0551_A_TAKE-CCSI-OVERHAUL PLATE COOLERS (10 YR) - Rev 1.docx

USNS Shepard

( TAKE 3 )

ABSTRACT

This work item describes the requirements to clean and regasket the two plate heat exchanger(s).

· MDG LO Cooler No. 1

· MDG LO Cooler No. 3

REFERENCES

1.1 MSC Tech Manual T9532-A2-MMC-010, Heat Exchanger, Plate, High Temp

ITEM LOCATION/DESCRIPTION

Location: Main Engine Room, 5-66-0 Description System: Lube Oil Mfg: Paul Mueller Company Model: AT80 B-20 Number of plate coolers: One Quantity: Two lube oil coolers.

GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE

Government Furnished Equipment (GFE): None Government Furnished Material (GFM)

Item

Part Number

NSN/TNICN

Description

Qty1

UOM2

(2 Each) 8L48/60 AT80 B-20 MDG LO Cooler AT80 B-20

1 Qty = Quantity 2 UOM = Unit of measure Government Furnished Services (GFS): None Government Furnished Information (GFI): None

NOTES

The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs including but not limited to GTRs 1 through 7, 22, 23, 24, 28, and 29.

1.2 This ship contains high voltage (hv) electrical systems. Obey all posted and verbal instructions regarding safety and exclusion from high voltage areas. At no time approach, work on, or enter a high voltage area without proper authorization.

The T-AKE class electrical color coding does not follow the consistent color scheme. The ship is known to have current carrying conductors colored green, blue, black, and white. Assume all electrical cables are energized until tested and proven otherwise. Test all electrical cables to ensure they are de-energized prior to working on the item.

QUALITY ASSURANCE REQUIREMENTS: None additional

STATEMENT OF WORK REQUIRED

Provide and operate equipment and supply all services and assistance to accomplish the thorough examination, cleaning and gasket renewal on the plate heat exchanger(s) using the Manufacturer’s requirements and Reference 2.1 as guidance.

1.3 Coordinate with ship’s force to have associated equipment locked and/or tagged out per ship’s lock out/tag out policy. When the maintenance is complete, coordinate with ship’s force to have associated equipment unlocked and/or tagged in per ship’s lock out/tag out policy.

1.4 Drain and dispose of any liquid in accordance with all local, state, and federal laws.

Provide temporary caps, blanks or plugs on open connections to adequately protect the system from contamination and leaks during the accomplishment of this work item. Coordinate removals and reinstallations with the Chief Engineer to ensure the vessel is always aware of system status until the cooler work is completed.

Fabricate a heavy-duty wooden crate(s) to temporarily store and transport the heat exchanger plates to prevent any possible damage.

Conduct inspections, maintenance and testing of the plate heat exchanger(s) listed in section 3.0 using Reference 2.1 as guidance.

Conduct an inspection of the plate heat exchanger(s). The examination shall:

Measure and record the plate pack thickness dimension prior to loosening and disassembling. Submit a report to the OMT REP.

Remove the protective shroud covering the plates Inspect the heat exchanger assembly for any signs of leakage Disassemble and remove the plates from the heat exchanger. Crate them and prepare for transport to the OEM-authorized shop.

WARNING: Gloves should be used when handling the plates to avoid injury.

Inspect the plates and gaskets for signs of damage, deformity, crush, holes, cracks, and scale. Perform die penetrant Non-Destructive Testing (NDT) of plates. Dark room light testing may be used with the inspection and permission of the Port Engineer or Chief Engineer.

Inspect the frame plate, pressure plate, carrying bar, guide bar, support column, collars, tightening bolts and connections for signs of damage or corrosion.

Conduct maintenance replacing all gaskets, boots, nozzles, collars and seals listed in paragraph 4.2 using the manufacturers design, installation, maintenance instructions and service bulletins as guidance. The maintenance and replacement will include/verify:

Crate and transport the heat exchanger plate pack(s) to the OEM authorized repair facility.

Remove the gaskets (liquid nitrogen debonding), chemically clean and inspect every plate for pin holes and cracks.

WARNING: Never use a steel brush or steel wool on the plates. Never use Hydrochloric Acid on Stainless Steel plates nor Hydrofluoric Acid on Titanium plates.

Regasket the plates using the GFM gaskets listed in paragraph 4.2 and OEM adhesive and procedures. The adhesive is contractor furnished.

Crate and transport the refurbished plate pack(s) back to the vessel.

Clean the end plates removing all corrosion and debris. Prime and paint using OEM guidance. Fair in any pits with belzona or equal to provide a smooth flat surface for gasket sealing.

Clean the tightening bolts removing all corrosion and old grease. Apply new lubricant grease to the threaded surfaces.

Determine the correct plate pack thickness with the OEM prior to reassembly and tightening.

Reinstall, reassemble and tighten the plate(s) using Reference 2.1 and the manufacturer’s guidance. Ensure that the plate pack stack is drawn up evenly, bolts are tightened uniformly using procedures in References 2.1 and result in a correct plate pack thickness. Take precautions to avoid over-torquing and not use pneumatic impact wrenches for torquing.

Measure and record the final plate pack thickness in the presence of the OMT REP.

Leave the heat exchanger(s) in a ready for service condition.

Conduct a test of the heat exchanger assemblies during Dock Trials. The testing will include/verify:

Open the vent valves and fill the unit(s) ensuring all air is removed from each side.

Conduct a hydrostatic test using operational system pressure. Inspect for any signs of leakage.

If leakage is noted, the OEM Rep is to adjust the plate pack thickness within allowable limits using Reference 2.1 as guidance.

Conduct an operational test of the heat exchanger(s) confirming no leakage during Dock Trials.

Testing is to be coordinated with the OMT REP, ABS and USCG Inspectors to allow for observation if deemed necessary.

Reports

1.4.1 When inspection, service and testing reveal any deficiency a condition report is to be submitted to the OMT REP with recommended repairs and parts required. Submit one electronic copy in Portable Document Format (PDF).

1.4.2 Submit a report that includes “as released” condition of the plate coolers. Submit one electronic copy in Portable Document Format (PDF).

1.4.3 All reports and checklists are to be completed and signed by the person who carried out the inspection and maintenance work and countersigned by the Company’s representative.

Painting: None additional Preparation of Drawings Provide electronic copies of all revised and/or updated technical documentation including drawings, technical manuals, service bulletins, parts lists, certification and test data associated with the work performed or parts supplied to the OMT REP.

GENERAL REQUIREMENTS: None additional 0551 - 7