Section 3 Documentation required for design review

3.1.1 The documentation described in Vol 2, Pt 1, Ch 3, 3.2 Documentation is to be submitted for design review before manufacturing has started.

3.2.1 Plans are to indicate clearly the scantlings and materials of construction. Any design alteration to the plan is to be resubmitted for approval, indicating clearly the alteration.

3.2.2 The following arrangement plans and documentation are required,

1. Plans showing the arrangement of machinery spaces indicating the location of machinery and equipment together with means of access and ventilation;

2. Plans showing the maintenance envelope and removal routes of machinery and equipment where routine removal for maintenance is proposed;

3. System Operational Concept documents, where required by Vol 2, Pt 1, Ch 3, 3.4 System operational concept;

4. System Design Descriptions, see Vol 2, Pt 1, Ch 3, 3.5 System design description; and

5. Documentation as required by the individual Chapters for specific machinery and electrotechnical systems or components. This is to include their System Design Descriptions, see Vol 2, Pt 1, Ch 3, 3.5 System design description.

Where elements or sub-systems are to be integrated into a higher level system, an interface definition document shall be submitted detailing all the interfaces between them, electrical, mechanical, software or environmental. The level of detail provided shall enable the system integrator to assess their compatibility for correct operation as part of the higher level system.

3.2.3 Where machinery system components have been approved under LR’s Type Approval System or Quality Assurance Scheme for Machinery for the proposed design conditions or service, plans of the component are not required to be submitted. Full details of the components and the existing LR approval are to be submitted.

3.2.4 Where operating requirements relating to the design, construction, testing, installation, and integration of machinery and engineering systems have been defined within the scope of Vol 2, Pt 1, Ch 3, 4 Operating conditions, evidence of capability and details of previous or proposed testing to demonstrate capability are to be submitted.

3.2.5 Where an oil or liquefied petroleum gas fired galley is proposed, details of the oil and gas storage and distribution arrangements together with ventilation arrangements and safety shutdown and alarms are to be submitted.

3.3.1  Service Profile. The machinery power/speed operational envelope, grade(s) of fuel and any short-term high power operation.

3.3.2  Classification rating. The following operational parameters, using the design conditions for the intended Class Notation(s):

See Vol 2, Pt 1, Ch 3, 4.4 Ambient reference conditions 4.4.1 for ambient reference conditions.

3.3.3  Short-term high power operation. Where the propulsion machinery is being considered for short-term high power operation, full details of the power, speed and time intervals together with fatigue endurance calculations, and documentary evidence indicating the suitability of the component design under these conditions and for the intended class notation are required. The following are to be considered; prime mover, gearbox, flexible coupling, vibration dampers, shafting and propeller:

1. The accrued number of load cycles and the percentage component overload are to be those recommended by the designers.

2. Excessive overload may require the interval between surveys to be reduced.

3. Plans showing the arrangement of resiliently mounted machinery which are to indicate the number, position, type and design of the mounts.

4. Machinery is to be maintained in accordance with manufacturer's requirements.

5. For electric propulsion:

   1. The prime mover rated power in conjunction with its overloading and load build-up capabilities shall be adequate to supply the power needed during transitional changes in operating conditions of the electrical equipment due to manoeuvring and sea and weather conditions.

   2. Reverse power:
      When manoeuvring, for example from full propeller speed ahead to maximum design propeller speed astern with the ship making full way ahead, the prime-mover shall be capable of absorbing a proportion of the regenerated power without tripping due to overspeed or reverse power.

Means external to the mechanical and electrical rotating machinery may be provided in the form of, for example, braking resistors to absorb excess amounts of regenerated energy and to reduce the speed of the propulsion motor. The amount of regenerated power shall be limited by the control system. Generators operating with semiconductor converters shall be designed for the expected harmonics of the system. A sufficient reserve shall be considered for the temperature rise, compared with sinusoidal load.

3.3.4  Damper and Flexible Coupling characteristics. Documentary evidence that the characteristics have been verified.

3.3.5  Machinery Fastening.

1. For NS3 type ships or where specified for other ship types, documentary evidence and calculations indicating that machinery is securely mounted for the ship motions and accelerations to be expected during service.

2. For NS3 type ships or where specified for other ship types, calculations to demonstrate that mountings of large masses such as main engines, auxiliary engines and electrical equipment can withstand the design collision acceleration according to Vol 2, Pt 1, Ch 3, 5.4 Collision load 5.4.1 without fracturing.

3. Plans showing the arrangement of resiliently mounted machinery which are to indicate the number, position, type and design of mounts.

4. Natural frequency calculation of resilient mounted machinery.

5. Plans showing the arrangement of resin chocks for machinery requiring accurate alignment with the following information:

   1. Resin type.

   2. The effective area and minimum thickness of the chocks.

   3. The total deadweight loading of machinery.

   4. The thrust load, where applicable, that will be applied to the chocked item.

   5. The loading to be applied to the holding-down bolts.

   6. The material of the holding-down bolts.

   7. The number, thread size, and waisted shank diameter (where applicable) of the holding-down bolts.

See Vol 2, Pt 1, Ch 3, 5.3 Machinery fastenings for requirements.

3.3.6  Manuals. The operation and maintenance manuals. For class notations covering propulsion and steering machinery redundancy, see Vol 3 Additional Class Notations

3.3.7 A Risk Assessment (RA), in accordance with the guidance in Vol 2, Pt 1, Ch 3, 18 Risk Assessment (RA), is to be carried out, covering the following systems:

1. Main and auxiliary machinery systems supporting propulsion, steering, Mobility systems or Ship Type systems.

2. Steering systems.

3. Electrical generation and distribution systems supporting “Main and auxiliary machinery systems supporting propulsion, steering, Mobility systems or Ship Type systems” and “Steering systems”, see Vol 2, Pt 10, Ch 1, 6.2 Physical environment 6.2.4.

This requirement is in addition to the requirements for class notations covering propulsion and steering machinery redundancy, and Ship Type piping systems (see Vol 2, Pt 7, Ch 5 Ship Type Piping Systems).

3.3.8  Fatigue Strength Analysis. Where undertaken as an alternative to the requirements of the individual Chapters, fatigue strength analysis of components indicating a factor of safety of 1,5 at the design loads based on a suitable fatigue failure criteria. The effects of stress concentrations, material properties and operating environment are to be taken into account.

3.3.9  CBRN Protection arrangements. Where the CBRN Protection requirements are specified, a design statement together with plans and particulars are to be submitted for information. See Vol 2, Pt 1, Ch 3, 4.12 Guidance for CBRN protection, detection and monitoring for CBRN Protection guidance.

3.3.10  Machinery shock resistance arrangements. Where shock capability requirements for machinery, engineering systems and equipment have been specified, the requirements of Vol 2, Pt 1, Ch 3, 4.11 Machinery shock arrangements apply and the following details are to be submitted:

1. The shock policy for the ship. This shall include the shock environment to be used for shock calculations; this will remain confidential to LR.

2. A design statement that details the shock capability levels for installed machinery, engineering systems and equipment. This statement is to detail how the shock policy has been applied and is to include how the specified shock levels have been accommodated within the design.

3. List of shock captive equipment identifying name, system/function, location, intended shock qualification and mounting arrangements.

4. List of shock capable equipment identifying name, system/function, location, intended shock qualification and mounting arrangements.

5. System plans required by other Sections of the Rules are to identify the location of equipment.

6. Evidence of shock testing.

7. Shock mount approval documentation.

8. In cases where numerical modelling and analysis have been carried out, the following supporting information should be submitted as applicable:

   1. Reference to a recognised and validated calculation procedure and software used.

   2. Evidence of software verification and validation.

   3. A description of the modelling.

   4. A summary of analysis parameters including properties and boundary conditions.

   5. Details of the loading conditions and the means of applying loads.

   6. Details of acceptance criteria and their derivation.

   7. A comprehensive summary of calculation results. Sample calculations should be submitted where appropriate.

   In general, submission of large volumes of input and output data associated with such programs as finite element analysis will not be necessary unless requested by LR. The responsibility for error-free specification and input of program data and the subsequent correct transposition of output rests with the designer.

3.3.11  Underwater signature arrangements. Where the underwater signature requirements for the ship and propulsion system have been specified, a design statement together with plans and particulars are to be submitted for information. See Vol 2, Pt 1, Ch 3, 4.10 Guidance for underwater signature for underwater signature guidance.

3.3.13  Fin stabilisers. Where fin stabiliser systems are fitted, the following details are to be submitted:

1. A System Design Description that details the stabiliser performance in terms of a specified roll angle that is not to be exceeded by more than a stated percentage of rolls in a specified wave environment (see Vol 1, Pt 5, Ch 2, 2.3 Wave environment) at a specified ship speed and heading. The performance is to be specified and is to recognise the requirements for ship-based operations, such as flight operations and replenishment at sea (RAS) systems, in terms of sea-keeping and platform heel/trim conditions, and the requirements of Vol 2, Pt 1, Ch 3, 4 Operating conditions regarding operating conditions as applicable. Details of any secondary function of the fin stabiliser to induce ship roll, for example routinely to test the fin stabiliser system (against its own induced roll), to facilitate weapon systems testing and to support CBRN Protection pre-wetting systems, are also to be included in the System Design Description.

2. Plans of all load bearing, torque transmitting components and hydraulic pressure retaining parts of the fin stabiliser system together with proposed rated torque, all relief valve settings and scantlings.

3. Schematic plans of the hydraulic system(s), together with pipe material, relief valves and working pressures.

4. Details of safety and control and electrical engineering arrangements.

5. Material specifications for components identified in (b).

6. Details of proposed testing and sea trials.

7. Details of any limits of operation for stabilisation and induced forced roll, e.g. sea states, ship speed, roll amplitude and periodicity limitations.

3.3.14  Machinery spaces and enclosures. Evidence is to be submitted demonstrating the suitability of the fire-extinguishing arrangements for a machinery space or enclosure as required by Vol 2, Pt 1, Ch 3, 5.15 Fire detection, alarm and extinguishing arrangements 5.15.2. The submission is to identify all standards applied in support of the proposed arrangements. The location of equipment, the degree of protection provided by the equipment itself, and the damage control and fire-fighting requirements in the specified fire safety standard are to be taken into account in determination of the suitability of the fire extinguishing arrangements.

3.3.15  Schedule of testing and trials. Schedules of testing machinery at the manufacturers, pre-sea trial commissioning and sea trials are to be submitted to LR and agreed before commencement of testing and trials. The testing and trials schedules are to identify all modes of ship and machinery operation and the sea trials are to include typical port manoeuvres under all intended operating modes. Reference is also made to the following Rules:

• Vol 1, Pt 3, Ch 5, 8 Anchor windlass design and testing - Windlass & capstan trials
• Vol 2, Pt 1, Ch 3, 16 Steering systems - Steering systems
• Vol 2, Pt 1, Ch 3, 17 Sea trials - Sea trials
• Vol 2, Pt 9, Ch 12, 1 Testing and trials - Testing and trials
• Vol 2, Pt 9, Ch 1, 6 Integrated computer control - ICC notation - Control engineering trials

Testing and trials are to be witnessed by an LR Surveyor unless an alternative arrangement is agreed in writing prior to the trials by the Surveyor. Reports of testing and trials are to be submitted to an LR Surveyor after completion.

3.3.16  Machinery operation. For mobility and ship type category engineering systems, the equipment/machinery manufacturer's instructions for installation and operation of lubricating and hydraulic oil systems are to be made available to the LR surveyors attending trials/testing/commissioning. The instructions should include information that may affect the safety and reliability of the equipment covering requirements for operating environment, monitoring arrangements, cleanliness, filter arrangements, oil change intervals and precautions to be taken at start-up, in operation and during prolonged periods of shutdown.

3.3.17  Operation of machinery outside its recommended continuous operating design envelope. Where equipment and machinery installed in mobility and ship type engineering systems may be required to operate for continuous periods outside its recommended continuous operating design envelope, details of the intended operating conditions, time intervals and frequency of use together with documentary evidence indicating the suitability of the design and any limitations under these conditions are required to be submitted. Arrangements may include time alongside manoeuvring, close-down and other military operations or trials. The following items of machinery and equipment are to be considered:

1. Prime mover(s);

2. Gearbox(s);

3. Steering systems;

4. Bearings;

5. Couplings;

6. Vibration dampers;

7. Shafting and related power and propulsion transmission items;

8. Other items of machinery and equipment in mobility and ship type engineering systems as identified in the specified standards and agreed by the Owner. The manufacturer's requirements and recommendations for operation and maintenance are to be addressed with provision as necessary of documentation such as manuals and warnings with particular reference to lubrication and cooling systems and any predicted adverse effects e.g. fouling. As far as practicable, the specification, selection and arrangements of machinery and equipment are to be agreed between the Shipbuilder and the Owner for foreseeable operating conditions.

3.3.18  Training and drill regimes. Where training and testing regimes for machinery capability and availability, reversionary modes of operation and breakdown drills have been identified by the Owner, full details of the intended regimes are required to be submitted in order to ascertain that the reliability of the machinery and associated systems is not significantly affected. The following are to be considered as applicable and included in the operating and maintenance manuals:

1. Machinery repair breakdown drills;

2. Post up-keep trials/Routine assessment trials;

3. Simulating fault conditions;

4. Rapid ship manoeuvres;

5. Electrical equipment and system configuration drills;

6. Damage control and work-up exercises. As far as practicable, the specification, selection and arrangements of machinery and equipment are to be agreed between the Shipbuilder and Owner for foreseeable training and drill regimes.

3.4.1 The purpose of this sub-Section is to ensure that LR is provided with all the necessary information at the whole ship system-level to perform design appraisal activities at sub-system and equipment level required by these Rules.

3.4.2 A System Operational Concept document is to be submitted, detailing the design intent and operational modes for complex systems which contain multiple sub-systems and significant items of equipment (e.g. Prime movers, propulsion devices, etc.). Examples of systems requiring the submission of a System Operational Concept include, but are not limited to:

• Propulsion (or Power and Propulsion for integrated systems).
• Electrical Power Generation and Distribution.
• Platform Management System.
• Replenishment at Sea (RAS) notation.
• Fire Protection (FIRE) notation.

3.4.3 The System Operational Concept is to include the following information, as appropriate to the system:

• Reference to the relevant requirements derived from the Concept of Operations;
• Operating modes and philosophy, including reversionary and emergency modes recognising the operational and manning philosophy for the vessel;
• Describe the designer’s intent and the criticality of particular system features or equipment (with particular reference to those elements required to maintain Mobility and/or Ship Type systems and those installed for capability only);
• Justify non-compliances with the Rules due to the system design and functionality (e.g. black start requirements applied to designated engines only);
• Information required to be included by the individual Chapters.

3.4.4 For ships without complex systems (e.g. single or dual engine installation), the System Operational Concept can be combined with the appropriate System Design Description, see Vol 2, Pt 1, Ch 3, 3.5 System design description.

3.4.5 The System Operational Concept documents are to be agreed between the designer and Owner. LR may accept alternative documents where these provide the information which would be included within the System Operational Concept. In such cases the relevant sections providing the information required to provide equivalence with the System Operational Concept are to be identified.

3.5.1 The requirements of this sub-Section aim to ensure that LR is provided with sufficient information at the sub-system and equipment level in order to undertake the design appraisal activities required by these Rules.

3.5.2 A System Design Description document is to be submitted to detail the system’s sub-system or equipment capability and functionality under all normal and reasonably foreseeable abnormal operating and fault conditions. Examples of systems/equipment requiring the submission of a System Design Description include but are not limited to:

• Engines.
• Water jet systems.
• Piping systems.
• HVAC systems.
• Refrigeration Machinery (PRM) notation.

3.5.3 The System Design Description is to include the following information, as appropriate to the system:

• Where appropriate, reference to the related Concept of Operations and/or System Operational Concept document;
• Operating modes and philosophy including reversionary and emergency modes recognising the operational and manning philosophy for the vessel;
• System parameters (capacity, power, discharge rate, etc.);
• System redundancy;
• Degraded performance under extreme operating conditions;
• Information required for inclusion in the System Design Description by individual Chapters.

3.5.4 The System Operational Concept documents are to be agreed between the designer and Owner. LR may accept alternative documents where these provide the information which would be included within the System Operational Concept. In such cases the relevant sections providing the information required to provide equivalence with the System Operational Concept are to be identified.