Section 6 Manufacture, Workmanship and Testing

601. General

1. The manufacture, testing, inspection and documentation are to be in accordance with the specific re- quirements and recognized standards given in the Guidance.

2. For FC fuel related equipment, the manufacture, testing and inspection not specified in this section are to be in accordance with relevant requirements in Pt.7, Ch.5 of the Rules for Steel Ships.

3. The fuel cell systems are to be subjected to type approval, and the type tests are to be in accord- ance with the IEC standard 62282-3-1 "Stationary fuel cell power systems-Safety", but will also have to take the environmental and operating conditions in a ship into account.

4. Each fuel cell system subjected to the type approval is to be performed following tests before in- stallation onboard. (Refer to IEC 62282-3-1, para.6)

(1) Gas leakage tests

(2) Coolant (liquid) leakage tests

(3) Normal operation test

(4) Dielectric tests simulating abnormal conditions

(5) Burner operating characteristics tests

(6) CO emission tests

5. For equipment storing, carrying or utilizing hydrogen, relevant specific recognised standards are to be performed in addition to the tests specified in

tests according to the Section.

602. Gas tanks

Tests related to welding and tank testing are to be in accordance with Pt.7, of the Rules for Steel Ships.

Ch. 5, 410. and 411.

603.

1.

FC fuel piping systems

The requirements for testing are to apply to FC fuel piping inside and outside the gas tanks. However, relaxation from these requirements may be accepted for piping inside gas tanks and open- ended piping.

2. Welding procedure tests are to be required for fuel piping and are to be similar to those required for gas tanks in the Pt.7, Ch.5, 603. 3 of the Rules for Steel Ships. Unless otherwise especially agreed with the Society, the test requirements are to be in accordance with para. 3 below.

3. Test requirements

(1) Tensile tests : Generally, tensile strength is not to be less than the specified minimum tensile strength for the appropriate parent materials. The Society may also require that the transverse weld tensile strength is not to be less than the specified tensile strength for the weld metal, where the weld metal has a lower tensile strength than that of the parent metal. In every case, the position of fracture is to be reported for information.

(2) Bend tests : No fracture is

to be acceptable after a 180° bend over a former of a diameter

(3)

4. In

four times the thickness of the test piece, unless otherwise specially required or agreed with the Society.

Charpy V-notch impact tests : Charpy tests are to be conducted at the temperature prescribed

for the base material being joined. The results of the weld impact tests, minimum average en- ergy (E), is to be no less than 27 J. The weld metal requirements for sub-size specimens and singe energy values are to be in accordance with Pt.7 Ch.5, 601. 4 of the Rules for Steel Ships. The results of fusion line and heat affected zone impact tests are to show a minimum average energy (E) in accordance with the transverse or longitudinal requirements of the base material, whichever applicable, and for sub-size specimens, the minimum average energy (E) is to be in accordance with Pt.7 Ch.5, 601. 4 of the Rules for Steel Ships. If the material thick- ness does not permit machining either full-sized or standard sub-size specimens, the testing pro- cedure and acceptance standards are to in accordance with recognized standards. Impact testing is not required for piping with thickness less than 6 mm.

addition to normal controls before and during the welding and to the visual inspection of the

finished welds, the following tests are to be required :

(1) For butt welded joints for piping systems with design temperatures lower than -10 °C and with

(2)

inside diameters of more than 75 mm or wall thicknesses graphic testing is to be required.

When such butt welded joints of piping sections are made

the pipe fabrication shop, upon special approval, the extent

greater than 10 mm, 100% radio-

by automatic welding processes in of radiographic inspection may be

(3)

(4)

(5)

progressively reduced but in no case to less than 10% of the joints. If defects are revealed, the

extent of examination is to be increased to 100% and shall include inspection of previously ac- cepted welds. This special approval is only to be granted if well-documented quality assurance procedures and records are available to enable the Society to assess the ability of the manu- facturer to produce satisfactory welds consistently.

For other butt welded joints of pipes, spot radiographic tests or other non-destructive tests are to be carried out at the discretion of the Society depending upon service, position and materials.

In general, at least 10% of butt welded joints of pipes is to be radio- graphed.

Butt welded joints of high-pressure gas pipes, hydrogen supply pipes and gas supply pipes in ESD- protected FC spaces are to be subjected to 100% radio-graphic testing.

The radiographs are to be assessed according to a recognized standard(Refer to ISO 5817:2003,

Arc-welded joints in steel-Guidance on quality levels for imperfections, and are to at least meet the requirements for quality level B).

5. After assembly, all fuel piping are to be subjected to a hydrostatic test to at least 1.5 times the design pressure. However, when piping systems or parts of systems are completely manufactured and equipped with all fittings, the hydrostatic test may be conducted prior to installation aboard ship. Joints welded on board are to be hydrostatically tested to at least 1.5 times the design pressure. Where water cannot be tolerated and the piping cannot be dried prior to putting the sys- tem into service, proposals for alternative testing fluids or testing methods are to be submitted for approval.

6. After assembly on board, each fuel piping system is to be subjected to a leak test using air, hal- ides or other suitable medium.

7. All fuel piping systems including valves, fittings and associated equipment for handling fuel are to be tested under normal operating condition before set into normal operation.

604. Ducting

If the FC fuel piping duct contains high-pressure pipes, the ducting is to be pressure tested to at least 1.0 MPa after manufacturing.

605. Valves

1. Type tests

Each size and type of valve intended to be used at a working temperature below -55°C is to be type approved in accordance with the Ch 3, Sec 15, Table 3.15.1 of the Guidance for Approval of Manufacturing Process and Type Approval, Etc. For valves intended to be used at a working temperature above -55°C, type approval is not required.

2. Production tests

All valves are to be tested at the plant of manufacturer in the presence of the Surveyor including the following.

(1) Hydrostatic test of the valve body at a pressure equal to 1.5 times the design pressure for all valves.

(2) Seat and stem leakage test at a pressure equal to 1.1 times the design pressure for valves other than safety valves. In addition, cryogenic testing at design temperature consisting of valve oper- ation and leakage verification for a minimum of 10% of each type and size of valve for valves other than safety valves intended to be used at a working temperature below -55°C.

(3) The set pressure of safety valves is to be tested at ambient temperature.

3. As

an alternative to the above 2, the manufacturer may request the Society to certify a valve sub-

ject to the following:

(1) The valve has been type approved as required by 1 for valves intended to be used at a work- ing temperature below -55°C, and

(2)

The manufacturer has a recognized quality system that has been assessed and certified by the Society subject to periodic audits, and

(3) The quality control plan contains a provision to subject the following, and

(A) Each valve to a hydrostatic test of the valve body at a pressure equal to 1.5 times the de sign pressure for all valves.

(B) Seat and stem leakage test at a pressure equal to 1.1 times the design pressure for valves other than safety valves.

(C) The set pressure of safety valves is to be tested at ambient temperature.

(4)

Cryogenic testing at design temperature consisting of valve operation and leakage verification at the design temperature for a minimum of 10 % of each type and size of valve for valves other than safety valves intended to be used at a working temperature below -55 °C in the presence of the Society’ representative.

4. When leakage test of Para. 1, 2, 3, valves for use in hydrogen pipes located in ESD protected FC spaces, are to be tightness tested with hydrogen to show that there is no leakage of hydrogen from the valve.

606. Expansion bellows

1. Each type of expansion bellows intended for use in FC fuel piping, the gas tank are to be type approved in accordance with Ch 3,

primarily on those used outside

Sec 15, Table 3.15.1 of the

Guidance for Approval of Manufacturing Process and Type Approval, Etc.

607. FC fuel pumps

1. Type tests

Each size and type of pumps are to be type approved in accordance with Ch 3, Sec 15, Table

3.15.1 of the Guidance for Approval of Manufacturing Process and Type Approval, Etc.

2. Production tests

All pumps which have been type approved are subject to the tests of following plant of manufacturer in the presence of the Surveyor.

(1) hydrostatic test of the pump body equal to 1.5 times the design pressure

(2) the following capacity tests;

(A) For submerged pumps, the capacity test is to be carried out with the with a medium below the design temperature.

(B) For deep well pumps, the capacity test may be carried out with water.

3. The manufacturer may request the Society to waive the test of above par. 2.

lowing:

(1) The pump has been type approved as required by par. 1 and

(1) and (2) at the

design medium or subject to the fol-

(2) The manufacturer has a recognised quality system that has been assessed and certified by the Society subject to periodic audits, and

(3) The quality control plan contains a provision to subject each pump to a hydrostatic test of the

pump body equal to 1.5 times the design pressure and a capacity test. The manufacturer is to maintain records of such tests.

608. Onboard tests of FC system

1. Before the tests commence, a detailed test programme is to be submitted and approved.

2. The FC entire system is to be subjected to the following tests after installation on board: However, the items to be tested during sea trial may be included in sea trial program.

(1) Functional trials of components :

Safety shut-off valves, automatic shut-off valves, level indicators, temperature measurement devices, pressure gauges, gas detection systems and alarm devices shall be subjected to a functional trial.

(2) Trials of the protective devices and system :

During the trial, it is to be verified that, in the event of the following faults, the FC system is automatically transferred into a safe condition:

(A) Alarm of the fire detection devices

(B) Alarm of the gas detection system

(C) Failure of the power supply

(D) Failure of the programmable logic controllers(PLCs)

(E) Faults in the protective devices or system

It is to be verified that the requirements of the risk analysis performed as per 101. 1, are met.

(3) Functional trials of the FC system

The following operating conditions of the FC system is to be tested (as far as applicable):

(A) Automatic start-up of the FC system

(B) Operational switch-off of the FC system

(C) Load change, load steps

(D) Load shedding

(E) Switch-off during system malfunctions that do not endanger the safety of persons and equipment

(4) Functional trials of the ship

Within the scope of the functional trials, the interaction of the FC system with the ship systems is to be tested as follows (as far as applicable):

(A) Power generation by the FC system alone

(B) FC system together with conventional shipboard generation of electrical power

(C) FC system together with batteries

(D) Change-over to the emergency source of electrical power

(E) Switching the FC system online or offline

If the FC system constitutes the main propulsion system of the ship, it is to be verified that the ship has adequate propulsion power in all maneuvering situations.