Section
23 Fuel installations using gases or other low-flashpoint fuels
23.1 General
23.1.3 This Section provides requirements for the survey of a fuel installation
using gases or other low-flashpoint fuels as defined in Pt 1, Ch 3, 1.5 Definitions 1.5.35 (gases or other low-flashpoint fuels are
hereinafter referred to as fuel).
23.1.5 The Annual Survey shall be scheduled, as far as practicable, to coincide
with a bunkering operation to allow for verification of fuel storage tank level alarms
and bunkering control, alert and safety systems under operational conditions. At annual
survey physical testing of alarms and shutdowns is not required unless it is considered
necessary by the attending Surveyor. In any case records of the alarms are to be
retained for the verification of the attending Surveyor.
23.1.6 The
Intermediate Survey supplements the Annual Survey by testing the fuel
bunkering system including automatic control, alert and safety systems
to confirm satisfactory operation. The extent of the testing required
for the Intermediate Survey may briefly interrupt the fuel installation
and therefore vessel operations and the survey are to be scheduled
accordingly.
23.1.7 The extent of the testing required for Complete Surveys will normally be
such that the full survey cannot be carried out with the fuel installation operating or
loaded with fuel. Consequently, aspects of the survey shall be coordinated to correspond
with dry-docking or another period when the system will be gas free. Completion of the
survey requires verification of satisfactory condition of the installation at the normal
operating temperatures and pressures so will normally be completed once the vessel has
been bunkered following reactivation of the system.
23.1.8 Prior
to any internal inspection of fuel storage tanks, associated piping,
fittings and equipment, etc. the respective items are to be made safe
for access by means of isolating relevant valves, purging and gas-freeing
the space.
23.1.9 Where
an approved condition-monitoring system is employed for the fuel system
and its constituent components, and the applicable Descriptive Note
is assigned, the requirements of these regulations for opening up
and internal examination may be waived where the condition of the
equipment can be shown to be within agreed acceptable limits as detailed
in Pt 5, Ch 21 Requirements for Condition Monitoring and Condition-Based Maintenance Systems.
23.1.10 The
following documentation, as applicable, is to be available on board
the ship:
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Relevant instruction
and information such as loading limit curve information, bunkering
procedures, cooling down procedures and fuel installation test
and inspection procedures.
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Condition-Monitoring
or Condition-Based Maintenance documentation as applicable.
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Test records
for bunkering ESD systems.
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Records of crew
tests/inspections of the fuel installation.
23.1.12 Where the design of any part of the fuel installation does not permit
opening up for internal examination, as required by these regulations, alternative
arrangements for testing and/or inspection will be specially considered.
23.2 Survey Following Repair
23.2.1 Following repairs, independent fuel storage tanks of Type C are to be
hydrostatically tested in accordance with Rules and Regulations for the Classification of Ships using Gases or other Low-flashpoint Fuels, July 2022 and in accordance with the manufacturer’s testing
procedures. The tank shall be subjected to a hydrostatic test at a pressure measured at
the top of the tanks of not less than 1.5 times the design vapour pressure. Other types
of fuel storage tank, such as membrane tanks, are to be tested in accordance with
approved procedures. provided by the fuel storage tank designers. After testing,
suitable drying and consequent air-purging procedures are to be followed to return the
tank to operational condition.
23.3 Annual Surveys - General Requirements for
Fuel Systems
23.3.1 The Annual Survey is to be carried out with the fuel installation
operational. Gas-freeing will not generally be necessary.
23.3.2 The ship’s log and operational records covering the period from the
previous survey, are to be examined. with regard to correct functioning of the gas
detection systems, fuel supply/gas systems, and other equipment related to the fuel
installation. The operating hours per day of the reliquefaction plant, the gas
combustion unit, as applicable, the boil-off rate, and nitrogen consumption (for
membrane containment systems) are to be reviewed and evaluated for equivalence on the
balance of the fuel handling, and considered together with any existing gas detection
records.
23.3.3 Any malfunction of the installation recorded in the log is to be
investigated. It is to be verified that any repairs have been carried out to an
acceptable standard and in accordance with the applicable Rules and Regulations.
23.3.4 The manufacturer/Builder instructions and manuals covering the operations,
safety and maintenance requirements and occupational health hazards relevant to fuel
storage, fuel bunkering, and fuel supply and associated systems for the use of the fuel,
are to be confirmed as being aboard the vessel.
23.3.5 All control systems, alerts and safety systems are to be tested as follows:
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The control, alert and safety systems for the fuel storage tanks and
processing system are to be verified in satisfactory condition by one or more of
the following methods:
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Comparison of read-outs from local and remote indicators.
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Consideration of read-outs with regard to the actual
conditions.
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Examination of maintenance records with reference to the
approved maintenance management system.
-
Verification of calibration status of the measuring
instruments.
-
All control, alerts and safety systems are to be tested, where
testing is not possible due to operational reasons simulated testing may be
accepted by the attending Surveyor. Which are to include but are not limited
to:
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fuel storage tank and processing system high and low pressure.
-
fuel storage tank high and high-high level
-
fuel storage tank overfill level
-
fuel storage tank high temperature.
- Gas detection and other leakage detection equipment in spaces containing fuel
storage, fuel bunkering, and fuel supply equipment or components or associated
systems, including indicators and alarms, is to be confirmed as being in satisfactory
operating condition. Recalibration of the gas detection systems shall be verified in
accordance with the manufacturers’ recommendations.
-
Fuel leakage detection systems (temperature sensors and gas detection
as applicable) are to be examined and tested in accordance with the manufacturer’s
instructions and calibrated using sample gas.
-
The electrical installation, equipment and cables in areas which may
contain flammable gas are to be examined in order to verify that they are in good
condition and have been properly maintained. Bonding straps that are installed to
control static electricity are to be visually examined.
-
Alerts and safety systems associated with pressurised installations
and any safety device associated with non-safe type electrical equipment that is
protected by air-locks or pressurisation, are to be verified.
- Verification, as far as is practicable, of the satisfactory
operation of the control, monitoring and automatic shutdown systems of the fuel
supply and bunkering systems.
- Operational test, as far as practicable, of the shutdown of ESD
protected machinery spaces.
23.3.6 Fuel installations are to be surveyed as follows:
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Portable and/or fixed drip trays, or insulation providing protection
in the event of fuel leakage, are to be examined.
-
Components of the fuel installation fitted with insulation to provide
protection against ice formation are to be examined for satisfactory
condition.
-
Fuel piping, valves and fittings are to be generally examined, with
particular attention to double-wall or ventilated ducting arrangements, expansion
bellows, supports and vapour seals on insulated piping.
- Fuel piping and components associated with the fuel processing equipment are to be
visually examined.
23.3.7 Inerting arrangements and associated alarms are to be verified as being in
satisfactory condition, including the means for prevention of backflow of fuel vapour to
the inert gas system.
23.3.8 Ventilation systems including portable ventilating equipment where fitted,
for spaces containing fuel storage, fuel bunkering, and fuel supply units or components,
or associated systems, including air locks, pump rooms, compressor rooms, fuel
preparation rooms, fuel valve rooms, control rooms and spaces containing gas burning
equipment, are to be surveyed as follows:
-
Ventilation systems and air-locks including their alarm system are to
be generally examined.
-
Ventilation fans in hazardous areas are to be visually examined.
-
For ventilated double-walled piping or ducting containing fuel piping
within machinery spaces, exhaust fans and/or supply fans are to be examined to
ensure that the air-flow is not impeded.
-
Where alarms, such as differential pressure and loss of pressure
alarms, are fitted, these shall be operationally tested as far as practicable.
23.3.9 The closing devices for all air-intakes and openings into accommodation
spaces, service spaces, machinery spaces, control stations and approved openings in
superstructures and deckhouses less than 10m from deck-mounted fuel storage tanks, are
to be examined.
23.3.10 Venting arrangements, including protection screens if provided, for fuel
storage tanks, inter-barrier spaces and tank hold spaces as applicable, are to be
visually examined externally. The external condition of the fuel storage tank relief
valves is to be verified and records of the last test of the opening/closing pressures
are to be reviewed.
23.3.11 Means for draining the vent arrangements from fuel storage tank pressure
relief valves and other system relief valves are to be examined to ensure that there is
no liquid build-up that would impede effective operation, drain valves are to be checked
as applicable.
23.3.12 Heating arrangements, if fitted, for steel structures in cofferdams and
other spaces are to be verified in satisfactory condition.
23.3.13 All gastight bulkhead penetrations, including any gastight shaft seals, are
to be visually examined.
23.3.14 Electrical equipment and bulkhead/deck penetrations, including access openings in
hazardous areas, are to be examined for continued suitability for their intended service
and installation area.
23.3.15 Electrical bonding arrangements in hazardous areas, including bonding straps where
fitted, are to be examined.
23.4 Annual Surveys – Fuel Processing Equipment
23.4.1 The
following fuel processing equipment is to be generally examined in
working condition and operational parameters verified. Insulation,
where fitted, need not be removed but any deterioration of insulation,
or evidence of dampness which could lead to external corrosion of
the vessels or their connections, is to be investigated:
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Heat exchangers
and pressure vessels.
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Fuel heaters, vaporisers, masthead heaters.
-
Heating arrangements,
including provision for continuous heating and circulation of heating
medium to prevent freezing during start up and when the fuel installation
is not in use.
-
Fuel piping and
components associated with the fuel processing equipment.
23.4.2 Where
the double wall or duct containing fuel piping is protected using
a pressurised inert gas atmosphere the monitoring and maintenance
of the inert atmosphere is to be confirmed in satisfactory condition.
23.4.3 The
condition of the fuel isolation valve and double block and bleed arrangements
for each consumer is to be examined with respect to:
-
Containment to
prevent fuel leakage from any valve arrangements installed within
the machinery space.
-
Connections to
the inerting and venting arrangements.
-
General examination to confirm that the valve arrangement and all
associated fuel monitoring, control, and shutdown equipment are in satisfactory
condition. The external examination is to be supplemented by a review of relevant
operational, maintenance and service reports.
23.4.4 Where
fuel processing equipment is located within an independent space that
functions as containment in the event of a fuel spill (e.g. a tank
connection space), the space is to be examined internally and externally
to verify that the structure remains in a satisfactory condition to
contain any potential leakage of fuel including any thermal isolation
to protect the surrounding structure from damage due to cryogenic
leakage.
23.4.5 Records of testing the operation of the master fuel valve for each engine
space are to be verified. Tests are to be carried out on regular basis as agreed with LR
and the scope of the testing shall incorporate a full test of the Emergency Shutdown
sequence. Where practicable, operation of the valve as described above is to be
witnessed at the time of survey.
23.5 Annual Surveys – Fuel Storage
23.5.1 Areas
in which fuel storage tanks are located (on and below deck) are to
be examined for any changes to the arrangements within those areas
that may affect the hazardous area rating.
23.5.2 For Type C pressurised fuel storage tanks the external surface of the fuel
storage tank insulation is to be visually examined for cold spots to verify the
condition of the insulation arrangements. This examination is to be carried out with the
fuel storage tanks loaded. Ideally fuel storage tanks shall be loaded to the maximum
loading limit; examination of partially-filled fuel storage tanks may be accepted
alongside a review of records of periodic cold spot examinations carried out by suitably
trained and qualified crew.
23.5.3 The
supporting structure between the deck plating and the tank is to be
examined to confirm that the saddle arrangement remains in satisfactory
condition in accordance with the approved design.
23.5.4 For
vacuum-insulated fuel storage tanks, monitoring records are to be
reviewed to confirm satisfactory maintenance of the vacuum. Any trends
identifying a breakdown or loss of vacuum containment are to be investigated.
23.5.5 For Type B fuel storage tanks where the insulation arrangements are such
that the insulation cannot be examined, the surrounding structures of wing tanks, double
bottom tanks and cofferdams are to be visually examined for cold spots. This examination
is to be carried out with the fuel storage tanks loaded. Ideally fuel storage tanks
shall be loaded to the maximum loading limit; examination of partially-filled fuel
storage tanks may be accepted alongside a review of records of periodic cold spot
examinations carried out by suitable trained and qualified crew.
23.5.6 For
membrane fuel storage tanks the performance of the insulation arrangements
is to be confirmed in accordance with approved procedures submitted
by the containment designers.
23.5.7 The fuel storage hold space is to be generally examined.
23.5.8 The tank connection space is to be internally examined.
23.5.9 Tank and relief valves are to be externally examined.
23.5.10 Satisfactory operation of the tank monitoring system is to be verified.
23.5.11 Bilge alarms and means of drainage of the space are to be examined and tested.
23.5.12 Remote and local closing of the main tank valve is to be tested.
23.6 Annual Survey - Fuel Bunkering System
23.6.1 The
fuel-bunkering system, including manifold connections, isolation valves,
bunker piping and linked Emergency Shutdown (ESD) system connection
equipment (including cabling and connectors), are to be visually examined.
23.6.2 Bunkering operations are to be observed as far as practicable; satisfactory
condition of the bunkering control, alert and safety system is to be verified. During
annual survey it is not expected that ESD1 (stoppage of bunker transfer) or ESD2
(disconnection of bunker piping) will be operationally tested where applicable but
records of maintenance and testing are to be reviewed. However, prior to starting the
bunkering operation, it is expected that an ESD1 is tested with no fuel in the system
(i.e. a dry test). Records of the testing are to be available during survey.
23.7 Intermediate Surveys
23.7.1 In
addition to the requirements below, the requirements of Pt 1, Ch 3, 23.1 General to Pt 1, Ch 3, 23.6 Annual Survey - Fuel Bunkering System are to be complied with.
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Control, alert
and safety systems for the bunkering system, fuel-containment systems
and processing equipment, together with any associated shutdown and/or
interlock, are to be tested under working conditions and, if necessary,
recalibrated. Shutdown sequence and extent are to be verified
against documented procedures where applicable. Such safety systems
include but are not limited to:
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Bunkering ESD
system is to be tested, without fuel in the piping, to verify that
ESD system operation will result in a closure of the isolation
valves and a shutdown of machinery associated with bunkering operations.
All ESD activations and outputs are to be tested including fuel storage
tank overfill protection, bunkering isolation valve closure and automatic
shutdown of machinery associated with bunkering operations.
-
Fuel-processing
equipment shutdown and closure of isolation valves resulting from:
- loss of the valve-actuating medium;
- loss of ventilation in fuel piping double wall /ventilated duct;
or
- loss of pressure of inert gas in pressurised double-walled pipe
arrangement.
-
Fuel processing
equipment shutdown and closure of isolation valves as a result of
deviation in the fuel supply to the engine-room from the normal operating
conditions (temperature and pressure).
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Fuel installation
shutdown as a result of gas detection.
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Safety interlocks
on fuel-processing equipment are to be examined and tested as necessary
to confirm satisfactory condition.
-
Gas detectors, temperature sensors, pressure sensors, level
indicators, and other equipment providing input to the safety system are to be
randomly tested to confirm satisfactory operating condition. The proper response
of the safety system upon fault conditions is to be verified.
23.7.2 Consideration
will be given to simulated testing, provided that it is considered
representative. Comprehensive maintenance records, including details
of tests carried out in accordance with the fuel plant and instrumentation
maintenance manuals may be presented for review. Acceptance of either
simulated testing or maintenance records including reports of testing
as described above is subject to the satisfaction of the attending
Surveyor.
23.8 Complete Surveys - General
requirements
23.8.4 Provided that the structural examination is satisfactory, that the gas
detection systems have been found to be in satisfactory condition, routine on board
checks and maintenance records are satisfactory and that the voyage records have not
shown any abnormal operation, fuel storage tanks will not require hydrostatic testing
(except as required by Pt 1, Ch 3, 23.8 Complete Surveys - General requirements 23.8.6.
23.8.5 The non-destructive testing (NDT) of independent fuel storage tanks is to
supplement visual inspection with particular attention to be given to the integrity of
the main structural members, tank shell and highly-stressed parts, including welded
connections as deemed necessary by the Surveyor. The following items are considered as
highly-stressed parts:
- structure in way of tank supports and anti-rolling/anti-pitching
devices,
- web frames or stiffening rings,
- swash bulkhead boundaries,
- dome and sump connections to tank shell,
- foundations for pumps, towers, ladders, etc.
- pipe connections.
23.8.6 The NDT testing requirements for different types of independent fuel storage
tanks are detailed below; where radiographic or ultrasonic testing is required, at least
10 per cent of the length of the applicable welded connections is to be tested. This
testing is to be carried out internally and externally as applicable. Insulation is to
be removed as necessary for the required non-destructive testing:
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For independent fuel storage tanks of Type B, the extent of
non-destructive testing is to be given in the test schedule specially prepared for
the tank design. The Owner is to submit proposals for the extent of
non-destructive testing of the fuel storage tanks in advance of the survey.
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For vacuum-insulated independent fuel storage tanks of Type C vacuum
monitoring is accepted as a demonstration of the internal integrity of the tank.
This is subject to verification that the monitoring equipment is being maintained,
operated and calibrated in a satisfactory condition. There is no further
requirement for internal examination and testing of these tanks. The tank support
arrangements are to be visually examined; non-destructive testing may be required
if the condition raises doubt as to the structural integrity.
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For non-vacuum insulated independent fuel storage tanks of Type C
non-destructive testing is required on the plating in way of supports and also
over selected lengths of welds. Where such testing raises doubt as to the
structural integrity, further testing is to be carried out in accordance with the
requirements of the manufacturer’s test and inspection instructions for hydraulic
testing (normally at 1,25 times the approved maximum vapour pressure).
Alternatively, consideration will be given to pneumatic testing under special
circumstances, provided full details are submitted for approval.
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At each alternate Complete Survey (i.e.at 10 year intervals);
non-vacuum insulated independent fuel storage tanks of Type C are to be either:
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Hydrostatically or hydro-pneumatically tested to not less than
1,25 times MARVS in accordance with the requirements of the manufacturer’s
test and inspection instructions. The requirements for non-destructive
testing in Pt 1, Ch 3, 23.8 Complete Surveys - General requirements 23.8.5 are to be carried out following this
test as required by the Surveyor; or
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Subject to a thorough, planned, non-destructive testing. This
testing is to be carried out in accordance with a test schedule specially
prepared for the tank design. If a special programme does not exist, the
following shall be tested:
- structure in way of tank supports and
anti-rolling/anti-pitching devices;
- stiffening rings;
- Y-connections between tank shell and a longitudinal
bulkhead of bi-lobe tanks;
- swash bulkhead boundaries if applicable;
- dome and sump connections to the tank shell if
applicable;
- pipe connections.
23.8.7 Membrane fuel storage tank surveys are to be carried out in accordance with
approved testing procedures provided by the containment designers.
23.8.8 Fuel bunkering, supply and storage tank pipe connections and fittings are to
be examined, and all valves and cocks in direct communication with the interiors of the
storage tanks are to be opened out for inspection and the connection pipes are to be
examined internally, so far as practicable. Special attention is to be paid to the fuel
storage tank master isolation valve(s); the valve seat is to be visually examined and
the valve tested at the maximum working pressure of the fuel storage tank prior to
re-commissioning the fuel installation.
23.8.9 All emergency shutdown valves, check valves, block and bleed valves, master gas valves,
remote operating valves, isolating valves for pressure relief valves in the fuel
storage, fuel bunkering, and fuel supply piping systems are to be examined and proven
operable. A random selection of valves is to be opened for examination.
23.8.10 Relief valves are to be surveyed as follows:
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The pressure relief valves for the fuel storage tanks are to be opened
for examination, adjusted to the correct operating pressure as indicated in Pt 1, Ch 3, 23.8 Complete Surveys - General requirements 23.8.10.(b), function-tested, and sealed. If the tanks
are equipped with relief valves with non-metallic membranes in the main or pilot
valves, such non-metallic membranes are to be replaced. Valves may be removed from
the tank for the purpose of making this adjustment under pressure of air or other
suitable gas.
-
Valves are to lift at a pressure not more than the percentage given
below, above the maximum vapour pressure for which the tanks have been
approved:
- For 0 to 0,15 MPa, 10 per cent.
- For 0,15 to 0,3 MPa, 6 per cent.
- For pressures exceeding 0,3 MPa, 3 per cent.
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Pressure relief valves for the fuel supply and bunkering piping are
to be opened for examination, adjusted, and function tested. Where a detailed
record of continuous overhaul and retesting of individually-identifiable relief
valves is maintained, consideration will be given to acceptance on the basis of
opening, internal examination, and testing of a representative sampling of valves,
including each size and type of liquefied gas or vapour relief valve in use,
provided there is logbook evidence that the remaining valves have been overhauled
and tested since the previous Complete Survey.
-
Relief valves on fuel piping are to have their pressure settings
checked. The valves may be removed from the piping for this purpose. At the
Surveyor’s discretion a sample of each size and type of valve may be opened for
examination and testing.
- The pressure/vacuum relief valves, rupture discs and other
pressure relief devices for interbarrier spaces and hold spaces are to be opened,
examined, tested and readjusted as necessary, depending on their design.
23.8.11 All fuel pumps, booster pumps and vapour pumps are to be opened out for
examination. Where applicable, pumping systems for inter-barrier spaces are to be
checked and verified to be in satisfactory condition.
23.8.12 Compressors, process pressure vessels, heat exchangers and other components used in
connection with fuel handling are to be examined.
23.8.13 Piping for the fuel processing system including valves, actuators and
compensators is to be opened for examination. Insulation may need to be removed, as
deemed necessary, to ascertain the condition of the piping. If any doubt exists
regarding the integrity of the piping based upon visual examination then, where deemed
necessary by the Surveyor, a pressure test at 1,25 times MARVS of the piping is to be
carried out. The complete piping systems are to be tested for leaks after re-assembly.
Where water cannot be tolerated and the piping cannot be dried prior to putting the
system into service, the Surveyor shall accept alternative testing fluids or alternative
means of testing.
23.8.14 Equipment for the production of inert gas is to be examined and shown to be
in satisfactory condition, operating within the gas specification limits. Piping,
valves, etc. for the distribution of the inert gas are to be generally examined.
Pressure vessels for the storage of inert gas are to be examined internally and
externally and the securing arrangements are to be specially examined. Pressure relief
valves are to be demonstrated to be in satisfactory condition. Liquid nitrogen storage
vessels are to be examined, so far as practicable, and all control equipment, alarms and
safety devices are to be verified as operational.
23.8.15 Gastight bulkhead shaft seals are to be opened out so that the sealing
arrangements may be checked.
23.8.16 Any sea connections associated with the fuel handling equipment are to be
opened out when the ship is in dry dock.
23.8.18 Testing of the tank connection space and cofferdam leakage-detection
arrangement (temperature sensors and gas detectors) is to be carried out.
23.8.19 Examination of electrical equipment to include the physical condition of electrical
cables and supports, intrinsically safe, explosion proof, or any other increased safety
features on the electrical equipment.
23.8.20 Functional testing of the equipment which is necessary to establish and maintain the
pressure within pressurised electrical equipment enclosures (Ex p) and associated alarms
is to be carried out.
23.8.21 Testing of arrangements for de-energizing electrical equipment which is not certified
for use in hazardous areas.
23.8.22 An electrical insulation resistance test of the circuits terminating in, or
passing through, hazardous areas, is to be carried out. If the ship is not in a gas-free
condition, the results of previously recorded test readings may be accepted together
with a review of the on-board monitoring of the earth loop impedance of relevant
circuits.
23.8.23 Gas detectors, temperature sensors, pressure sensors, level indicators, and other
equipment providing input to the fuel safety system are to be tested to confirm
satisfactory operating condition. Pressure, temperature and level indicating equipment
are to be calibrated in accordance with the manufacturer’s requirements.
23.9 Complete Surveys - Consumers and other
equipment
23.9.1 Heat
exchangers associated with the fuel installation are to be opened
out and examined as follows:
-
The water end
covers of evaporators are to be removed for examination of the tubes,
tube plates and covers.
-
Heating medium
pumps, including standby pump(s) which may be used on other services,
are to be opened out for examination.
-
Where a pressure
vessel is insulated, sufficient insulation is to be removed, especially
in way of connections and supports, to enable the vessel’s
condition to be ascertained.
Note this refers to external insulation, not additional insulation
that may be installed in the annular space of a vacuum insulated tank.
-
Insulated piping
is to have sufficient insulation removed to enable its condition to
be ascertained. Vapour seals are to be specially examined for
their condition. Vacuum-insulated piping is to be visually examined
and records of maintenance and vacuum monitoring are to be reviewed.
23.9.2 The
steam side of steam heaters is to be hydraulically tested to 1,5 times
the design pressure.
23.9.3 Fuel
pipe ducts or casings are to be generally examined and the exhaust
or inerting arrangements are to be verified.
23.9.4 All alarms associated with the fuel burning systems are to be verified;
including, but not limited to, main and auxiliary engines, boilers, incinerators and gas
combustion units.
23.9.5 The
satisfactory condition of all pressure relief valves and/or safety
discs throughout the installation is to be verified.
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