WI-0001_REF_7081122_GTR_Searchable.pdf

MILITARY SEALIFT COMMAND

GENERAL TECHNICAL REQUIREMENTS

(GTRs)

DRAWN BY: CHECKED BY:

JJMA-WMF

D. P. RUSSELL

Head, Policy Branch

J.C. BOHR

Head, Project Coordination

ROBERT E. VAN JONES

Director, Technical Division

K. D. BAETSEN

JJMA-MSM

DATE

16 May 97

DATE

16 May 97

DATE

16 May 97

DATE

22 May 97

DATE

SIZE

A

DEPARTMENT OF THE NAVY

MILITARY SEALIFT COMMAND

WASHINGTON D.C., 20398

MILITARY SEALIFT COMMAND

GENERAL TECHNICAL REQUIREMENTS

(GTRs)

CAGECODE SWBS DWGNO

803 7081122

REV

T. G. CONNORS 23 May 97 SCALE NONE STD PLAN SHT 1OF120

REVISION SHEET

REV REVISION DESCRIPTION APPROVED

MSC DRAWING NO. 803-7081122 MSCGTR SHEET 2 OF 120

CHANGES TO GENERAL TECHNICAL REQUIREMENTS (GTRs)

It is expected that this document will be dynamic. Any omissions, discrepancies, or suggestions for improvements to this document shall be forwarded to COMSC N7 using the Feedback Form at the end of GTR 29. All feedback will be retained and thoroughly evaluated for incorporation into subsequent revisions to the GTRs. Originators will be advised of action on their proposed change.

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GENERAL TECHNICAL REQUIREMENTS (GTRs) INDEX

1 Regulatory Bodies, Standards, And Certificates

2 Access For Inspection, Operation, Maintenance, And Repair

3 Tests, Trials, Inspections, And Certificates

4 Brand Name Or Equal

5 Drawings, Drawing Review, And Drawing Approval Requirements

6 Contractor Furnished Material And Workmanship

7 General Painting

21 Joiner Work

22 Insulation And Lagging

23 Piping

24 Manufacturer's Representatives

25 Structure And Foundations

26 Interior Deck Coverings

27 Heating, Ventilation And Air Conditioning (HVAC)

28 Electrical And Electronic Systems

29 Identifying Markings

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GENERAL TECHNICAL REQUIREMENTS (GTRs) INDEX

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GTR No. 1

GENERAL TECHNICAL REQUIREMENTS

REGULATORY BODIES, AND ORDER OF PRECEDENCE

1.0 ABSTRACT

This Item identifies regulatory body requirements and order of precedence requirements.

2.0 REFERENCES: None

3.0 REGULATORY BODIES

Whether or not specifically required in a work item or GTR, all of the applicable laws of the United States and the requirements of the various regulatory bodies in force at the time of contract award shall apply to the work performed under the contract, including but not limited to those listed below:

3.1 American Bureau of Shipping (ABS), Rules for Building and Classing Steel Vessels, Requirements for Certification of Construction and Survey of Cargo Gear on Merchant Vessels, Rules for Building and Classing Steel Vessels Under 200 Feet [61 Meters] in Length, Guide for Certification of Cranes, Guide for Construction of Shipboard Elevators, and Rules for Building and Classing Underwater Vehicles, Systems, and Hyperbaric Facilities.

3.2 United States Coast Guard (USCG), Code of Federal Regulations, Title 46 - Shipping (46 CFR), Code of Federal Regulations, Title 33 - Navigation and Navigable Waters (33 CFR), Code of Federal Regulations, Title 35 - Panama Canal (35 CFR), and Navigation and Vessel Inspection Circulars.

3.3 International Maritime Organization (IMO): Including all resolutions and amendments as adopted for the International Convention for the Safety of Life at Sea (SOLAS), the International Convention for the Prevention of Pollution from Ships (MARPOL), and the International Convention for the Prevention of Collisions at Sea (COLREGS).

3.4 United States Public Health Service (USPHS), including Publication No. 393, "Handbook on Sanitation of Vessel Construction", and USPHS and MARAD's Joint Publication No. P 161019 "Ratproofing of Ships", to entitle ship to receive Deratization Exemption Certificate and Certificate of Sanitary Construction.

3.5 Federal Communications Commission (FCC).

3.6 U.S. Department of Labor, "Safety and Health Regulations for Longshoring" and "Occupational Safety and Health Act (OSHA)".

3. 7 Panama Canal Company Regulations.

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GTR No. 1

GENERAL TECHNICAL REQUIREMENTS

REGULATORY BODIES, AND ORDER OF PRECEDENCE

3.8 Suez Maritime Canal Universal Company Rules of Navigation.

4.0 ORDER OF PRECEDENCE

4.1 As a subcategory of FAR Clause 52.215-33(e) (Order of Precedence), the following order of precedence in descending order shall apply:

4.1.1 Regulatory requirements.

4.1.2 Work item requirements.

4.1.3 Contract Drawing.

4.1.4 Contract Guidance Drawings.

4.1.5 GTR.

4.2 Order of Precedence within Work Package

General work items in the Work Package (001 through 099) state the broadest requirements and apply to the complete contract. Specific work items may require additional or different services or work and shall prevail over the general work items.

4.3 Specific Requirements

Where requirements of the Contract, Contract Drawings, Contract Guidance Drawings, or the Work Package are in excess of regulatory body requirements, the Contract, Contract Drawings, Contract Guidance Drawings, or the Work Package shall prevail.

MSC DRAWING NO. 803-7081122 MSCGTR GTR 1 SHEET 2 OF 2

GTRNo. 2

GENERAL TECHNICAL REQUIREMENTS

ACCESS FOR INSPECTION, OPERATION, MAINTENANCE, AND REPAIR

1.0 ABSTRACT

This Item establishes the general requirements for inspection, maintenance, operation, removal, installation, and repair access to Government furnished and Contractor furnished equipment, machinery, and associated foundations.

2.0 REFERENCES

2.1 American Society for Testing and Materials (ASTM), Fl 166, Standard Practice for Human Engineering Design for Marine Systems, Equipment, and Facilities.

3.0 LAYOUT

3.1 Machinery, equipment, and associated foundations shall be installed to permit ready access to all parts for inspection, maintenance, operation, removal, installation, and repair without disturbing other structures or ship's components. Piping runs, cable runs, ventilation ducts, controls, valves, and wireways shall not be installed in areas rendered inaccessible by the location of fittings or by other obstructions. When layouts call for the installation of permanent ladders, doors, catwalks, manholes, scuttles, and bolted plates, they shall be installed for ease of removal and reinstallation. Battens and gratings in holds, storerooms, and other spaces and protective casings around pipes shall be readily removable.

3 .2 Equipment and accompanying local operating panels and gage boards shall be installed to conform with manufacturer's requirements for clear access to equipment for ease of maintenance, repair, inspection, and operation. This includes but is not limited to providing clearance for opening and closing of operating panels, motor controller boxes, drawers, and doors.

3.3 Outfitting arrangements shall be designed to allow full opening and closing of all drawers, doors, and pull down desk tops.

3.4 Equipment shall be installed to ensure personnel safety and protection of equipment in accordance with Reference 2.1.

3.5 Installation and modification arrangements shall not degrade the capabilities, operability, human engineering considerations, safety, alignment, maintainability, electromagnetic capability, and intended use of new or existing equipment.

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GTRNo. 2

GENERAL TECHNICAL REQUIREMENTS

ACCESS FOR INSPECTION, OPERATION, MAINTENANCE, AND REPAIR

4.0 MANHOLES AND ACCESS OPENINGS

4.1 Access openings and manholes shall not be restricted by interferences including but not limited to cable runs, pipes, valves, heating coils, girders, longitudinals, web frames, or major bulkhead stiffeners. When access openings or manholes require ladders, rungs, and/or grabrails for accessibility, they shall be installed in line with the openings. All trunks and casings shall be large enough to facilitate unobstructed servicing of piping, manifolds, and other items.

4.2 Where access to components such as piping cleanout connections, wiring, ducts, vents, piping, air conditioning controls, filters, heaters, valves, and ducting access plates are needed due to maintenance/inspection requirements, the access shall comply with Reference 2.1, be hinged and fitted with quick acting catches, and be clearly labeled to identify the concealed equipment.

4.3 Duct access openings shall have bolted cover plates and shall comply with Reference

2.1. Cover plates shall be of the same thickness and material as the duct, transition, or trunk to which it is attached. A gasket shall be installed between the cover plate and the duct, transition piece, or trunk. Access openings shall be as large as possible but not more than 600 by 600 mm (24 by 24 in) and not less than 200 mm (8 in) by 230 mm (9 in). Access openings in transition sections shall be rectangular, circular, or trapezoidal. Access openings shall be installed in the bottom of the duct unless the top side of the duct is more accessible.

5.0 PROVISIONS FOR REMOVALS

New equipment shall be installed in locations to facilitate removal of components in accordance with the manufacturer's requirements. This includes but is not limited to shafting, tube bundles, and machinery parts. Provisions for removals may consist of areas of decks, bulkheads, etc. which have been soft patched and arranged so that when a section is removed, the remaining structure will be self-supporting.

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GTRNo. 3

GENERAL TECHNICAL REQUIREMENTS

TESTS, INSPECTIONS, TRIALS AND CERTIFICATES

1.0 ABSTRACT

This Item describes the general requirements associated with perf arming tests, inspections and trials and obtaining certificates to demonstrate total compliance with the Work Package requirements as well as specific testing requirements and procedures for each type of work being performed (HV AC, electrical, piping, etc.).

2.0 REFERENCES

2.1 Society of Naval Architects and Marine Engineers (SNAME), Technical and Research Bulletin 3-39, Guide for Shop and Installation Tests.

2.2 Institute for Electrical and Electronic Engineers (IEEE) Standard 45, Recommended Practice for Electric Installations on Shipboard.

2.3 MIL-STD-1605 (Series), Procedures for Conducting a Shipboard Electromagnetic Interference (EMI) Survey.

2.4 Institute for Electrical and Electronic Engineers (IEEE) Standard 149-1979, Standard Test Procedures For Antennas.

2.5 Institute for Electrical and Electronic Engineers (IEEE) Standard 43-1974, Recommended Practice For Testing Insulation Resistance Of Rotating Machinery.

2.6 Institute for Electrical and Electronic Engineers (IEEE) Standard 112-1991, Standard Test Procedure For Polyphase Induction Motors And Generators.

2. 7 Institute for Electrical and Electronic Engineers (IEEE) Standard 115-1983, Test Procedures For Synchronous Machines.

2.8 Institute for Electrical and Electronic Engineers (IEEE) Standard 120-1989, Master Test Guide For Electrical Measurements In Power Circuits.

2.9 U.S. Public Health and Human Services, Standards of Sanitation and Ratproofing for the Construction Vessels.

2.10 American Society of Mechanical Engineers (ASME), Al 7 .1, Safety Code for Elevators and Escalators, Part X: Routine, Periodic, and Acceptance and Tests.

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2.11 American Society of Mechanical Engineers (ASME), Al 7.3, Safety Code for Existing Elevators and Escalators.

2.12 NA VSHIPS Technical Manual (NSTM) 772, Cargo and Weapons Elevators.

2.13 ASHRAE Standard 151 P, Practices for Measurement, Testing, Adjusting and Balancing of Shipboard HV AC and Refrigeration Systems.

3.0 DEFINITIONS

3.1 Completion Test - A completion test verifies that all aspects of the work item have been completed. For compartments, it means all equipment, piping, electrical, deck coverings, overheads, etc. is installed and tested and proves the compartment is complete and ready for service. For tanks, it means all cleaning, flushing, installations, testing has been completed, all temporary services are removed and the tank is ready for service. A completion test may include a series of functional, operational, and structural tightness tests.

3.2 Functional Test - A functional test verifies that equipment, material, components, and gear meet their intended purpose and that all work has been perf armed satisfactorily to the specific instructions of the work item and the manufacturer's instructions. For instance, functional tests shall be used to verify the proper installation and operation of components and gear such as doors, scuttles, cabinets, etc.

3.3 Operational Test - An operational test verifies that:

• All work has been performed satisfactorily and to the specific instructions and requirements of the work item, manufacturer, and regulatory bodies.

• The equipment, material, machinery, or system including all flows, levels, temperatures, loads, and alarms complies with manufacturer's parameters.

• The equipment, material, machinery, or system performs its intended purpose.

3.4 Tightness Test - A tightness test verifies that all structural work including any structural attachments which would affect the tightness of the structure, is complete and ready for service. This may be accomplished using air or water depending on the specific instructions in the work item, regulatory body requirements and the intended service.

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TESTS, INSPECTIONS, TRIALS AND CERTIFICATES

4.0 GENERAL

4.1 Tests and inspections are required on all systems, equipment, machinery, surfaces, items, and components that are installed, repaired, overhauled, relocated, or modified. Tests, trials and inspections shall be conducted as indicated in the individual items of this Work Package and in the presence of the MSCREP. All applicable Regulatory Bodies and required Technical Representation shall attend each test, trial and inspection.

4.2 Preliminary tests are required to be conducted on all units before calling for an official test.

4.3 A test, trial, or inspection is successful if it meets the requirements of the test procedure and if it is completed to the satisfaction of the MSCREP, technical representatives, and regulatory bodies.

4.4 Ensure that all industrial work which may impact the test, trial, or inspection outcome is completed before its conduct. The Contractor is responsible for notifying all applicable regulatory bodies of scheduled testing and retaining of required technical representatives at contractor expense for verification of test results. Failure to obtain regulatory body representatives to witness testing, trial, or inspection shall require rescheduling the test, trial, or inspection at Contractor's expense.

4.5 Provide materials, power, equipment, instrumentation, and personnel to perform each test, trial, and inspection and to record data. Materials, equipment and services include but are not limited to manlifts, lighting, ventilation, and instrumentation to conduct each inspection.

Operation of (existing/installed) shipboard equipment shall only be accomplished by ship's force.

4.6 Notify the MSCREP at least 4 hours but not more than 24 hours before the test, trial, or inspection to be witnessed. When work to be witnessed is scheduled to occur after the normal day shift working hours, on a weekend or holiday, or off-site testing is required, the MSCREP shall be notified at least 24 hours in advance but not less than 4 hours prior to the end of the last normal day shift.

5.0 INSTRUMENTS AND GAGES USED FOR DATA RECORDING

Contractor furnished measuring instruments shall be calibrated within 6 months of the date of the test. Calibrated equipment shall be identified with a label stating date of most recent calibration and calibrating agency. Ship installed gages and test instruments shall not be used to

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TESTS, INSPECTIONS, TRIALS AND CERTIFICATES

obtain test, trial, and inspection data unless approved by the MSCREP prior to conduct of the test.

6.0 LEAK TESTING OF SYSTEMS CONTAINING REFRIGERANTS OR HALON

Refrigerant containing chloro-flouro carbons (CFC) shall not be used as a leak test gas.

One of the following leak test gases shall be used:

• A mixture of trace quantity of non-CFC refrigerant and dry air or nitrogen. In this case, leak test gas shall be recovered and reused and not released into the atmosphere.

• A non-ozone depleting alternative gas.

• An EPA SNAP (Significant New Alternatives Policy) approved alternative refrigerant.

7.0 PAINTING TEST AND INSPECTION REQUIREMENTS

7 .1 The Contractor and the MSC REP shall conduct a joint inspection of areas to be prepared and painted before surface preparation begins to ensure that protective measures are implemented.

7 .2 The Contractor shall perform inspections after completion of each stage of surface preparation, each coat, and each stripe coat, to verify surface condition, DFT and space cleanliness, and before securing space. At least 2 DFT readings shall be taken per 100 square feet.

7 .3 The Contractor shall stop the inspection if surface preparation, coating, or final inspection fails to meet acceptance criteria of the inspection. The cause of the failure shall be identified. After failure correction, the complete inspection shall be reconducted. The Contractor shall remedy failed areas at no additional cost to the Government.

7 .4 The Contractor shall conduct a final inspection of space, surfaces, and tanks to ensure that spaces are clean.

8.0 STRUCTURAL TIGHTNESS AND COMPLETION TESTS

New, repaired, and modified ship's tanks, cofferdams, void spaces, and structures designated as oiltight, watertight, airtight, or fumetight shall be tested to ensure tightness. New weather decks and interior steel decks, coamings, and deck connections of steel bulkheads, in way of toilets, washrooms, and other wet spaces shall be tested to ensure tightness before installing deck or bulkhead covering.

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GENERAL TECHNICAL REQUIREMENTS

TESTS, INSPECTIONS, TRIALS AND CERTIFICATES

8.1 Test Requirements

8.1.1 Air Tests

a. Air tests (either an air hose test or an air pressure test), hydrostatic tests, or vacuum box tests shall be used to test the tightness of oiltight, watertight, or airtight compartments.

b. Air hose testing shall be used to test the tightness of structure separating two main machinery spaces. Air hose testing shall be used to test the tightness of bulkheads separating cargo holds, or separating cargo holds and a main machinery space, where main deck cargo hatch covers are not designed to be watertight under a pressure head.

c. If air testing (air hose or air pressure) is used, structural integrity and tightness shall be considered satisfactory if no bubbles develop in the leak indicator solution.

d. Inaccessible spaces adjacent to the sea, including skegs, fairwaters, rudder support assemblies, and vee-type bilge keels, shall be tested at an air pressure of 14 kPa (2 psi). Shaft tubes and rudders shall be tested for tightness with air pressure of 14 kPa (2 psi).

These tests shall be conducted before filling with preservative coating.

8.1.2 Water Tests

a. If hydrostatic tests are conducted, other tightness tests are not necessary providing tests are conducted after work affecting structural integrity has been completed.

b. Where water hose testing is used, the nozzle shall be within 3 meters (10

ft) of the structure under test, and the stream shall be directed against structure portions in a manner most likely to reveal leaks. The nozzle diameter shall be at least 13 mm (0.5 in) and the pressure at the nozzle shall be at least 210 kPa (30 psi). Compartment boundaries, plate connections, closures, fittings, and boundary penetrations shall be tested. The opposite side of the structure shall be inspected to detect leakage.

c. When conducting air pressure tests, Contractor's air pressure test fixture shall be comprised of a pressure gage with a range suitable for the required test pressure, a quick acting manual relief valve at least 25 mm (1 in) in diameter, and an automatic relief valve at least 25 mm (1 in) in diameter set to relieve pressure at 7 kPa (1 psi) over the required test pressure. Manometers are acceptable in lieu of a pressure gage.

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d. Where an air hose test is used, the nozzle shall be 300 mm (12 inches) from the tested item and the stream directed against all compartment boundaries, plate connections, closures, fittings, and boundary penetrations in the manner most likely to reveal leaks. The nozzle diameter shall be at least 10 mm (.375 in), and the pressure at the nozzle at least 620 kPa (90 psi). A soap solution shall be applied on the opposite side of the structure and the structure inspected to detect leakage.

e. If water hose testing is used, structural integrity and tightness shall be considered satisfactory if no visible leakage develops.

f. Airports, fixed lights, and fixed, hinged, or otherwise movable weather windows shall be hose tested with at least 207 kPa (30 psi) water pressure.

8.1.3 Visual Test

Visual examinations of fumetight structures shall be made by lighting one side of the structure and darkening the other side. Inspection shall be made from the dark side and shall be considered satisfactory if no light penetrates into the dark side.

8.1.4 Functional and Tightness for Doors, Hatches, and Manholes

Doors and scuttles shall be functionally tested by opening and closing them by their operating gear to demonstrate operability to the MSCREP in accordance with Reference

2.1. They shall also be chalk tested and air box tested to prove tightness.

9.0 TESTS FOR HULL FITTINGS AND APPURTENANCES

9 .1 Accommodation Ladder

Static load and operational tests shall be perf armed on accommodation ladders in accordance with Reference 2.1.

9.2 Pilot's Ladder

The rigging of the Pilot's Ladder at port and starboard deployment stations shall be demonstrated to the MSCREP.

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9.3 Liferails and Stanchions

At least one liferail end stanchion and one other liferail stanchion on each platform or deck shall be tested by a 136 kg (300 lb.) horizontal load, outboard at the stanchion's top, and perpendicular to the railings. The load shall be held for 10 minutes. 20 % of top liferail sections on each platform or deck (one of which shall be an end section), as selected by the MSCREP, shall be tested by applying a 136 kg (300 lb.) load horizontally outboard and perpendicular to the rail at the rail's midpoint. The load shall be held for 10 minutes. Permanent deformation or damage shall not be visible after load release from the liferails and stanchions.

9.4 Padeyes

Pad eyes shall be given a static test of twice the design working load for a period of 10 minutes without damage or permanent distortion occurring to the fitting. The weight of power hoists shall be considered as part of the design working load for test purposes.

10.0 ELECTRICAL AND ELECTRONICS

1 0 .1 General

Shop and installation tests shall be perf armed on electrical, electronic, navigation, and interior communication equipment that is new or removed from the ship for modification, overhaul, or repair in accordance with References 2.2 through 2.8. Operational tests on equipment that is modified, overhauled, or repaired onboard the ship shall be performed in accordance with References 2.2 through 2.8.

10.2 Insulation Resistance Tests

10.2.1 End to end continuity and electrical insulation resistance tests on new, modified, overhauled, or repaired system cables shall be perf armed in accordance with Reference 2.2.

10.2.2 The MSCREP shall be immediately notified if insulation values of equipment or cable are less than 1 Megohm.

10.3 Enclosure Ground Tests

Electronic equipment enclosures shall be tested for continuity and resistance of the grounding path. The resistance of the grounding path between the equipment enclosure and a ship structural member shall not exceed 0.1 ohm.

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10.4 Propulsion And Auxiliary Generator Tests

New, modified, overhauled, or repaired generators shall be tested in accordance with Reference 2.1.

10.5 Switchboard/Switchgear Tests

New, modified, overhauled, or repaired switchboards, switchgear, and automatic and manual bus transfer equipment shall be tested in accordance with Reference 2.2.

10.6 Power Distribution

Each new, modified, overhauled, or repaired circuit shall be operationally tested.

The voltage dip shall be recorded using an oscilloscope to demonstrate that a temporary voltage dip during motor starting or speed change does not interrupt service to other equipment.

10.7 Motors And Controls

10. 7 .1 New, modified, overhauled, and repaired motors and associated controllers shall be tested in accordance with Reference 2.1.

10. 7 .2 Individual line amperes shall not differ from the nameplate average value by more than + 10 %. The motor nameplate full load ampere value shall be compared with the value indicated on the motor controller overload heater coils to ensure that the heater coil is of the correct rating to provide motor protection.

10.8 Lighting

New, modified, overhauled, and repaired ship's service lighting circuits shall be tested in accordance with Reference 2.2.

10.9 Storage Batteries And Chargers

The Contractor shall test new storage batteries and their associated battery charging units in accordance with manufacturer's recommendations. Voltage and specific gravity values for each cell for the fully discharged and fully charged conditions shall comply with manufacturer's specified values for each condition.

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1 0 .1 0 HF Antennas

New, repaired, overhauled, or modified HF antennas shall be tested in accordance with References 2.3 and 2.4.

11.0 AUXILIARY SYSTEMS TESTS REQUIREMENTS

Operational tests on contractor and government furnished auxiliary systems, machinery, or components and installation tests on auxiliary systems, machinery, or components that are repaired, overhauled, or modified shall be performed in accordance with Reference 2.1.

11.1 Fresh Water Systems

11.1.1 The fresh water system, including compression tanks, shall be hydrostatically tested to 150 percent of working pressure.

11.1.2 Potable water systems shall be tested by filling from shore and also by transferring water from one tank to an overboard connection using the ship's pumps. To demonstrate that the specified water delivery (pressure and quantity) is met, the water supply to groups of fixtures at the most remote forward, after, and topside location shall be checked. The capacity of the pump or pumps used to supply the group of fixtures shall meet the flow requirements for these fixtures.

11.1.3 The Contractor shall disinfect the potable water tank in accordance with Reference 2.9. After the Contractor has disinfected the potable water tank, the Contractor shall conduct the tests required by Reference 2.9 and submit results to the MSCREP. If tests results do not comply with the limits established in Reference 2.9, the Contractor shall repeat the tank flushing, superchlorinating, and testing. The operation of the disinfection system shall be demonstrated after potable tank disinfection and again before the sea trials. Minimum residual concentration readiness shall be determined by taking water samples from each installed sampling connection.

11.1.4 The hot potable water system shall be tested to demonstrate the ability of the system to deliver hot water at a minimum of 49 °C (120 °F) at the most remote plumbing fixtures of each heater loop within 10 seconds.

11.1.5 The chilled water system shall be tested to insure that, with all valves in the open position, the measured water flow (gpm) at each plant is within 90-110 % of the connected load.

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11.2 High and Low Pressure Evaporators, Distillers, Auxiliary Steam Generators, and Miscellaneous Heat Exchange Equipment

The Contractor shall test evaporators, auxiliary steam generating equipment, and heat exchangers, in accordance with Reference 2.1.

11.3 Dumbwaiters and Passenger and Stores Elevators

The Contractor shall test dumbwaiters and passenger, cargo and stores elevators in accordance with References 2.10, 2.11, and 2.12.

11.4 Firemain, Flushing, Sprinkling, Washdown and Salt Water Service Systems

After installation or repair and prior to sea trials, the firemain, flushing, sprinkling, washdown and salt water service systems shall be hydrostatically tested at 150 percent of maximum working pressure as required for USCG certification.

11.5 Fire Fighting Equipment

11. 5 .1 Carbon Dioxide Systems

a. Prior to connection the cylinders, a pressure test shall be applied. Only carbon dioxide or other inert gas shall be used for the test. The piping from the cylinders to the stop valves in the manifold shall be subjected to a pressure of 1,000 psi with no additional gas being introduced to the system. The pressure drop shall not exceed 150 psi per minute for a 2 minute period. The individual branch lines to the various spaces protected shall be subject to the same test except that a pressure of 600 psi shall be used. The distribution piping shall be capped within the space protected at the first joint ahead of the nozzles.

b. Remote control for release of carbon dioxide equipment shall be operated.

c. Operation of the discharge delay and alarm shall be checked. Discharge of gas into spaces that may be occupied shall be delayed for a sufficient period to allow escape from any portion of the space. The alarm shall be audible throughout the space with the machinery operating.

d. Operating levers, selector valves, etc. shall be properly identified.

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e. Pressure switches for automatic shut-down of ventilation shall be operated.

f. All carbon dioxide cylinders shall be checked for weight. Cylinder weight shall be within 10 percent of the stamped weight.

11.5.2 Halon 1301 Systems

a. Prior to connecting the cylinders, a pressure test shall be applied. Only carbon dioxide or other inert gas shall be used for the test. The piping from the cylinders to the stop valves in the manifold shall be subjected to a pressure of 1-1/2 times the design pressure of the system (900 psi for nominal 360 psi systems and 2800 psi for nominal 600 psi systems).

With no additional gas being introduced to the system, pressure drop shall not exceed 150 psi per minute for a 2 minute period. The individual branch lines to the various spaces protected shall be subject to the same test. The distribution piping shall be capped within the space protected at the first joint ahead of the nozzles.

b. Remote release mechanisms shall be checked to insure that cables and pulleys are free to move and that the mechanism operates properly.

c. The discharge alarm must be checked and operated with dry air or nitrogen. The alarm shall be audible throughout the space with machinery operating.

d. Pressure switches for automatic shut-down of ventilation and equipment shall be operated.

e. The weight and pressure of each cylinder shall be checked. Cylinder charge shall be 5 percent or less. Cylinder pressure shall not vary more than 10 percent from normal pressure (adjusted for temperature).

11.5.3 Aqueous Potassium Carbonate System (APC)

The nitrogen pressurization piping of the galley APC system shall be gas pressure tested for tightness and strength to 135 percent of design pressure.

APC switches shall be operated by a reduction of line pressure to verify cut off of fryer element power. Verification of unobstructed flow through piping and nozzles shall be performed using compressed air at 85 to 100 psi. Activation of the APC system by remote manual means shall be demonstrated.

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11.5.4 Portable Fire Fighting Equipment

The installation, charge, tagging, and placement of portable fire extinguishers shall be verified.

11.5.5 Aqueous Film Forming Foam (AFFF) System

The system piping for AFFF stations shall be hydrostatically tested for strength and tightness. Compressed air at 85 to 100 psi shall be used to demonstrate unobstructed flow through piping and sprinkling nozzles. Outlets may be temporarily capped if necessary to allow testing of one or two outlets at a time. All AFFF concentrate tanks shall be tested for strength and tightness by a hydrostatic pressure of 10 psi. All installed AFFF systems shall be operationally tested for AFFF making ability. Duration of the test shall be 1 minute, after which an AFFF sample shall be taken. The AFFF (seawater) solution produced shall be checked by the refractometer method for 4 percent minimum concentration. AFFF hose reel units shall be test-operated with the AFFF station set up in the AFFF recirculation mode.

Seawater shall be discharged overboard. During the test, the local and remote controls shall be operated.

a. High Capacity AFFF Systems

The systems, exclusive of the AFFF sprinkler groups, shall be tested hydrostatically as specified for the firemain. In addition, the systems shall be given an operational test during which all remote actuation controls shall be selectively operated and flow observed at the respective service outlets. Flow test of AFFF sprinkler groups shall be conducted by removing the cap from the group control valve, installing the test fitting, connecting a 2-1/2-inch hose to the test fitting, and positioning the other end at the discharge location. During the above operational tests, AFFF stations shall be aligned to recirculate AFFF concentrate to the AFFF concentrate tank. All lines containing seawater shall be drained after testing.

b. Machinery Space AFF Systems

The systems, exclusive of AFFF sprinkler groups, shall be tested hydrostatically as specified for the firemain. The systems shall be given an operational test during which all manual control valves and nitrogen cylinder actuating valves shall be selectively operated. The AFFF concentrate shall be recirculated and the PKP cylinders shall be isolated during the test. Flow shall be observed from a hose reel and from a 1-1/2 inch hose attached to the group control valve test fitting. All lines containing seawater shall be drained after testing.

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c. AFFF Monitor System

The AFFF monitor installation shall be given an operational test with the AFFF system lined up to recirculate back to the tank. Operation of the "Sea-Water", "AFFF", and "OFF" controls shall be demonstrated.

11.6 Bilge System

The bilge system shall be hydrostatically tested at 150 percent of working pressure.

11. 7 Fuel Oil Filling, Venting, Stowage and Transfer Systems

11. 7 .1 Hydrostatic tests shall be conducted after cleaning. Fuel piping shall be hydrostatically tested after installation with clean fresh water or the service fluid to 150 percent of the design pressure or 50 psi, whichever is greater. Pumps in fuel stripping, transfer and service systems shall be isolated during hydrostatic tests of the system piping.

11. 7 .2 An operational test of the filling and transfer system shall be perf armed to demonstrate compliance of in-port fueling with service fluid rates.

11. 7 .3 Power operated system and tank valves shall be operated. Operation of the valves shall be confirmed by actual observation of each valve. Correct operation of valve position indicators shall be observed during this test.

11.8 Compressed Air System

11.8.1 Shop tests on a standard production air compressors are not required except for the usual tests perf armed by the manufacturer for production line units.

11.8.2 Air compressors shall be tested with the diving equipment after all necessary piping and accumulator tanks have been installed and pressure tested. Tests shall be conducted for one hour to demonstrate satisfactory operation of the compressor and its automatic controls and safety devices.

11.8.3 Compressed air piping shall be tested hydrostatically at 150 percent of maximum allowable working pressure.

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TESTS, INSPECTIONS, TRIALS AND CERTIFICATES

11.9 Auxiliary Steam, Exhaust Steam and Steam Drains

After installation, the auxiliary steam, exhaust steam and steam drain systems shall be tested hydrostatically at 150 percent of maximum allowable working pressure. The exhaust steam shall be tested at the maximum pressure under full load conditions using the working fluid.

11.10 Distilling Plant

The distilling plant should be operated with sea water feed to demonstrate the specified capacities. The ability of the distilling plant to produce the maximum quantity and required distillate for period of not less than six ( 6) hours should be demonstrated in its normal underway mode of operation. Record operating data from the ship's instrumentation at 30 minute intervals for not less than six ( 6) hours.

11.10.1 Piping systems operating at pressures above atmospheric shall be hydrostatically tested at 150 percent of maximum allowable working pressure. Piping systems operating at atmospheric or sub-atmospheric pressure shall be tested for leakage using air at 10 .

psi.

11.10.2 Shipboard performance tests of 24 hour duration shall be conducted dockside and during sea trials while underway to demonstrate production of rated capacity and specified salinity. However, where the distilling units are exact duplicates of design which has passed the above tests, the duration of the dockside performance tests may be reduced to 8 hours.

11.10.3 Automatic operation of the three-way solenoid-operated valves shall be demonstrated.

11.11 Steering System

11.11.1 Shop Tests

a. The steering gear shall be completely assembled (including remote control provisions, rudder tiller and connecting links, if feasible) in a manner simulating the shipboard installation. It shall be operated at no load from hard over to hard over for at least one-half hour to demonstrate satisfactory mechanical an/or hydraulic operation and that the dimensional, control and lubrication aspects of the design are satisfactory. A check should be made for proper rate of travel, helm response, follow-up action, storage motion, hydraulic fluid

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and pump temperatures and, where feasible, mechanical rudder and helm indicator accuracy.

Temporary piping or flexible hose may be used for ship tests.

b. Where feasible, the hydraulic, electric or pneumatic steering control components should be assembled to demonstrate satisfactory operation as a complete system.

11.11.2 Installation Tests

a. The fallowing preliminary checks shall be conducted:

1) Measure insulation resistance of motors and electrical steering control system including cable to remote control stations.

2) Demonstrate proper operation of relief valves.

3) Where applicable, demonstrate proper operation and setting of horsepower limiter (pressure compensator).

4) Where applicable, test replenishing system relief valves.

5) Check setting of control limit stops and copper and steel hard-over stops for proper rudder motion limits.

6) Demonstrate satisfactory operation of differential control unit for full storage motion and correct follow-up action.

b. The following operating checks shall be conducted:

1) Operate steering gear at no load for one-half hour on each power unit, moving rudder hard-over to hard-over at least five times for each steering station. Check setting of control limit stops, number of handwheel turns hard-over to hard-over and rate of rudder travel.

2) Check alignment of ship's rudder and position of rudder angle indicators on ram unit and at each steering station (where applicable).

3) Demonstrate operation of steering gear on either set of two opposed cylinders if required by design.

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11.12 Pumps

4) Operate steering gear from either power unit and check the rapidity of shifting from one power unit to the other. Where specified, demonstrate operation of steering gear on both power units.

5) Demonstrate operation of electrical low voltage release feature.

6) If separate servo-pump motors are utilized, demonstrate that servo motors start before main motors and that interlocks are operating properly.

7) Demonstrate operation of overload audible and visible alarms and indicator lights.

11.12.1 Each pump shall be operated at the normal service conditions while handling, where practicable, its normal working fluid.

11.12.2 The pumping equipment shall be operated with all governors and control apparatus in place and operating.

11.12.3 Pump tests may be conducted in conjunction with piping system tests.

11.12.4 All pumps shall be given a continuous test for a period of at least one hour, or longer if required, for the test of the source of motive power. Not less than three sets of readings at approximately equal time intervals shall be taken on all instruments and shall be recorded on data sheets.

11.12.5 All pumps shall be operated as near to the rated suction pressure, discharge pressure and capacity as practicable; for units such as main and auxiliary feed pumps and main condensate pumps, capacities obtained when the main machinery is operating under dock trial conditions will be satisfactory.

11.12.6 In addition to he continuous operating test, other tests shall be conducted on the pump and associated equipment as follows:

a. The ability of the unit to take its suction through each suction connection and to discharge through each discharge connection shall be demonstrated.

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b. The ability of the unit to operate in parallel shall be demonstrated where parallel operation is required. This may take place during sea trials.

c. The operation of automatic level switches and automatic pressure switches shall be demonstrated.

d. For pumps fitted with automatic priming systems, the operation of each priming system shall be demonstrated.

e. Where pumps are specified and designed to deliver various capacities at different operating conditions or speeds, they shall be operated at the specified heads and speeds.

f. The correct settings and/or operation of the relief valves, governor valves, and recirculating valves shall be demonstrated. Where not practicable to test relief valves in the ship, they may be tested in the shop.

11.13 Navigation Equipment

All navigation equipment should be proven operational during dock trials and any calibration or adjustments necessary shall be performed during initial phases of the sea trials.

12.0 HVAC TESTING

12.1 General

The Contractor shall perform operational tests on new, repaired, overhauled, or modified HV AC systems, equipment, or components in accordance with Reference 2.1. The tests must demonstrate compliance with Work Package and contract requirements.

12.2 Test Requirements

12.2.1 General

All HV AC systems shall be balanced and operationally tested in accordance with the requirements of Reference 2.13.

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12.2.2 Installation Tests

Installation tests shall be perf armed after complete installation and prior to sea trials, at a time when testing conditions are such that accurate, realistic data can be obtained.

All readings shall be recorded at half-hour periods and coordinated with recorded data from the installed system instruments and test instruments.

a. Equipment Tests

Prior to testing the HV AC system as a complete system, fans, motors, coils, filters, compressors, pumps, all control devices and dampers, etc., shall be checked for satisfactory operation, adjusted for full load operating conditions; such components shall not be readjusted during tests. All related companion heating, ventilation and common trunk systems, whether intakes or discharges, shall be in simultaneous operation and all doors closed while these tests are in progress.

b. System Tests

The entire air conditioning plant shall be operated for at least 6 hours with the entire connected load at approximately the maximum design operating conditions, to verify the ability of the system to develop design load at specified temperature and pressure. All controls, regulating, modulating and expansion valves, thermostats, dampers, etc. shall be checked for proper operation.

c. Ventilation Volumetric Tests

Determine that all instruments used to conduct ventilation and system tests have been calibrated within the preceding six months.

1) The average velocity of the air passing through each supply and exhaust terminal and through the entire system shall be determined and compared with design conditions. Barometer and psychrometer readings shall be taken at the system intake and discharge.

2) All data taken shall be corrected for standard air and compared with design criteria for adequacy. The following air delivery rates are considered satisfactory unless otherwise specified.

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• Each system shall be capable of handling 100 to 110 % of designed air volume.

• Air supply, recirculating and exhaust terminals shall be balanced to deliver 95 to 110 % of the designed volume.

d. Noise Level Test

1) Noise level readings shall be taken in passageways, offices, and living spaces with all vent system in operation. Readings shall be taken on American Standards Association "A" or "B" weighted network, as applicable, at a time when the ambient level without the vent systems in operation is ten decibels less than those mentioned above.

2) Primary reading (ambient noise level with vent systems secured) - At least two readings shall be taken in each place; the average reading shall be recorded for sound level with space unmanned and all equipment, including vent systems, secured.

3) Final reading (with vent systems in operation) - The average of two or more readings shall be taken at different locations, three feet from each terminal, close to but not within the airstream.

4) Sound level readings and space vent system and terminal numbers shall be recorded on the test form.

e. Draft Survey

Performance of terminals in air conditioned spaces shall be checked during the noise level survey for conformance with maximum air velocity requirements.

12.2.3 Dehumidification Systems

a. All dehumidification plants shall be operated for six hours, with the entire connected load and maintaining the temperature, humidity, and air supply to the cargo holds and or other areas.

b. The satisfactory operation of the regulating dampers shall be demonstrated.

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MSC DRAWING NO. 803-7081122 MSCGTR GTR3 SHEET 20 OF 20

GTRNo. 4

GENERAL TECHNICAL REQUIREMENTS

BRAND NAME OR EQUAL

1.0 ABSTRACT

This Item establishes procedures and standards for determining equivalence of Contractor Furnished Material (CFM).

2.0 REFERENCES: None

3.0 COMMERCIAL BRAND NAMES OR EQUIVALENT EQUIPMENT

When CFM is required and specified by brand name in the contract or work item, equivalent material may be proposed. The salient physical, functional, and other characteristics which "equal" products meet shall include but are not limited to:

3 .1 Compliance of proposed item, equipment, component, or material with regulatory body requirements and other design standards.

3.2 Data that demonstrates that the proposed item, equipment, component, or material meets or exceeds the specified performance requirements.

3.3 Data that demonstrates that the proposed item, equipment, component, or material has functionally equivalent:

a. Dimensions.

b. Weight.

c. Power, HV AC, cooling water, and other required services.

d. Suitability for marine service.

e. Material.

f. Maintenance features and requirements.

g. Vendor furnished training.

h. Life cycle cost and maintenance cost.

i. Structureborne and airborne noise characteristics.

j. Warranty provisions.

k. Maintenance manpower requirements.

1. Worldwide support and service infrastructure.

m. Spare parts availability.

n. Prior provisioning through the Naval Supply System.

o. Estimated spare parts costs for one year's use.

p. Compatibility with interrelated systems and arrangements.

MSCDRAWINGNO. 803-7081122 MSCGTR GTR4 SHEET 1 OF2

GTRNo. 4

GENERAL TECHNICAL REQUIREMENTS

BRAND NAME OR EQUAL

MSCDRAWINGNO. 803-7081122 MSCGTR GTR4 SHEET 2 OF 2

GTRNo. 5

GENERAL TECHNICAL REQUIREMENTS

DRAWINGS, DRAWING REVIEW, AND DRAWING APPROVAL REQUIREMENTS

1.0 ABSTRACT

This Item establishes drawing preparation, review, and approval requirements.

2.0 REFERENCES

2.1 Military Sealift Command Standard Drawing 7080803, Preparation of Computer Aided Designed (CAD) Drawings for USNS Ships.

2.2 American Society of Mechanical Engineers (ASME), Y14.24M, Types and Applications of Engineering Drawings.

2.3 Military Sealift Command Standard Drawing 7079667, Preparation of Selected Record Drawings for USNS Ships.

3.0 DRAWINGS

3.1 Ship's Drawings

After contract award, MSC will…