ENG CIRCULAR 17
Dated: Oct 8, 2003
Sub: Guidelines for the procedures of approval for the FFA Manufacturers, Service stations,
Maintenance and inspection of fire protection systems and appliances, etc.
(Supersedes circular No.
ENG/MMAM-37 (6)/99 dated 01.08.01)
During the period it is observed that some of the companies are not following the condition stipulated in the said guideline, neither any surprise inspection were conducted by the respective MMD's to ascertain the quality standard. In view of the importance of stringent quality standard with the manufacturing and testing of Fire protection system and appliances for use on board ship, it is imperative for the Directorate to ensure that all safety equipment on board ship have undergone various tests in the presence of MMD surveyors. In view of the above it has been decided by the Directorate that the units who have qualified themselves through ISO 9001:2000 accreditation and are engaged in manufacturing and /or servicing the fire appliances need to follow the following guidelines:
1. Manufacturing Unit
b) Any organization who are engaged in manufacturing BIS approved fire safety product and intend to obtain approval for the FFA appliances are required to have acquired ISO 9001-2000 accreditation, have to send their application with their product manufacturing drawing and relevant documents to support their manufacturing process to Mercantile Marine Department.
c) The drawings shall be scrutinized by the surveyors at Mercantile Marine Department, and forwarded to DGS for approval along with the feasibility report of manufacturing unit. The surveyor shall include the detail process of manufacturing in their report. After the drawings are approved, the various tests for prototype approval shall be carried out, and if found satisfactory, the company shall be informed accordingly, and instructed to offer first batch for inspection. If found satisfactory, report shall be forwarded to DGS, with recommendation. The approval shall be given for a period of three years, subject to withdrawal in case any complaints from the shipping companies or irregularity found during surprise inspection.
d) Any approved unit undergoing any change in their manufacturing procedure or intending to market a new product should apply to MMD directly with the drawings etc. for approval.
e) In addition to the above D .G. Shipping or the Principal Officers of the respective MMDs shall depute surveyors to visit the DGS approved units at any time for surprise inspection, as well as on receipt of any specific complaint.
f) The unit has to maintain their ISO 900-2000 accreditation all the time and if at any circumstances the ISO Certification ceases to exist, they must stop servicing/marketing their product to the Maritime industry forthwith under intimation to DGS.
2. Service Stations
(ii) Must have ISO accreditation within six months after the company starts its operation.
(iii) Company must have updated DGS, FFA Rule books as well as latest ISO specification for all the portable and non- portable extinguishers and DGS guidelines for CO2 system maintenance.
(iv) In order to weigh the CO2 bottles on board itself, apart from having electronic balance, manual measuring scales also required. Each year the balance to be calibrated by an approved organization.
(v) Portable hydraulic testing machine for on board tests and fixed hydraulic testing machines at the workshop required for testing.
(vi) Provision for keeping the necessary spares for all safety items.
(vii) Good in -house facility for workshops to undertake overhauls of fire line, safety valves, CO2 relief system relief valves, hydrant valves, etc.
(viii) Units to be headed by qualified MEO Class 1 (Motor) with at least 2 years experience as Chief Engineer on board.
b) After the inspection of the
company by MMD, report is to be forwarded to DGS for approval. The
checklist for approval is attached
(Annex II). After
the approval is granted, the service station is free to service and issue
service certificate with a stamp of D.G.S. approval number. Copies of
every certificate issued, are to be forwarded six monthly basis to MMD.
Initial approval may be for the period of two years. For renewal, the
company shall apply to MMD, same shall be inspected by the surveyors and
report forwarded to DGS with recommendation. Approval for a period of
three years may be granted.
The following items are not under the purview of the guidelines as detailed in "2". Separate instructions are provided for the following:
(i) Total fire protection system i.e. (CO2,
foam, water sprinkler system, etc.).
(b). 10 yearly routines:
(c ) 15 yearly routines:
2) The medium pressure section (open ended pipes where they run through accommodation spaces, together with the section of the main supply line running to the engine room, boiler room or pump room between the stopcock and the room concerned):
At a pressure of at least 80 kgf/cm2 using a
Pipes running from the pilot
cylinders to the servo-cylinders and the sections of pipes to deep tanks,
which can be shut off, must be considered as part of the high-pressure
system. Pipe sections and valves tested hydraulically with water must be
blown dry with air.
(iii) The alarm system to be tested with the engine operating to full capacity;
(iv) The setting of the spring loaded safety valves at 180 kgf/cm2 .
(v) The proper operation and correct connections to the cargo holds to be checked
(vi) The free flow of carbon dioxide out of the nozzles into the engine room, boiler room or pump room to be checked by opening one or more cylinders of the battery or by using air at a minimum pressure of 25 kgf/cm2;
(vii) The entire installation to be checked to make sure that it operational.
The high-pressure section that can be shut off, the stopcocks and the controls to be checked for tightness under operational conditions by opening one cylinder of the battery. This check may be omitted if the equipment is intended solely for the engine room and consists of not more than 15 cylinders.
(d) Periodical Tests
At intervals of 24 months the whole installation must be inspected externally to the extent that this is possible and blown through with air.
Before servicing shipping companies /service stations will apply to the respective MMD regarding carrying out the periodical pressure testing of the CO2 system. The surveyors are required to witness the hydraulic pressure testing. The servicing of CO2 systems shall be carried out by the DGS approved service stations/ Approved by Maritime Administration only.
4. Periodical Inspection of
Carbon Dioxide Cylinders
Before servicing Shipping
Companies /service stations will inform/apply to the respective MMD
regarding carrying out hydraulic testing of cylinders. The servicing of
CO2 bottles shall be carried out by the DGS approved service stations
only. The Chief Engineer of the approved service station shall witness the
hydraulic pressure testing and endorse the certificate, and submit a copy
to MMD. The surveyors are required to witness the hydraulic pressure
testing in case the service station is not approved by DGS.
The approved servicing station shall undertake the weighment of the CO2 cylinders only. The company/service stations are required to submit an application to MMD, and the same is to be witnessed by the surveyor of the department and certificate of weighment endorsed. In case of non-availability of surveyor, Principal Officer may allow the servicing station to carry out the weighment of the cylinders. In such cases the endorsement shall not be done by the MMD, however during the safety equipment survey, the Company shall have the certificate of weighment endorsed by the attending surveyor. Prior to endorsement of the weighment certificate, surveyor may carry out weighment of CO2 bottles on sample basis to his satisfaction. To avoid duplication of the work, company may plan the weighment during the annual/renewal of safety equipment survey.
All service stations that are registered with Directorate General of Shipping are required to follow the above procedure.
7. Guidelines for inspection
of the CO2 Retrofit on board any vessel
(b) Old CO2 bottles should not be fitted if the vessel is less than 10 years old. (From the date of delivery).
(c) Sectional drawing with original Test Certificate of the CO2 bottles to be produced for new CO2 bottles.
(d) For using old CO2 bottles
following conditions must be met:
(v) If original Test Certificates are available and bottles can be identified with the certificates, the requirement of cutting the sample bottle and testing as specified in (iv) above is not required.
(vii) Inspection and testing of Line Valves, Relief Valves, Diffuser Nozzles, Pipeline, Unions and Deck penetration to be carried out and results submitted to the D.G.S.
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