DIRECTORATE OF NAVAL ARCHITECTURE

INTEGRATED HEADQUARTERS MINISTRY OF DEFENCE (NAVY), NEW DELHI - 110011

NCD/1447

ISSUE-1

JUL 2009

SPECIFICATIONS FOR WT DOORS FOR IN SHIPS

ISSUING AUTHORITY

INTEGRATED HEADQUARTERS MINISTRY OF DEFENCE (NAVY) DIRECTORATE OF NAVAL ARCHITECTURE D-WING, SENA BHAWAN NEW DELHI 110 011

INTEGRATED HEADQUARTERS MINISTRY OF DEFENCE (NAVY) NEW DELHI 110 011 DIRECTORATE OF NAVAL ARCHITECTURE

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RECORD OF AMENDMENTS

SL

AMENDMENT

AUTHORITY

DATE

SIGNATURE

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

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CONTENTS Page No 1. 2. PREAMBLE TECHNICAL REQUIREMENT Para No, 1 2. 3. 4. 5. 6. 7 8 9. 10. 11. 12. 13. 14. 15 16. 17 18 19 20. Topic Scope of Supply Material Type Deliverable Dimensions Pressure Dog Clips/wedge/bolts and door handle/lever Other design parameters Air Test Plugs EMI/EMC Consideration Welded Joints Surface finish Ra for machined surfaces Painting Marking Quality Assurance Guidelines for Test and Trials Guideline Drawings Check Methods Maintenance Documentation 8 8 8 8 9 9 10 10 11 11 11 11 11 11 12 12 14 14 16 16 7 8

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CONDITIONS OF RELEASE

1. This NCD specification has been prepared for the use of the Indian Navy and of its contractors in the execution of contracts for the Indian Navy. 2. This document is Indian Navy copyright and the information therein may be subjected to Indian Navy rights. It is not to be released, reproduced or published without written permission of the Integrated Headquarters Ministry of Defence (Navy). 3. Indian Navy reserves the right to amend or modify the contents of this specification without consulting or informing any holder of the specification. 4. This specification may call for the use of processes, substances and procedures that may be injurious to health if adequate precautions are not taken. It refers only to technical suitability and in no way absolves either the supplier or the user from statutory obligations relating to health and safety at any stage of manufacture or use. 5. Where attention is drawn to hazards, those quoted may not necessarily be exhaustive. 6. This specification is the property of the Indian Navy and, unless otherwise authorized in writing by the Integrated Headquarters Ministry of Defence (Navy), must be returned on completion of the contract or submission of the tender, in connection with which it is issued. 7. Enquiries in connection to this NCD specification maybe made from Directorate of Naval Architecture, Integrated Headquarters Ministry of Defence (Navy), Sena Bhawan, New Delhi, Tel: 011-23011580/ 23013029, 23010047 Fax: 011-23010126. 8. Unless otherwise specified, reference in this specification to any document pertains to its latest issue, inclusive of all amendments.

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APPENDICES APPENDIX A APPENDIX B : GENERAL GUIDELINES FOR THE DOOR SELECTION : DOOR FRAME FOR INSTALLATION AND SECURING TO THE BULKHEAD APPENDIX C : DRAWINGS 18 19 17

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PREAMBLE 1. This NCD specification is sponsored by the Indian Navy, Integrated Headquarters of the Ministry of Defence (Navy), Principal Director, Naval Architecture, Sena Bhawan, New Delhi 110 011. 2. It is to be applied as required in the contracts / work assignments concerning manufacture of WT/GT doors for IN ships. 3. This NCD specification gives a description of the objectives, scope and the procedures for manufacture of WT doors . 4. If it is found to be technically unsuitable for any particular requirement the Sponsor is to be informed the reasons in writing of the circumstances with a copy to the Principal Director, Naval Architecture, Integrated Headquarters of the Ministry of Defence (Navy), Sena Bhawan, New Delhi 110 011. 5. Any user of this specification may propose an amendment to the relevant portions of the NCD. Proposals for amendments are to be dealt as under :(a) Not directly applicable to a particular contract /work assignment are to be made to the Sponsor of the NCD. (b) Directly applicable to a particular contract / work assignment are to be dealt with using existing procedures or as specified in the contract / work assignment. 6. No alteration is to be made to this NCD specification except by the issue of a formal amendment by the Principle Director, Naval Architecture. 7. Unless otherwise stated, all approvals and authorisations pertaining to the references covered in this NCD specification will be exclusively given by the Integrated Headquarters of Navy

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TECHNICAL REQUIREMENTS

Scope of Supply

Following details are to be included in the scope of supply by ordering authority (a) (b) Quantity Type (i) Left Handed/ Right Handed (ii) With porthole/ without porthole (iii) With/Without indicator test plug (iv) Type of locking arrangement (c) Requirement of installation, test and trial etc (d) Requirement of Painting. (a) MS conforming to IS 2062 or Marine grade steel explicitly specified by the ordering authority. (b) Door Clips - Stainless Steel (AISI 316) for doors exposed to weather and nickel chrome plated for other doors (c) Wedges - Brass (d) Rubber sealing gasket EPDM/Neoprene, in accordance to the specifications of NCD 5904. (a) Die formed (for door cover) watertight/gastight. (b) Single Embossing

2.

Material

3.

Type

(c) Quick acting with Lever bolting- total two lever, each connecting to 3 dogs. (d) Angle fabricated frame or Bar fabricated frame.

(e) With provision of portholes (Only on doors with 3 mm thickness) and spring loading (on sloping bulkhead.) (f) (a) With left and right version for the opening. Complete door set should be supplied.

4.

Deliverable

(b) Supplied set should include assembled door (including frame) and associated OBS. (c) OBS for each set should include the following:-

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5. Dimensions (Tolerance : + 3mm)

(i) Spring for latch handle (ii) Hinge Washer (iii) Bolt/dog clip Washer (iv) Packing ring for bolt/dog clip pin (v) Packing ring for latch pin (vi) Two shims (vii) One rubber seal for each five and less doors of the same dimension. (viii) One glass for each 10 and less doors with portholes. (ix) Any Other OEM recommended spare (d) Documentation Clear Door Thickness Dimensions Weight(kg) Openings Dimensions of the door of door (Deviation (in mm) along with (in mm) cutouts from weight with frame (in made in ship not to be 150mm mm) hull (in mm) greater than corner with 200 mm 5%) radius corner radius

1600X750 1600X750 1600X750 1400X600 1400X600 1800X750

1756X923 1756X925 1756X927 1556X773 1556X775 1956X923

3 5 7 3 5 3

1690X840 1690X840 1690X840 1490X690 1490X690 1890X840

120 145 165 100 115 130

The doors are to be provided with 06 bolts. The thickness of the door for different areas has to be selected by the designer, however the general guidelines are placed at Appendix A The door frame section for installation to the bulkhead is shown at Appendix B Pressure (a) For 3 mm (excluding 1800X750) 19.6 K Pa (b) For 3 mm ( 1800X750) 9.8 KPa (b) For 5 mm 39.2 K Pa (c) For 7 mm 78.5 K Pa Note:The pressure corresponds to the pressure halfway to the door height

6.

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7 Dog Clips/wedge/bolts and door handle/lever

Pressure separating the door from the frame is the required pressure. (a) The doors are to be locked by two levers. Locking force is not to be more than 0.392 KN, whereas the force applied to handle when opening the door should not be more than 0.157KN. (b) Clips must engage downwards to prevent them shaken free by vibration or shock (c) Arrangements are to be provided to hold doors in the open position, either by gravity type clips or by hooks fitted on adjacent structure engaging in eyes on the door. (d) Door lever dimensions should be such that it is easy to grip by hand when opening or closing (e) The time required for dogging down the door should not exceed 10 sec. (f) In addition to the locking lever, doors are to be provided with a spring loaded latch lever so that when the doors are closed with a slight push, they remain in closed condition and air-conditioning discipline is maintained. (g) Dog set and latch set should be fitted with lubrication fitting or should have lubricating holes

8 Other design parameters

(a) Sealing gasket should be secured to door with rubber holder as indicated in Appendix C. (b) Non Flatness of door frame coaming along the perimeter for doors should not exceed 1 mm. (c) When doors are closed the sealing gasket should be uniformly pressing against the frame. (d) Door surface should not have mechanical damages and deformation affecting its strength and aesthetics.
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(e) Door leaf and frames, wedge, bolts and other parts should not have sharp edges. Welds should be dressed (f) The doors located on the inclined bulkheads shall be provided with a hydraulic/ spring loaded mechanism to facilitate easy opening and closing even with the ship listed to 15 degree either way (g) The surface of the door and hatch should not have any groove at the bottom in which dirt might lodge and prevent the door closing properly (h) The doors must be resistant to seawater in Indian tropical conditions (j) In case of doors with portholes, the porthole shall be manufactured from a suitable transparent glass material and fixed on to the door panel such that the watertight performance and strength of the door is not affected (k) Locking arrangement to be as per project requirement 9. Air Test Plugs (a) To be provided on doors fitted in Red Risk Zone. (a) All doors and opening to weather are to be provided with Type I bonding where both the ends of the grounding wire connected using crimping sockets to be welded at both ends. (a) Should exhibit good workmanship. It should be free from defects. (a) Not to exceed 25 (a) (a) it:As indicated in scope of supply. Each door should have the following marked on (i) (ii) (iii) OEM name or trade marked on it. Door identification symbol. Date of fabrication (month, year)

10. EMI/EMC Consideration

11.

Welded Joints

12. Surface finish (Ra) for machined surfaces 13. Painting 14. Marking

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(b) Marking should be punched. Marking symbols should be prominent and legible. 15 Quality Assurance (a) The detail design, material & workmanship shall be in accordance with the good Engg practices, to ensure reliability, durability & ease of maintenance which comply with ships requirements. The design should ensure no compromise in reliability, safety or significant design criteria. (b) Based on the above specifications and technical requirements, detailed manufacturing drawings are to be prepared and forwarded to inspection agency for approval prior to manufacture. (c) All works covered by these specifications shall be subjected to Quality Surveillance by Navy nominated inspection agency. The manufacturer shall submit a quality Assurance plan detailing out intended inspection, testing and other quality assurance arrangements, along with the drawings including that of subcontracted work. The QAP should clearly bring out the sequence of manufacturing process. The approval of the QAP is to be obtained from inspection agency and shall be adhered to. (d) All standard bought out items are to be offered for inspection along with manufacturers certificates. (e) Material specifications, to which the components should be made, along with the inspection requirement , wherever appropriate, shall be indicated on the drawings

16. Guidelines for Test and Trials

(a) Items will be inspected by Navy nominated agency. (b) Schedule of inspection & test are to be obtained from the inspector prior to commencement of production.

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(c) Facility for inspection, test & shop trial is to be provided. (d) Following certificates also duly signed by the inspector are to be issued. (i) (ii) Weight of equipment with C.G. Shop trial report.

(e) The manufacture of all items are to be strictly as per specifications and requirements stated in the Technical Requirements in respect of dimensions, materials, tolerances, finish, etc. (f) No deviations will be allowed once the order has been placed. In unavoidable circumstances, for deviation, however minor, prior approval of inspection agency is to be obtained. (g) Minor modifications suggested by ordering authority/ inspection authority will have to be incorporated. (h) Doors are to be submitted for approval tests in batches. Each batch should consist of the doors of the same dimensions. The number of doors in one batch should not exceed 100. (j) The entire batch is to be tested for compliance with Para 2, 5 (except for permissible weight), 7 (except 7 (a) and 7(e)), 8, 9, 10, 12,13. (k) One door from each batch should be tested for compliance with Para 5 (with respect to weight), 6 (for permissible pressure by subjecting to hydrostatic pressure as indicated at para 18(k)), and para 7(e). (l) 10% of doors from the batch should be tested for compliance with Para 7(a) by random sampling (m) Requirement of para 5 (for main parameters and dimensions) should be ensured by design and material selection.

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(n) Test results are considered to be positive if the doors meet the requirements of this standard. (o) Doors which do not meet the requirements of this standard should be returned for defect rectification. The test is to be repeated thereafter. Additionally a fresh door is to be selected randomly for similar trials (p) Re-testing results are considered to be final and to cover the entire batch. Doors which do not meet the requirements of this standard should be rejected. (a) The guideline drawings for the manufacture of doors have been placed at Appendix C. It may be noted that the drawings are for general reference, and in case if any deviation in the drawing with respect to the specifications mentioned earlier in this standard is observed, the requirement mentioned in the earlier paragraph of this standards should be considered.

17

Guideline Drawings

18

Check Methods

(a) Door design and dimensions (Para 3, 5) are monitored by comparing to design documentation and checking the dimensions using measuring devices of the specified accuracy. (b) Grade of materials (Para 2) are checked from the OEMs certificate or based on lab findings. Compliance to para 4 will be checked as per approved drawings (c) Weight (Para 5) is to be checked by weighing scale having the least count of not more than 2.0kg. Weight certificate, has to be provided by the firm. (d) Surface finish (Para 12) is checked visually and by comparing to standard samples. (e) Non-flatness (Para 8(b)) is to be checked using filler gauge by laying the door frame on a reference flat bed.

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(f) The quality of paint coating and preservation is checked by visual inspection. The coating should be uniform and continuous. (g) The force of door opening (closing) para (7(a)) is to be checked with dynamometer , attached to bolt handle at the distance of 40mm from handle end. The check should be done with door in vertical position. (h) Bolting time (Para 7(e)) is to be checked using a stop watch. (j) Even fit of the packing gasket to the frame (Para 8(c)) is checked by taking the chalk imprint when the door is being slowly closed to the fully engaged position. In this case the chalk imprint should be continuous and minimum 2 mm wide. Do the check with the door in vertical position. (k) Door water tightness is tested by filling up with pressurized water. For testing the door is installed on the test stand and secured in working position (vertical). Hydrostatic pressure, equal to internal pressure (Para 6) is created in test chamber gradually using mechanical or hand pump. Test duration is 5 min. During the test, the nonwetting surfaces at the place of seating, axle of clips and latches should not leak in the form of jet, stream or drops. Door is considered to be watertight if there will be no residual deformation and damage to door structure after the test is completed and the pressure is dropped. (l) Water tightness at sea is testing by hosing down the door from distance of not more than 3m using high pressure fire hose with outlet diameter not less than 16mm, creating the height of water jet not less than 10m. Water jet direction should be perpendicular to the door specifically covering the hinged areas

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19

Maintenance

(a) Requirement for routine maintenance are to be kept to a minimum. (b) Lubrication points are to be easily accessible.

(c) The likely maintenance routine interval of the doors may be approximated for guidance as follows. (i) Greasing / oiling once in six months. (ii) Rubber seating replacement once in three to four years. (iii) Replacement of bushes washers, latch spring etc. once in six years. Keeping above requirements in view the supplier must workout a maintenance schedule and include it in the standard documentation. DESCRIPTION CONTENT COPIES (a)Technical Technical Manual and 10 Manuals Detailed Drawings Onboard Maintenance 10 Manual Field and Depot 10 Maintenance Manual Installation and Testing 10 Manual Including Welding sequence for installation Details of All Parts of 10 and Tools Catalogue Material specification 10 Technical Data of all the parts Installation drawings 10 As Fitted Drawings 10 Conformation of 10 Standards specified along with a copy of the standards Test Procedure and 10 Documentation Certified Test Report 10

20.

Documentation

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APPENDIX A (Refer to Para 5) GENERAL GUIDELINES FOR THE DOOR SELECTION 1. Doors leading to outside of the ship, ( 1 dk, 01 dk, 02 dk..) and installed on the longitudinal bulkhead 5mm 2. Doors leading to outside of the ship and installed on the transverse bulkhead (athwart-ship direction) and opening to fore of the ship 7 mm 3. Doors leading to outside of the ship and installed on the transverse bulkhead (athwart-ship direction) and opening to aft of the ship 5 mm 4. Doors to Magazine- 7mm. 5. Doors leading to Isolated Compartment on the weather deck, (like potato store etc), not connected with the main living spaces 5 mm for longitudinal bulkheads and transverse bulkheads( opening to fore of the ship), and 3 mm for doors opening to the aft of the ship. 6. Doors on continuous (shipside to shipside) transverse bulkhead and which are not the main transverse bulkhead 7mm. (No doors on the main transverse bulkhead) 7. Doors on transverse bulkhead of underwater machinery compartment (e.g fire pump compartment etc) 7mm 8. Doors on underwater machinery compartment, with one boundary as shipside or common with a tank -5mm 9. Underwater non machinery compartments upto deck 3 (3mm doors), and at deck 4 and below 5mm doors. Those non machinery compartments which dont have any boundary as shipside or any boundary common with a tank, 3 mm door may be used

Note The above values are for general reference, and in case if any compartment is expected to encounter pressure values, more than the door can sustain, the designer should accordingly select the door.

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APPENDIX B (Refer to Para 5) DOOR FRAME FOR INSTALLATION AND SECURING TO THE BULKHEADS

Note: l, and b are the dimensions of the cutout made in the hull (Refer para 5)

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APPENDIX C (Refer to Para 17)

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