2984_Armor_One_Section_E_(8-19-19).pdf

SECTION E - INSPECTION AND ACCEPTANCE

E01 INSPECTION

The project will be managed by the Marine Design Center (MDC) of the U.S. Army Corps of Engineers (USACE) and is subject to inspection by its appointed representatives to insure strict compliance with the terms of the Contract. No Government Representative, except the Contracting Officer, is authorized to change any provision of the Contract, nor shall the presence or absence of an inspector relieve the Contractor from any requirements of the Contract.

When steel construction commences, the Contractor shall coordinate with ABS to ensure the frequency of onsite inspections are not less than once every two weeks.

The Contractor shall provide “Safe for Workers” labels, in accordance with the OSHA regulations stated in 29 CFR 1915.11-12, for all confined and enclosed spaces prior to permitting entrance for work or inspection. This procedure shall be reflected in the Contractor’s Safety Plan. See Section H.

Entry shall not be permitted to any confined or enclosed space that does not have a current “Safe for Workers” label.

E02 LAUNCHING

The Contractor shall be responsible for the successful launching operation of the vessel at the time selected and mutually agreed upon by the Contractor and the COR.

After agreement, the Contractor shall provide a written notice to the Contracting Officer 10 calendar days prior to the launching. The Contractor shall carry out the necessary calculations required for a safe launching of the vessel.

Prior to launching, all painting below the main deck (interior and exterior) must be completed. The hull interior and exterior surfaces shall be thoroughly inspected by an authorized Government representative to verify compliance with the requirements of the specification. The vessel shall not be launched until the hull painting has been approved by the COR. The Contractor shall schedule at least 3 days between hull inspection and launch to allow any new paint on the hull interior and exterior to cure properly.

The condition of the vessel shall be recorded at the time of launch. This shall include the levels of all tanks, draft and freeboard readings at the port and starboard forward, midship, and aft locations, a list of shipyard equipment on board, an estimate percent of the vessel complete, and the time and date of the launch.

After launching, all tanks and voids shall be inspected for damage and leaks, and their conditions shall be recorded.

E03 QUALITY CONTROL AND INSPECTION

A. GENERAL

After Notice To Proceed with Phase I “PLANNING AND SCHEDULING” the Contractor shall develop a Contractor Quality Control (CQC) and Inspection Program for the work required in this Contract. This program shall contain two sub-programs which will provide for review and quality control of the “Engineering and Scheduling” submittals and regular inspection and testing of the construction work in progress and the preparation and maintenance of documentation and records.

The first sub-program, (CQC of the engineering phase), must be submitted within 14 calendar days after the Notice To Proceed with the Phase I “PLANNING & SCHEDULING” phase of the Contract.

The second sub-program, (CQC of the construction phase), must be submitted and accepted in the “ENGINEERING” phase of the Contract. The Notice To Proceed with Phase III “CONSTRUCT BARGE “and Phase IV “CONSTRUCT GFE INTEGRATION AND INSTALL”, will not be issued until this document is accepted.

The documentation and records of sub-program 1 shall:

• Define the review and correction process for all “Planning, Engineering and Scheduling” phase submittals with particular attention given to the Final Design Drawings.

The documentation and records of sub-program 2 shall:

• Define Contractor tests and inspections to be accomplished for each work item of the Contract. Such tests and inspections shall be keyed to the appropriate paragraph of each clause.

• Be commensurate with the complexity of the work in the specification and adequate to assure the Contractor that the product or sub-product offered conforms to the requirements of the Contract.

• Be available to the Government Representative at all times and contain recorded data of all Contractor conducted inspections and tests conducted to date. All Quality Control reports, including those of subcontractors and regulatory agencies will be maintained and included in the Test Report of Contract Clause E05.

• List by name and title, the Contractor’s representatives who are authorized to witness or perform and sign for each test and inspection.

• The following are the minimum requirements for data to be recorded:

• Type of inspection or test (e.g., visual, mechanical, liquid penetrant, radiographic), accept/reject criteria, and a statement as to whether the inspection was satisfactory or unsatisfactory.

• Number and type of deficiencies of material or workmanship found in the product or subproduct inspected and corrective action taken to correct the deficiencies and, for repetitive deficiencies, to preclude recurrence.

• Date and signature of the Authorized Contractor Representative who witnessed or performed the test or inspection.

• Responsible authorized personnel shall inspect the work in progress and all completed work, conduct necessary tests and record the data required. An Authorized Contractor Representative shall sign the records attesting to the validity of the information.

Contractor certified inspection is an integral part of all work, therefore the COR will consider the entire Contract incomplete if Contractor documentation and records signed by the Contractor’s Authorized Representative are not complete.

B. SUBCONTRACTORS

Work subcontracted and/or performed away from the shipyard is covered by this inspection system. The prime Contractor cannot delegate the authority to witness or perform, and sign for tests and inspections conducted away from the shipyard, without approval of the COR.

If the subcontractor has an established Quality Control program with designated organization and personnel, the prime Contractor may designate an appropriate individual in that organization as his authorized representative. Such designation shall clearly indicate that the individual is an employee of a subcontractor and his appointment shall be subject to the approval of the COR.

C. TESTING

When any workmanship, material, or apparatus fails to pass any test or inspection, it shall be fully retested only after all known faults have been eliminated. Where directed by the COR, such failed material or apparatus shall be completely removed from the work and renewed. Any defects in workmanship or material shall be remedied by the Contractor at no additional cost to the Government, except where work was performed on material furnished by the Government.

D. ABS AND ABS-G ONSITE INSPECTION

When steel construction commences, the Contractor shall coordinate with ABS & ABS-G and to ensure the frequency of onsite inspections are not less than once every two weeks. The Contractor shall provide a schedule for the ABS and ABS-G Onsite Inspections. The schedule shall include the scheduled inspection date(s), actual inspection date(s), and signature blocks for the ABS/ABS-G Inspector and Contractor, and notes for what inspection(s) were conducted. This report shall be kept current and upon request be made available to the COR.

E04 FACILITIES FOR PERSONNEL

The Contractor shall provide an office trailer at the construction site for use by government personnel (5). The Contractor shall avail this space and all privileges contained in this section to the Robotics Integrator Representative as well.

The trailer shall be convenient to the work site and consist of six (6) desks with chairs, a drawing table with chair, six (6) half-height lockers, one commercial telephone per desk, with access to six (6) phone lines. The commercial telephones shall have speakerphone capability. The Contractor shall provide access to high speed internet for up to six (6) laptops. A 43 inch, wall mounted monitor with HDMI input will be provided (monitor is to be used for collaborative meetings).

The trailer shall be air conditioned, heated, ventilated, well maintained and well secured. The trailer shall be equipped with two restrooms, potable water, a full size refrigerator and a microwave. The space and facilities shall be suitable for both male and female staff.

Government Representatives attending the construction may bring with them communication equipment, cameras, and various items of test equipment. The Contractor shall permit unencumbered ingress and egress to and from the shipyard with such equipment.

Upon request, the Government representative shall have the unrestricted use of a facsimile machine, photocopier, word-processing equipment, paper, supplies, etc.

The Contractor shall furnish an up-to-date set of drawings for exclusive use of USACE personnel while in the shipyard.

In addition, the Contractor shall furnish six parking spaces within the shipyard, in safe locations and accessible to the assigned offices.

E05 TRIALS, TESTS AND DEMONSTRATIONS

A. GENERAL REQUIREMENTS

1. LEVELS OF TESTING

The Contractor shall perform tests on all equipment, machinery, and systems; individually, and integrated as a whole. The tests shall be performed as necessary to demonstrate satisfactory compliance with the Specification requirements contained in Section C, “DESCRIPTIONS/ SPECIFICATIONS/WORK STATEMENTS,” of this Contract.

The following 4 levels of inspection and testing shall be performed for this contract:

LEVEL 1 PRE-TRIAL TESTS

LEVEL 2 BUILDER’S DOCK TRIALS

LEVEL 3 DOCK TRIALS & GFE ROBOTICS TESTS

LEVEL 4 FINAL ACCEPTANCE DEMONSTRATIONS

All demonstrations, tests, and trials shall be performed as specified herein and as specified in Contract Section C.

The Contractor shall furnish all labor, materials, tools, and test equipment as necessary and perform the testing, trials, and demonstrations specified.

2. CONSUMABLES AND OPERATING FLUIDS

The Contractor shall furnish all fuel oil, lubricating oil, hydraulic oil, engine coolant, refrigerant, , treatment chemicals, degreasing agents, gases, and any other consumables required to perform the tests and demonstrations, and as required in Contract Section C.

B. TEST AGENDA AND TEST MEMORANDA

The Contractor shall prepare an Agenda and Test Memoranda of the required tests and trials for the vessel in accordance with the requirements set forth herein. The Agenda and Memorandum shall be developed by the contractor with input and participation from the Robotics Integrator. Two copies of the Agenda and Test Memoranda shall be submitted to the COR for review and approval 60 days prior to the scheduled testing (see Clause H02).

1. TEST AGENDA

For the vessel, the Contractor shall prepare a Test Agenda for LEVEL 3 DOCK TRIALS & GFE ROBOTICS TESTS. The Agenda shall be a complete, detailed schedule of all tests, trials and demonstrations specified in this clause. The Test Agenda shall be arranged by day, not date, and shall list the specific tests, trials, and demonstrations, and the sequence in which these will be performed.

2. TEST MEMORANDA

For the vessel, the Contractor shall prepare Test Memoranda for all systems and equipment tested under the LEVELS 1, 2, 3, and 4 test and trial requirements of this clause.

The test memoranda shall describe the actual test procedures, and data to be taken. The procedures shall be in accordance with the “start-up” procedures for the equipment, as delineated in the operating manuals furnished for the equipment by the manufacturer. The Contractor shall incorporate demonstrations of all applicable controls, instruments, and alarms, into each system’s BUILDER’S DOCK TRIALS, DOCK TRIALS & GFE ROBOTICS

TESTS, and FINAL ACCEPTANCE DEMONSTRATIONS sections of the Test Memoranda. Data recorded in time intervals shall be tabular so that data trends can be easily recognized.

Each test memorandum shall:

• List the major equipment

• Include a space for nameplate data, make, model and serial number of equipment, etc.

• List the characteristics of equipment (i.e. impeller size, motor size horsepower and amperage, flow capacity, line pull capacity, cfm, etc.)

• Reference the manufacturer’s manual(s) used to format the test procedure

• Describe instrumentation for each test

• Describe the test procedure

• List the Pass/Fail limits

• List the expected results

• Include a space for the actual results

• Include a space for the ambient conditions

• Include signature blocks for Contractor Representative, Government Representative, and Robotics Integrator

Representative (where appropriate) witness signatures, times and dates

• Include a space for writing comments

The Test Memoranda shall be typed on 8-1/2 inch by 11-inch sheets of paper, single side, in three-ring notebook, with dividers for each section. Each page shall include the contract number at the top, along with the Marine Design Center project number (#2984) and hull number (#822).

The memoranda shall be arranged by system and equipment, with each level of testing for a specific system or piece of equipment recorded under the respective heading.

The Test Memoranda shall be arranged by system and level of testing similar to the following outline:

X. System (or equipment)

a. PRE-TRIAL TEST

b. BUILDER’S DOCK TRIALS

c. DOCK TRIALS & GFE ROBOTICS TESTS

d. FINAL ACCEPTANCE DEMONSTRATIONS

3. TEST REPORTS

Completion of system or vessel testing shall be reported to the COR in the following manner:

• Within two days of the completion of any tests, a copy of the memorandum for that specific test shall be available for review at the request of the COR.

• Upon completion of any level of testing, the COR shall be notified that the specific level of testing has been completed. At his discretion, the COR may request to review the test memoranda for that level of testing.

• With completion of subsequent levels of testing, all test memoranda shall be filled-in, and placed in the Test Report. Results of all vendors’ tests shall be filled with the applicable test section. The Test Report, with all prior test results, must be current at all times, and shall be available for review at the request of the COR at any time.

The Test Report shall be reviewed and approved by both the Contractor and the COR at the conclusion of each level of testing. Review and approval of the Test Report by the Contractor and the COR is a precondition of moving to the next level of testing.

Within 10 calendar days following the successful completion of Final Acceptance Demonstrations (Level 4), the Contractor shall submit the Final Acceptance Demonstrations report to the COR for review.

The final version of the Test Report, including results of the previous three levels of the tests and trials, shall be bound in three ring binders and two copies shall be submitted, within 30 calendar days following successful completion of the Level 4 demonstrations, and prior to Final Payment. A scanned version of the final Test Report shall be provided to the Government. The electronic version of the Test Report shall be in .pdf file format.

4. DEFICIENCIES

The COR will compile a list of deficiencies which will be given to the Contractor. All deficiencies shall be corrected.

Final Acceptance of the vessel will be made following remedy of all deficiencies.

The successful completion of all tests, trials, demonstrations and remedied deficiencies, shall be determined by the

COR.

C. PRE-TRIAL TESTS (LEVEL 1)

The PRE-TRIAL TESTS are designed to ensure proper construction, and installation of all equipment, piping, and electrical systems, tanks, and exterior and interior bulkheads. PRE-TRIAL TESTS shall be performed during the course of construction and prior to the beginning of BUILDER’S DOCK TRIALS (LEVEL 2).

Note: The PRE-TRIALS TESTS include a requirement for load testing the overhead gantry frame prior to the installation of the overhead gantry cranes.

The COR shall be notified at least 24 hours in advance of any such testing and may, at his discretion, send a Government representative to witness any or all tests. The Contractor shall coordinate with ABS to ensure that they are present for all tests required to be witnessed for class.

Documentation of all pre-test inspections shall be in accordance with the requirements of Section E03 (Quality Control and Inspection). All deficiencies, including cracks, leaks, grounds detected in new circuits, and poor workmanship shall be corrected prior to commencement of BUILDER’S DOCK TRIALS (LEVEL 2). PRE-TRIAL TESTS shall include the following:

1. HULL

All tanks and watertight bulkheads shall be tested in accordance with ABS Rules. All watertight/oiltight doors, manholes and hatches shall be tested in accordance with ABS Rules. All doors, hatches and manholes shall be tested to ensure they open and close properly and completely, are securable in the open and closed position, and they fit properly at jamb or knife-edge seal.

Verify the hull anodes are installed (prior to launch).

Verify all insulation is installed prior to joinery, ceilings or sheathing being applied.

Verify all joinery, ceilings and sheathing are installed.

2. CONTROL HOUSES AND ACCESS HOUSES

All weather-tight exterior bulkheads and decks shall be hose tested for tightness prior to coating. All weather-tight doors, windows, manholes, and hatches shall be hose tested for tightness. All doors shall be tested to ensure they open and close properly and completely, are securable in the open and closed position, and they fit properly at jamb or knife-edge seal. Verify that all exterior doors have watersheds installed over them.

Verify all insulation is installed prior to joinery, ceilings or sheathing being installed.

Verify all joinery, ceilings and sheathing are installed.

3. PIPING SYSTEMS

a. General

The testing requirements set forth herein include system flushing procedures which shall be performed to demonstrate system cleanliness and integrity.

b. Compressed Air

Upon completion of installation, the piping of each compressed air system shall be hydrostatically tested in accordance with the ASME code. The system shall be inspected for leaks at the welds, fittings, etc. Upon completion of the hydrostatic test, the entire system shall be blown dry with air. The Contractor shall take proper precautions to protect any controls and air tool stations.

c. Piping Systems

Hydrostatically test all piping systems (except CO2 piping) for leaks at 1-1/2 times working pressure for a period of not less than 10 minutes per test. Each system shall be inspected for leaks at the welds, fittings, hoses, etc. Upon completion of a system’s hydrostatic testing, the system shall be thoroughly flushed with its respective fluid and Contractor furnished filters (not system filters) to collect all contaminants.

System equipment (e.g. pumps, engines, coolers, etc.) shall be bypassed with a jumper line. After flushing, the jumper line shall be removed, strainer(s) will be cleaned, and filter element(s) replaced.

d. CO2 Piping

Upon completion of the CO2 piping and prior to the cylinders being connected to the system, the piping shall be pressure tested with CO2 or another inert gas. Testing of the piping shall be in accordance with the requirements outlined by USCG in 46 CFR, subchapter H, subpart 76.15, paragraph 76.15-15.

e. Exhaust Systems

Blank off and test the flanges, welds, and gaskets of each exhaust system using compressed air and soap bubbles. All generator engine exhausts shall be checked in this manner.

f. HVAC

Blow out with compressed air all installed ductwork. Operationally test each supply and exhaust fan, along with the ducting to ensure absence of leaks, adequate support, and acceptable vibration levels.

4. ELECTRICAL CABLING

Insulation resistance readings of all installed power and lighting cable shall be taken using a 500 volt megger, and shall be in accordance with IEEE Standard 45, Section 46. The measured cable insulation resistance must meet or exceed the minimum values outlined in the referenced IEEE publication. Also, measure the voltage drop of all electrical circuits. A complete record of all readings shall be kept to assure that all circuits and equipment have been checked.

5. OVERHEAD GANTRY FRAME LOAD TESTING

Once the installation of the overhead gantry frame is approved, the Contractor shall perform load testing on the overhead gantry frame – prior to installation of the overhead gantry cranes. The load testing shall utilize six weights simultaneously to simulate the six GFE overhead gantry crane weights and their CG locations. The Contractor shall measure the displacement of the overhead gantry frame at each of the crane locations using laser measurement techniques. The Contractor produce a report detailing the load testing and displacement results including locations of the weights and the measurement locations and methods. The Contractor shall submit the report to the Government for review.

D. BUILDER’S DOCK TRIALS (LEVEL 2)

BUILDER’S DOCK TRIALS are a preliminary “run-through” of all required DOCK TRIALS & GFE ROBOTICS TESTS (LEVEL 3) by the Contractor. The intent of this testing is to provide both the Contractor and the COR reasonable assurance that all equipment and systems have been thoroughly prepared and are ready for formal testing and that the Contractor has made adequate provisions for DOCK TRIALS & GFE ROBOTICS TESTS (LEVEL 3).

BUILDER’S DOCK TRIALS shall be conducted at the Contractor’s facility listed in Section B of the contract. The COR shall be notified, in writing, at least 5 working days prior to the scheduled commencement date of Builder’s Trials. The Test Report must be current prior to commencing BUILDER’S DOCK TRIALS.

The LEVEL 2 tests on the barge shall be of sufficient scope and duration to assure that all machinery and equipment is properly installed and all systems are complete. The intent of this testing is to provide the Contractor, the Robotics Integrator, and the COR, reasonable assurance that installation of equipment and assembly of systems have been executed satisfactorily, and that the barge is ready for formal DOCK TRIALS & GFE ROBOTICS TESTS

(LEVEL 3).

E. DOCK TRIALS & GFE ROBOTICS TESTS (LEVEL 3)

1. GENERAL

DOCK TRIALS & GFE ROBOTICS TESTS are the operability tests the Contractor must perform in the presence of the Contracting Officer's Representative to demonstrate the proper installation, operation, control, and performance of all equipment, machinery, and systems installed as part of this Contract. Specific dock trials and demonstrations are defined in paragraph F.

Each test or demonstration shall include control, instrumentation and alarm operation as applicable. DOCK TRIALS & GFE ROBOTICS TESTS shall be conducted at the Contractor's facility, and shall be of sufficient scope and duration for the intended objective.

Prior to the start of DOCK TRIALS & GFE ROBOTICS TESTS, all construction and installations must be complete, except for final cleaning and touch-up painting, and all LEVEL 1 and LEVEL 2 testing must be successfully completed and documented. Please note that there are specific test items and system cleaning that shall be completed prior to the vessel’s launch. The Test Report must be current through the two levels of testing.

Commencement of DOCK TRIALS & GFE ROBOTICS TESTS shall not be sooner than one full working day after completion of BUILDER’S DOCK TRIALS. The COR shall be notified immediately of any condition which would delay the start of DOCK TRIALS & GFE ROBOTICS TESTS.

The COR shall be notified in writing 10 working days in advance of the date set for testing of the vessel. Results of the Level 2 Testing shall be transmitted to the Marine Design Center, COR, at least one day prior to the start of the Dock Trials, if Level 2 Testing was not attended by a Government Representative.

All testing and trials shall be conducted in the presence of a Government representative and vendor representatives for the following equipment:

• Diesel Generator Sets

• Variable Frequency Drives

• HPU’s

• Main Switchgear

• GFE Robotics Systems (Robotics Integrator will operate)

• Fire Detection, Alarm & Extinguishing System

• Air-Conditioning System

With the exception of the GFE Robotics, the cost to have the vendor representatives identified above on-site during testing shall be the responsibility of the Contractor. The Contractor is not responsible for the costs associated with the Robotics Integrator’s onsite support.

95% of the tests shall be performed using the diesel generators for power, and the other 5% shall be performed using shore power. The Contractor shall indicate in the test memoranda which tests will be performed using the diesel generators and which tests will be performed using the shore power

The success of all tests and the existence of any deficiencies shall be determined by the COR. Deficiencies shall be remedied prior to the start of FINAL ACCEPTANCE DEMONSTRATIONS (LEVEL 4).

2. SAFETY REQUIREMENTS

During DOCK TRIALS & GFE ROBOTICS TESTS and thereafter, the atmosphere in spaces being prepared for, and preserved by, paints and tank coatings dissolved in highly volatile, toxic, and flammable solvents (29 CFR 1915.35(b)), shall be tested frequently and shall be in accordance with the U.S. Occupational Safety and health Agency Standards regulations stated in CFR 1915.31-36.

Within 24-hours of final inspection, and before any representative of the U.S. Government boards the vessel for such duties, each compartment or space to be inspected shall be certified “SAFE FOR WORKERS” by the National Fire Protection Associations (NFPA) competent person. This means that in the compartment or space so designated:

• The oxygen content in the atmosphere is at the least 19.5 percent by volume;

• Toxic materials in the atmosphere are within permissible concentrations;

• The residues are not capable of producing toxic materials under existing atmospheric conditions while maintained as directed on the Marine Chemist’s certificate.

The Contractor shall notify the Government when this certificate has been issued. The vessel will not be inspected and accepted by the Government without an NFPA Marine Chemist certificate for each hull compartment designated

“SAFE FOR WORKERS.”

F. SPECIFIC DOCK TRIALS AND DEMONSTRATIONS (LEVEL 3)

The following paragraphs describe the minimum DOCK TRIALS and DEMONSTRATIONS required.

1. COATING SYSTEM, FLOOR COVERINGS, SHEATHING JOINERY & CEILINGS

The hull coating system shall be inspected and approved prior to the vessel’s launch. Please refer to Contract Section C, Clause C406, for specific details.

Verify all anodes are installed properly.

Verify all sheathing, joinery and ceilings are installed to the satisfaction of the COR. Verify access panels are provided where necessary.

2. HULL & VESSEL MARKINGS

Prior to the vessel’s launch, the hull markings shall be visually inspected for continuous welding and placement. The location of each hull marking shall be verified to ensure it is correct (i.e. draft marks measured from the bottom of the hull). Verify the spelling of all hull markings.

Verify that the communication marks and signatures are provided and properly installed and secured.

Verify all nameplates, notices, signage, labels, tags, pipe markings and electrical markings are installed per Contract Section C, Clause C460, Clause C601, and Clause C702.

Verify the fire control plans are correct and installed.

3. VESSEL LAUNCH

The condition of the vessel shall be recorded at the time of launch. This shall include the levels of all tanks, draft readings at Port/Starboard forward and aft locations, a list of shipyard equipment on board, an estimate percent of the vessel complete, and the time of launch.

After launching, all tanks and voids shall be inspected for damage and leaks.

4. INCLINING TEST

Upon completion of all work and after the GFE Robotics systems have been installed, with the vessel in the lightship condition and all major movable equipment in the stowed position, the Contractor shall conduct an inclining test and deadweight survey in accordance with Clause C115.D. The contractor shall retain the services of a Registered Professional Engineer in the Naval Architecture field for the completion of this work. The inclining test shall be carried out in accordance with ASTM F 1321-92 (2008). The Contractor shall be responsible for developing the inclining test procedure/plan, providing all certified inclining weights, pendulum setups, support equipment and personnel, directing the experiment, recording all data and completing the inclining test report. The Government will participate in the incline experiment as a witness.

The Contractor shall prepare an incline plan and submit it to the Government and ABS for review and approval.

The plan shall be numbered 822-C115-02 “INCLINE EXPERIMENT PLAN.” For the Government’s review, the plan shall be submitted at least 60 days prior to the scheduled inclining.

Based on the intended ABS class of the vessel, ABS will require engineering review and surveyor witness with the incline experiment. The Contractor shall coordinate submittals and on-site surveyor representation with ABS to ensure the construction and testing schedules are maintained.

Following the completion of the incline experiment, the Contractor shall complete the incline test report and determine the lightship displacement, centers of gravity and hydrostatic properties of the barge. The report, numbered “822-D115-03 “INCLINE EXPERIMENT RESULT”, shall be submitted to the Government and ABS for review and approval.

The Contractor shall be responsible for all costs associated with ABS reviews (including at least one iteration to reflect any ABS comments made) and all surveyor costs.

The inclining test report shall be finalized and submitted to the COR at least 14 days prior to the start of the GFE

ROBOTICS TESTS (LEVEL 3).

5. HULL & TANKS

The Contractor shall show that each hull compartment is dry and free from leakage. The hull compartment paint shall be complete, intact and fully cured.

For the integral and independent tanks, all liquid level indicators, float switches, petcocks, sampling valves, and drains shall be demonstrated and verified.

Verify all gratings are provided, properly isolated and secured. Verify access panels in the grating are provided where necessary.

6. SUPERSTRUCTURE

Using a pressure hose and visual checking for leaks and demonstrate weather tightness of all doors, windows, hatches, manholes and bulkheads.

7. DOORS, WINDOWS, HATCHES, AND MANHOLES

Demonstrate that each hatch and manhole is functioning by opening and removing (for non-hinged hatches) and replacing/closing it and securing it in place. Required markings on the escape hatch and voids shall be confirmed.

Test hatches and manholes for water tightness with a pressure hose.

Demonstrate that each door (joiner, watertight, fume tight, weathertight) is functional by opening, closing, securing in opened and closed positions, and locking/ unlocking (where applicable). Watertight doors shall be cleaned and greased. The watertight door shall be adjusted to close and dog with minimal effort.

Demonstrate the open/close operation of the hydraulic hatches. Demonstrate the functionality of the hatch controls.

8. DECK FITTINGS & DECK WINCHES

Demonstrate that all deck fittings have been properly installed and verify continuous welding and installation of all support structure.

Demonstrate the operation of the roller chocks and all fairleads, including verifying the fleeting angles.

Demonstrate the free running operation of the mooring winches in forward, reverse and stop. Perform pull tests to demonstrate rated load capability for each winch. Demonstrate that each winch will operate at the rated speed.

Demonstrate the operation of the controls local to the winch.

Four Positioning (Mooring) Winches

Demonstrate the free running operation of the Positioning winches in forward, reverse and stop. Perform pull tests to demonstrate rated load capability for each winch. Demonstrate that each winch will operate at the rated speed.

Demonstrate the operation of the controls local to the winch. Note: The winches and their independent hydraulic control systems shall be proven to be fully functional without any control input from the Robotics Control Consoles.

The winches shall be tested to the satisfaction of the Robotics Integrator. Later during GFE ROBOTICS testing, the integration of the winch controls with the Robotics control consoles will be tested.

9. SPUD DIMENSIONS

The as-built dimensions of the spuds, as well as the Spud Depth Markings, shall be verified by the COR prior to installation of any spuds on the vessel. At a minimum, perform the following on each spud:

• The design spud length overall (LOA) shall be verified and recorded.

• Check the accuracy of the spud markings and the locking pin/dog locations with respect to the spud tip and the stowage position.

• Check the sheave for freewheeling rotation motion.

• Check the wire rope keeper clearance with the spud sheave rim to ensure the rope cannot jump from the groove.

10. VERTICAL & INCLINED LADDERS

Demonstrate that all vertical ladders have been installed and are functional.

Demonstrate that all inclined ladders have been installed and are functional.

Demonstrate the removal process for vertical and inclined ladders, where applicable. Ladders do not have to be removed for testing.

11. DIESEL GENERATORS

In the presence of an authorized diesel engine manufacturer representative, validate the installation and operation of each of the barge’s diesel generator engines demonstrating the following:

• Cold starting.

• Stability of operation.

• Starting and stopping of the generator from all control panels.

• Operation of all emergency stops.

• All engine controls, and instrumentation.

• Operation of all engine alarms from all control panels. Ensure the proper operation of all alarm test circuits for each engine.

• Operation of automatic shutdowns.

• Demonstrate automatic start-up of a fourth generator in case of genset failure.

• Operation of jacket water and generator heaters.

12. LOAD BANK TESTING

Each of the barge’s diesel generator sets shall be load bank tested. An authorized representative from the diesel generator set’s manufacturer shall be present for the load bank test and shall sign off on the completion of the test.

Operate each generator set at 1/4, 1/2, 3/4 and full loads in 15 minute intervals, 100% rated load (with the use of a load bank) for 2 hours, and 110% rated load (with the use of a load bank) for 2 hours. All engine and generator parameters shall be recorded at 5 minute intervals for the partial and full load periods, and at 15 minute intervals for the 100% and 110% load period.

Demonstrate the ability of the generators to be paralleled automatically and manually. Demonstrate reverse power protection trips for each of the generators.

Operate the barge’s diesel generator sets in parallel at 1/4, 1/2, 3/4 and 100% of the combined rated load (with the use of a load bank) in 15 minute intervals. Record all engine and generator parameters at 5-minute intervals.

13. ENGINE COOLING SYSTEM

Demonstrate proper cooling of each of the barge’s diesel generator sets. Inspect the system for leaks. Check the expansion tank levels and the inlet and outlet temperatures for each cooling circuit. Demonstrate the operation of the expansion tank level alarms.

14. ENGINE EXHAUST SYSTEM

Demonstrate the operation of each of the barge’s diesel generator exhaust system. Inspect the system for leaks and verify that the back-pressure on the system is within the manufacturer’s requirements.

15. FUEL OIL SYSTEM

Ensure proper fuel oil flow to each diesel generator. Demonstrate the ability of the each diesel generator to take suction from the fuel oil day tank. Demonstrate the operation of all remotely operable emergency shut-off valves on both the shipboard service and fuel oil transfer side.

Demonstrate both the manual and automatic transfer of fuel from the two main fuel tanks to the two fuel oil day tanks. Ensure proper function of the automatic fuel transfer on and off level switches within the day tank.

Demonstrate the ability/operation of all liquid level indicators, electronic tank level system, fuel measurement devices, audible and visual alarms, pump start-stop controls, pump run-indicating lights, and equipment status indicators.

Demonstrate the ability to take on fuel into both fuel main fuel tanks from any fill station.

The Contractor is responsible for maintaining the fuel tanks with sufficient fuel to complete all four levels of testing.

16. LUBE OIL SYSTEM

Demonstrate the ability of the lube oil transfer pumps to transfer lube oil from both of the lube oil tanks to the respective lube oil transfer stations. Demonstrate the ability to fill the generator set engines. Check the system for leaks. Demonstrate operation of the transfer pumps. Demonstrate the operation of the emergency shut off valves.

Demonstrate the operation of each hose reel and meter.

Demonstrate the ability/operation of all liquid level indicators, audible and visual alarms, pump start-stop controls, pump run-indicating lights, and equipment status indicators.

The Contractor is responsible for maintaining the lube oil tanks with sufficient oil to complete all four levels of testing.

17. WASTE OIL SYSTEM

Demonstrate the ability of the Tank stripping-pump to pull waste oil from the tank to the shore connection on deck.

Demonstrate the ability of the engine waste oil pumps to pull waste oil from each generator set drain connection to the waste oil tank.

Demonstrate the ability of the portable pneumatic pumps to pull waste oil from the machinery room bilge area to oily water tank.

Demonstrate the ability/operation of all liquid level indicators, audible and visual alarms, pump start-stop controls, pump run-indicating lights, and equipment status indicators.

Demonstrate the operation of each hose reel and meter.

18. HYDRAULIC OIL SYSTEM

Demonstrate the ability of the hydraulic oil transfer pumps to transfer hydraulic oil from the hydraulic oil storage tank to the HPU hydraulic oil tanks. Check the system for leaks. Demonstrate the operation of the transfer pumps.

Demonstrate the operation of the emergency shut off valves.

Demonstrate the ability of the HPU’s #1 and #2 to provide the required hydraulic pressure to each of the various consumers.

Demonstrate the ability/operation of all liquid level indicators, audible and visual alarms, indicator lights, and pump start-stop controls.

The Contractor is responsible for providing sufficient quantities of oil to complete all four levels of testing.

19. BILGE SYSTEM

Demonstrate the ability of the bilge system using each bilge pump to take suction of water from each compartment bilge suction and discharging the water overboard.

Demonstrate the ability/operation of the bilge level sensors in each compartment outfitted with the equipment.

Demonstrate the ability/operation of the audible and visual alarms for the bilge system.

Demonstrate the ability to pump water overboard via all of the overboard discharge points. Check the system for leaks.

20. DRAINAGE SYSTEM

Demonstrate the operation and capability to drain water from each drain to the overboard discharge. Check the system for leaks.

21. BALLAST SYSTEM

Verify the calibration of all inclinometers.

Demonstrate the ability of the ballast pumps by filling and emptying a tank with each pump. Record the time required to fill and the time required to empty, and calculate the average pump flow rate, based on the known size of the tank. Record the discharge pressure during both operations. The water shall be discharged overboard during the emptying of the ballast tanks.

Demonstrate the ability of the ballast pumps to transfer water from one tank to another. Demonstrate the ability for each ballast pump to fill and empty a tank on the opposite side of the barge via the crossover pipe.

Demonstrate the ability of the ballast pumps to pump water to and take suction from each ballast tank.

The contractor shall demonstrate all functions of the ballast control system to include the following:

• Demonstrate ballast pump(s) start/stop functions and run indication

• Demonstrate tank level transducer accuracy by verifying level indication against actual tank soundings

• Demonstrate the automatic shutdown of the pumps once tank level reaches a user adjustable setpoint

• Verify accuracy of system operating parameters (discharge pressure, suction vacuum, flow rate) and demonstrate user adjustable alarm setpoints.

• Demonstrate audible alarm

• Demonstrate alarm acknowledge/silence function

• Verify accuracy of vessel list and trim indication by comparing to mechanical heel and trim inclinometers.

Demonstrate the ability/operation of the local pump start-stop controls, pump run-indicating lights, and equipment status indicators.

22. JETTING SYSTEM

Demonstrate the ability of the Jetting system to pump water to all of the discharge nozzles on the mat deck.

Demonstrate the ability to adjust the nozzles and throttle the flow to adjust discharge pressure by measuring the nozzle pressure before and after adjusting using a pitot gauge.. Record each pump discharge pressure and the dishacrge pressure for all the nozzles.

Demonstrate the function of the backpressure relief valve and its discharge over the side. Demonstrate the functionality of the pumps. Demonstrate the function of the local and all remote pump start-stop controls, pump run-indicating lights, and equipment status indicators.

Demonstrate the function of the system operating modes.

23. SEACHESTS

Demonstrate the function of all seachest sea valves. Check the system for leaks.

24. FIXED FIRE EXTINGUISHING SYSTEM

Demonstrate the proper operation of the installed CO2 system. Tests shall be performed in accordance with NFPA12, with the exception of the full discharge requirement, to demonstrate proper operation of the trip devices, nozzles, audible alarms, visual alarms, and the automatic shutdown of the ventilation system fans. These tests may be done concurrently with the required ABS tests of the system. The ABS representative and a Government representative must be present to witness the tests. A representative of the CO2 system shall be present during the test and trials of the CO2 system.

Proper operation of each CO2 system shall be demonstrated by discharging a test cylinder through the respective system. The system supplier, in accordance with his test procedures, shall conduct each test.

The demonstration shall include:

• Operation of local activation system.

• Operation of all remote pull stations.

• Operation of the audible alarms in the engine room.

• Verify 60 second discharge delay.

• Automatic shutdown of the generator room supply and exhaust ventilation fans.

• Automatic closure of the dampers of the supply and exhaust ventilation fans for the generator room.

• Automatic shutdown of HVAC and ventilation systems on the vessel, see Contract Section C, Clause C685.

• Verify required signage, including warnings and instructions are posted.

Note: The Government representative and ABS inspector must be present to witness both the Level 1 hydrostatic piping test and the operational test described here. All tests shall be performed to the satisfaction of the ABS Inspector, responsible for issuing a Statement of Fact for the CO2 system. As such, these tests may be performed prior to the commencement of Dock Trials.

27. FIRE DETECTION AND ALARM SYSTEM

Demonstrate the operation of the fire detection system. The testing and trials shall demonstrate:

• The activation of the alarms from each smoke detector and heat sensor.

• The automatic shutdown of the HVAC System and any ventilation fans.

• The activation of alarms from each CO detector.

• The activation of all audible and visual alarms.

• The ability/operation of all alarm panels (main and remote).

• Operation of the back-up power supply and the system battery charger.

A representative of the alarm system manufacturer shall be present during the tests and trials of the detection and alarm system.

28. LIFE SAVING & FIRE SAFETY EQUIPMENT

Verify that all Lifesaving (Contract Section C, Clause C445) and Fire Safety Equipment (Contract Section C, Clause C679) required by their respective contract clauses have been installed and each is fully functional. Ensure that each portable fire extinguisher is charged to the correct operational pressure, properly mounted and is USCG approved.

Ensure that the waterlights on the life rings and buoyant apparatus are functional. Ensure that each life ring is marked and labeled in accordance with Contract Section C, Clause C445.

Ensure that the AED is functional and verify service plan.

29. HVAC

a. Heating and Cooling

Demonstrate the satisfactory operation of the air conditioning and ventilation systems to cool, and to draw outside ventilation air to the air-conditioned and ventilated spaces.

Demonstrate the operation of all thermostat temperature controls and fan controls.

b. Ventilation

Demonstrate the satisfactory operation of all supply and exhaust fans for all ventilated spaces. Record the air velocities at each fan and duct discharge and calculate the cfm flow rate.

Demonstrate the satisfactory operation of all louvers and dampers. Demonstrate louver operation during fan startup and shutdown for the pressure/gravity operated louvers. Demonstrate operation for all motorized louvers to include automatic control linked to the respective fan controller.

Demonstrate all automatic shutdowns linked to the fire alarm and detection system and CO2 activation.

Demonstrate operation of all swivel-arm fans.

30. COMPRESSED AIR SYSTEM

For each compressed air system/pump, demonstrate the charging of the air receiver from atmospheric pressure up to the system design pressure. Record the amount of time to charge the receiver.

Demonstrate:

• Start/Stop from local controls.

• Ability of the equipment status indicators.

• That the compressor will cut-in and will cut-out at the required operating pressures.

• Air flow to all air stations.

• The operability of the reducing station, all relief valves, and receiver drain valves.

• The compressed air system blow-down of the sea chests and box coolers.

• Provide certifications for the air receivers.

• Verify the operation of the hour meter for the compressors.

31. SPUD HANDLING SYSTEMS

Perform pull tests to demonstrate rated load capability for each winch and toggle hydraulic cylinder. Demonstrate the operation of the spud handling system by performing the following operations from all control stations:

• Power-down and power-up operation at the rated speed.

• Stopping, braking and holding.

• Activation of the brake in a loss of power situation.

• Raise the spud to the stowage position and secure with the locking dog engaged.

• Near free fall mode.

• Ability to tilt spud with hydraulic cylinder through the required range of motions.

• Use of the spud collar.

• Ability to disassemble and reassemble spud sections

• Weekend/Unattended mode.

32. LAUNCH CABLE REEL SYSTEM

Demonstrate the ability to install a reel on its axel in the reel alley using the girder crane and electric hoists.

Demonstrate the ability to remove the reel. Repeat this for four different reels in four different reel locations in the reel alley.

Demonstrate the ability to install the existing reels (slimmer) onto the axels with the spacers.

33. LAUNCH CABLE REEVING SYSTEM

Demonstrate the functionality of the reeving for the launch cables from the reel alley to the top of the mat deck.

Demonstrate the functionality of the reeving for the launch cables from the reel alley to the top of the mat deck with the slimmer reels.

34. LAUNCH CABLE REEL BRAKES

Demonstrate the functionality of the launch cable reel manual brakes.

Demonstrate the functionality of the launch cable reel manual brakes with the slimmer reels and spacer.

35. FINGER SYSTEM

Demonstrate the operation of the finger system for all six sets of fingers.

Extend and retract the fingers through their full range of extension twice for each finger set. Demonstrate the functionality of the all of the limit switches to stop the finger motion.

Demonstrate the functionality of all the controls.

Demonstrate the ability to stow the fingers in a locked position.

36. REEL ALLEY GIRDER CRANES

Load test the girder cranes to 100% of the rated load.

Demonstrate the operation of the reel alley girder cranes. Move both cranes from midship to the respective hatch using the crane controls. Demonstrate the functionality of all the controls.

Demonstrate the ability to move reels in and out of the reel alley through the reel alley hatches using the girder crane.

Demonstrate the ability to stow the cranes in a locked position.

37. MOTORIZED ELECTRIC HOISTS

Load test all the motorized electric hoists to 100% of the rated load.

Demonstrate the operation of the electric hoists. Demonstrate the ability of the electric hoists to travel their entire range of motion on their respective rails. Demonstrate the ability of the hoists to hoist up and down through their full reach capacity.

For the overhead gantry crane hoists, hoist a weight up and down from the deck up to the overhead gantry.

Demonstrate the functionality of all the controls.

For the reel alley girder crane electric hoists, demonstrate the ability to lift and handle the launch cable reels using the Contractor furnished lifting frames.

38. EOS ROOM AC UNIT COOLING SYSTEMS

Demonstrate the operation of the cooling pumps and piping systems.

Demonstrate the functionality of all the controls.

39. RESISTOR BANK COOLING SYSTEMS

Demonstrate the operation of the resistor bank cooling system. Demonstrate the ability to cool the resistor banks under load.

Demonstrate the functionality of all the controls.

40. TRANSDUCERS

Demonstrate the transducers provide accurate depth measurements at the digital display screens on the barge in accordance with C775.

Coordinate with the Robotics Integrator to demonstrate the GFE Sonar transducer provides accurate hydrographic data to the Robotics Control Consoles.