. MPDE #1

d. MPDE #2

e. SSDG #1 (LRIP Only)

f. SSDG #2 (LRIP Only)

Figure 1-7:

Battery Disconnect

10. Upon completion of the welding task restore all systems disconnected in steps 1-9.

11. END

2-1

2. Beach Module

2.1. Procedure: Step By Step Instructions

1. Follow Lockout / Tagout procedures IAW Command policy. If a tag is required, de-energize all incoming sources of power, and tag DANGER DO NOT OPERATE.

Test equipment with multi-meter to ensure that voltage has been isolated. Until electrical isolation has been proven and is verified, assume that power is on and use applicable precautions.

2. If connected to shore power disconnect and Tag, ensure the craft is grounded.

3. A checklist is included in section 3.2 to ensure completion of all items in steps 4-8.

4. Locate and open all breakers in the following panels (see fig.2-1 for reference):

a. Switchboard b.PP2-11-2

c. LP2-11-1 d.LP2-11-4

e. LC2-11-3

f. LP2-11-5 g.LP2-9-1

Figure 2-1:

Panel LP2-9-1

2-2

5. Open the following breakers:

a. All breakers in the UPS.

b. All breakers in the 24V distribution panel.

Figure 2-2:

24V Distribution Panel

6. Disconnect all PC cables in the LOS. Also remove the “Ground” and “KE” wires from the Ground Fault Monitor in the LOS.

Figure 2-3:

LOS PC Ground Fault Monitor

2-3

7. Locate the Deif enclosure mounted to the side of SSDG. Locate and disconnect the 12 and 40 pin harnesses on the side of the Deif enclosure.

12 Pin (Left side) 40 Pin (Right side)

Figure 2-4:

Deif Harness Location

8. Locate and disconnect the four (4) harnesses from the MPDE ECM unit on the main engine. Also disconnect four (4) harness assemblies from the bottom of the MPDE LCP for the main engine.

Figure 2-5:

ECM and LCP Harness Location

2-4

9. Locate and open the battery disconnects then disconnect both the Positive and Negative output terminal battery cables for the following:

a. Inverter (Emergency House Batteries)

b. MCS UPS

c. MPDE

d. SSDG (LRIP Only)

Figure 2-6:

Battery Disconnect

10. Upon completion of the welding task restore all systems disconnected in steps 1-7.

11. END

3-1

3. Checklist

3.1. Causeway Ferry Power Module / Warping Tug

Note: Full electrical isolation is not attained until all items in the checklist have been completed.

1) Open all breakers in the following panels:

Pre Post Avail

Switchboard

PP2-6-1 (LRIP) or PP2-6-2 (FRP)

LC2-6-7 (LRIP) or LC2-6-5 (FRP)

LP01-9-1

PP2-9-2

LP2-7-1

LP01-9-3

LP2-6-3 (LRIP) or LP2-6-1 (FRP)

LP2-6-9 (LRIP) or LP2-6-3 (FRP)

LP2-6-5 (LRIP Only)

LP1-7-1

2) Open the following breakers:

All breakers in the UPS

All breakers in the 24V distribution panel

3-2

3) Disconnect all PC cables in the MCC, CP and LOS.

DC Power

Control NET A

Control NET B

USB Alarm Speaker

Ethernet

12” Monitor

15” Monitor

Keyboard

Trackball

Touch Screen

3-3

USB 3-Axis Joystick

Ethernet

Monitor

Keyboard

3-4

Touch Screen

Control NET A

Control NET B

Ethernet

Monitor

Keyboard

4) Disconnect Ground Fault Monitor’s ground in SPU 1.

5) Disconnect 3 pin on top, 12 and 40 pin harnesses on the sides of the Deif enclosures.

6) Disconnect 4 harnesses from the MPDE ECM and LCP units for engines #1 and #2.

3-5

7) Open the battery disconnects and remove battery cables for the following:

8) Inverter (Emergency House Batteries)

MCS UPS

MPDE #1

MPDE #2

SSDG #1 (LRIP Only)

SSDG #2 (LRIP Only)

3.2. Beach Module

Note: Full electrical isolation is not attained until all items in the checklist have been completed.

1) Open all breakers in the following panels:

Switchboard

PP2-11-2

LP2-11-1

LP2-11-4

LC2-11-3

LP2-11-5

LP2-9-1

2) Open the following breakers:

All breakers in the UPS

All breakers in the 24V distribution panel

3) Disconnect all PC cables in the LOS

3-6

ControlNET A

ControlNET B

Ethernet

Monitor

Trackball

Disconnect the “Ground” and “KE” wires from the Ground Fault Monitor in the LOS

4) Disconnect the 12 and 40 pin harnesses on the sides of the Deif enclosure.

5) Disconnect 4 harnesses from the MPDE ECM and LCP units for engine.

6) Open the battery disconnects and remove battery cables for the following:

Inverter (Emergency House Batteries)

MCS UPS

MPDE

SSDG (LRIP Only)