Guidance on the maintenance and inspection of fixed CO 2 fire-extinguishing systems

Transcription

1 Translation. Only the Danish document has legal validity. Guidance no of 9 July 2014 issued by the Danish Maritime Authority Guidance on the maintenance and inspection of fixed CO 2 fire-extinguishing systems 1. Introduction 1.1 This guidance is a reproduction of the circular MSC.1/Circ.1318 issued by the International Maritime Organization (IMO), Guidelines for the maintenance and inspections of fixed carbon dioxide fire-extinguishing systems. 1.2 The purpose of this guidance is to provide a minimum level of maintenance and inspection of CO 2 fire-extinguishing systems in ships so that the systems are in good working order and ready for immediate use. The guidance supplements the manufacturer's maintenance manual for the systems. Maintenance and inspection may be carried by crewmembers holding the necessary competences; however, certain maintenance functions and inspections should be carried by especially trained personnel. This should be clearly stated in the ship's maintenance plans. 2. Safety plan 2.1 When maintenance and inspection of CO 2 fire-extinguishing systems are carried, the necessary safety precautions shall be followed. Prior to performing any work, a safety plan shall be developed to account for all personnel involved, including the ship's crew and service personnel. An effective communication system shall be established between the service/inspection personnel and the ship's other crewmembers. Measures shall be taken to avoid accidental release of the system, such as insertion of a blind flange after the main stop valve or any other means of preventing accidental release of the system. The entire crew and other personnel shall be informed that work is on-going. 3. Maintenance and inspection plan 3.1 CO 2 fire-extinguishing systems shall be kept in good working order and ready for immediate use. Maintenance and inspection should be carried in accordance with the ship's maintenance plan so as to secure the functions and reliability of the system. The plan should be part of the ship's ISM system and be based on the manufacturer's recommendations, including: 1) maintenance and inspection procedures and instructions; 2) required schedules for periodic maintenance and inspection; 3) listing of recommended spare parts; and 4) records of inspection and maintenance, including description of works carried to maintain the operability of the system. 4. Monthly inspections 4.1 At least once a month, a visual inspection should be made of the overall system condition for obvious signs of damage, and this shall contain a verification of the following: 1) all valves are in the proper position (open or closed); 2) all releasing controls are in the proper position and readily accessible for immediate use; 3) all piping and servo pipes/control pipes are intact and undamaged; 4) all pressure cylinders are in place and properly secured; and 5) all alarm devices are in place and undamaged. 4.2 In addition to the above, inspections of low-pressure CO 2 systems shall also verify that: 1

2 1) pressure gauges are reading the normal range; 2) the liquid CO 2 level indicator is reading within the proper level; 3) the manually operated storage tank main service valve is secured in the open position; and 4) the CO 2 vapour supply line valves are secured in the open position. 5. Annual inspections 5.1 The following minimum level of maintenance and inspection shall be carried in accordance with the manufacturer's instructions and safety recommendations: 1) the boundaries of the protected spaces are inspected visually in order to ensure that no modifications have been made that may have created uncloseable openings that would render the system ineffective; 2) all storage containers are inspected visually for any signs of damage, corrosion and loose mounting hardware. Cylinders that have leaked, have corroded, have indents or bulges are pressure tested or replaced; 3) all piping is inspected visually for damage, loose supports and corrosion. It is checked that there is free passage to and from all nozzles; 4) the manifold is inspected and it is verified that all flexible hoses and other fittings are correctly tightened; and 5) all entrance doors to the protected spaces close properly and are provided with a clear mark stating that the spaces are protected by CO 2 and shall be evacuated in case the alarm sounds. All remote releasing controls shall be checked for clear instructions and indications. 6. Minimum recommended maintenance 6.1 At least biennially in passenger ships or at each intermediate, periodical or renewal survey in cargo ships, the following maintenance should be carried (examples of checklists are enclosed as annexes 1 and 2): 1) All cylinders and pilot cylinders are weighed, or the content of the cylinders is verified in some other manner so as to check whether the content of each cylinder exceeds 90% of the nominal charge. Cylinders containing less than 90% of the nominal charge shall be recharged. The liquid level of CO 2 in low-pressure systems shall be checked so as to verify that the required quantity of CO 2 is available. 2) The date of the last pressure testing of all pressure cylinders, servo containers and pressure containers shall be checked. Pressure cylinders shall be periodically tested at least every ten years. At a 10-year inspection, a minimum of 10% of the total number of cylinders shall be checked. The control shall consist of an internal inspection and a hydrostatic test. If one or more cylinders fails, 50% of the total number of pressure cylinders shall be tested; if one more pressure cylinders fails, all the pressure cylinders shall be tested. Flexible hoses shall be replaced in accordance with the manufacturer's instructions; however, they should as a minimum be replaced every ten years. 3) It shall be checked that distributing pipes and nozzles for supplying CO 2 to the protected space are not blocked. This is checked by isolating each individual CO 2 pipe section and flowing dry air or nitrogen through them. 6.2 At least biennially in passenger ships or at each intermediate, periodical or renewal survey in cargo ships, the following maintenance should be carried by service technicians/specialists: 1) Where possible, all activators from the cylinders valves shall be dismounted and their functioning shall be tested at full working pressure through the pilot lines. Where this is not possible, the pilot lines shall be disconnected from the cylinders valves and blinded off or connected and tested with full 2

3 working pressure from the release station, whereafter a leak test is carried. In both cases, this shall be carried from the release station(s). In case manual pull cables/wires operate the remote release controls, it shall be checked that all cables and corner pulleys are in good condition, move freely and that an unreasonably great pull is not needed to activate the system; 2) all components of the cable carrying shall be cleaned and, if necessary, adjusted and all cable connections shall be adjusted. If the remote-release uses a pneumatic pressure, the connections shall be checked for leakages and the charge of the servo containers shall be checked. All controls and alarms shall function normally and the time-delay shall, if installed, prevent the release of CO 2 during the required period of time; and 3) when the above has been carried with a satisfactory result, the system shall be re-established in the normal operating condition. It shall be verified that all release controls are in the proper position and are connected to the correct control valves. All pressure gauges and interlocks, etc. shall be reset to zero and re-established in the normal operating condition. It shall be ensured that all valves are in the proper position (open or closed). Danish Maritime Authority, 9 July 2014 Per Sønderstrup / Palle Kristensen 3

4 Annex 1 Example of checklist for high-pressure CO 2 systems High-pressure CO 2 system Date Name of ship/system IMO no. Description of system No. Text To be filled in 1 Manufacture 2 Number of pressure cylinders 3 Pressure cylinder capacity (each) 4 Number of pilot cylinders/servo cylinders 5 Pilot cylinder capacity (each) 6 Number of distribution lines 7 Oldest cylinder pressure test date 8 Protected space(s) 9 Date flexible hoses fitted/renewed Description of inspection/test No. Description 1 The system is secured against accidental release by insertion of a blind flange after the main stop valves or in any other manner. 2 Contents in pressure cylinders checked by weighing. 3 Contents in pressure cylinders checked by liquid level indicator. 4 Contents of pilot cylinders checked. 5 All cylinder valves visually checked. 6 All cylinders, securing arrangements and connections checked. 7 Manifold visually inspected. 8 Manifold tested for leakage by applying dry working air. 9 Main stop valves and distribu- Not carried Not applicable Comments 4

5 No. Description tion valves visually inspected. 10 Main stop valves and distribution valves tested for operation. 11 Time-delay devices tested for correct setting (if installed). 12 Remote release systems visually inspected. 13 Remote release systems tested. 14 Servo tubing/pilot lines pressure tested at maximum working pressure and checked for leakage and blockage. 15 Pull cables/wires, pulleys, gang releases, etc. tested, serviced and tightened/adjusted as necessary. 16 Release stations visually inspected. 17 Alarms (audible/visual) tested. 18 Fan stop tested % of pressure cylinders and pilot cylinders pressure tested (every ten years). 20 Distribution lines and nozzles blown through by applying dry working air. 21 All doors, hinges and locks inspected. 22 All instruction and warning signs inspected. 23 All flexible hoses renewed and check valves in manifold inspected (every ten years). 24 Release control, control valves, distribution valves reconnected and system put back in service ready for immediate use. 25 Inspection date tags attached. Not carried Not applicable Comments 5

6 Example of checklist for low-pressure CO 2 system Annex 2 Low-pressure CO 2 system Date Name of ship/system IMO no. Description of system No. Text To be filled in 1 Manufacture 2 Number of tanks 3 Tank capacity (tonnes or m 3 ) 4 Number of pilot cylinders/servo cylinders 5 Pilot cylinder capacity (each) 6 Number of distribution lines 7 Protected space(s) Description of inspection/test No. Description 1 The system is secured against accidental discharge, e.g. by securing the tank main service valve in the closed position. 2 Distribution valves in the closed position. 3 Check correct function of liquid level indicator. 4 Contents of CO 2 tank checked by tank level indicator. 5 Contents of CO 2 tank checked by external level tube. 6 Contents of CO 2 tank checked by level control valve. 7 Supports of tank inspected. 8 Insulation on tank inspected. 9 Safety valves of tank inspected. 10 Safety valves of tank tested. 11 Contents of pilot cylinders checked. 12 Start/stop of cooling compressors tested. 13 All electrical alarms and indi- Not carried Not applicable Comments 6

7 No. Description cators tested. 14 Main manifold valves inspected. 15 Main manifold valves tested. 16 Distribution valves inspected. 17 Distribution valves tested. 18 Release stations inspected. 19 "Total flooding" release mechanism inspected. 20 "Total flooding" release mechanism tested. 21 Time delay devices checked for correct setting (if installed). 22 Alarms tested. 23 Fan stop tested. 24 Distribution lines and nozzles inspected. 25 Distribution lines and nozzles tested. 26 Distribution lines and nozzles blown through. 27 All doors, hinges and closing mechanisms checked. 28 All instruction plates checked. 29 Tank main service valve reopened and secured open. 30 System re-established in normal operation and ready for immediate use. 31 Inspection date tags attached. Not carried Not applicable Comments 7