WP-25 Steel Replacement REV 1.pdf

Abstract

This work package describes the requirement to identify and perform structural repairs in various locations aboard NOAA Ship Ronald H. Brown. It also includes the requirement to perform structural modifications to increase the holding capacity of the vessel’s double-bottom Sewage Holding Tank and to renew all bilge well plating. Thickness Gauging shall be conducted on various structural elements to confirm structural adequacy.

Revisions

References

1. Work Package: General Requirements, ECS, WP-00, 18 DEC 2020

2. Work Package: Repower, Glosten, 20065.01-01-WPS, 11 DEC 2020

3. Work Package: Drydocking, ECS, WP-26, 11 NOV 2020

4. Work Package: AC Spaces General Modifications, ECS, WP-07A, 10 DEC 2020

5. Report: NOAAS Ronald H. Brown (R 104) ABS Service-Life Extension Program (SLEP)

Technical Report, American Bureau of Shipping (ABS)

6. Drawing: Paint Schedule, ECS, 00-631-001, 11 SEP 2020

7. Drawing: Sewage Holding Tank Expansion, ECS, 25-113-001

8. Drawing: 03 Deck Fan Room BERP Installation, ECS, 25-154-001

9. Drawing: Shell Expansion, NAVSEA, 6932827, Rev. D, 26 OCT 1993

10. Drawing: Deck Scantlings, NAVSEA, 6932825, Rev. D, 25 MAR 1994

11. Drawing: Structural Module Assembly No. 1, NAVSEA, 6932801, Rev. B, 10 MAY 1993

12. Drawing: Structural Module Assembly No. 2, NAVSEA, 6932802, Rev. C, 5 APR 1993

13. Drawing: Structural Module Assembly No. 4, NAVSEA, 6932804, Rev. A, 8 APR 1993

14. Drawing: Structural Module Assembly No. 13, NAVSEA, 6932813, Rev. D, 3 AUG 1993

15. Drawing: Structural Module Assembly No. 14, NAVSEA, 6932814, Rev. D, 22 APR 1994

16. Drawing: Structural Module Assembly No. 16, NAVSEA, 6932816, Rev. B, 7 DEC 1993

17. Drawing: Structural Module Assembly No. 20, NAVSEA, 6932820, Rev. C, 7 JAN 1994

18. Drawing: Bilge & Ballast System Diagram, NAVSEA, 6932930, Rev. C, 12 AUG 1993

19. Drawing: Structural Module Assembly No. 3, NAVSEA, 6932803, Rev. E, 31 MAR 1993

20. Drawing: Structural Module Assembly No. 5, NAVSEA, 6932805, Rev. E, 21 APR 1993

WP-25 STEEL REPLACEMENT

NOAAS Ronald H. Brown | Rev 1

PREPARED FOR: PREPARED BY: DATE:

NOAA Office of Marine & Aviation Operations 8403 Colesville Road, Suite 500 Silver Spring MD 20910-3282

Nick Tontarski ECS 20 September 2020

CHECKED BY: DATE:

Stephen Laverty ECS 20 October 2020

APPROVED BY: DATE:

CONTRACT #: - Jamie LeCompte NOAA 15 Dec 2020

Section Rev Description Date

All 0 Initial Release 15 Dec 2020 References, 100.4

1 Updated Table 100.4-1 and added References 19, 20. 10 June 2021

WP-25 Steel Replacement NOAAS Ronald H. Brown

10 June 2021 2 Rev 1

21.

000 GENERAL REQUIREMENTS

The Contractor shall perform structural modifications and renewals inside the Sewage Holding Tank, Fore Peak Ballast Tank, and various bilge wells throughout the vessel, including piping renewals.

The Contractor shall perform inspections and thickness gauging of the specified areas and prepare written reports to the Owner. All areas marked for inspection shall be inspected within the first 20% of the shipyard schedule. Inspection reports shall be delivered to the Owner no more than five (5) working days following an inspection and shall list the conditions and measured thickness of the plate or structural member compared to as-built values. Repair items may be exercised as individual options at the Owner’s discretion.

ABS Grade A steel shall be used for all renewals, installations, and modifications throughout this work package unless specified otherwise.

The end result of this work package is to identify and address unacceptable corrosion on the vessel.

Additionally, the goal is to identify these issues as early as possible so repair may be better integrated into the overall workflow. The Contractor shall be responsible for all removals, inspections, modifications, installations, and testing as described below and in Reference 1. All fees for these services shall be the responsibility of the Contractor and included in the bid.

The Contractor shall include removal and reinstallation of insulation, piping, HVAC components, electrical cables, and incidental interferences in way of all work described herein. Upon completing the work, the Contractor shall clean the work area and its surfaces of all work debris and recoat existing coated surfaces damaged by welding and other hotwork in accordance with Reference 1 and this section.

All temporary openings and removals necessary to facilitate the work described in this package shall be carried out as part of this work package. All temporary openings and removals shall be reinstalled and restored to original condition. All affected mechanical and electrical components shall be tested to the Owner’s satisfaction after reinstallation.

Prior to commencing the work described in Sections 100.1 and 100.3, submit a written plan to Owner’s Representative and the attending ABS Surveyor which includes the following:

Locations and dimensions of any access cuts necessary to complete this work Plans for temporary reinforcement, shoring, extra blocking, etc. to support the vessel during all aspects of the modifications or renewals. Plans shall include structural calculations to prove no undue bending moments or shear forces will be placed on the vessel.

Installation plan for structural members Welding plan and sequence for all new and reinstalled structural members and plating.

Reference 1 contains general design, production, and documentation requirements relevant to the work described in this package, including lot pricing for structural renewals that may be deemed necessary upon completion of inspections required by this work package. Reference 1 contains Contractor responsibilities for providing or arranging and integrating all required work. The requirements included in Reference 1 shall be applied to all aspects of this work. The requirements described herein shall be considered as additional to the requirements of Reference 1. Unless otherwise noted, all equipment and material permanently removed from the vessel shall become the property of the Contractor.

3 Rev 1

000.1 NOTES

000.1.1 Related Work Packages

The Contractor and all subcontractors, regardless of tier, are advised to review other work items under this contract to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Reference 1.

000.1.1.1 WP-01 Repower (Reference 2)

WP-01 describes the requirement to repower the vessel, including the removal of the main generator sets and multiple pieces of auxiliary equipment.

000.1.1.2 WP-07A AC Spaces General (Reference 4)

WP-07A describes the replacement of Air Handler Units (AHUs) throughout the vessel. Coordinate the AHU removals described in WP-07A with the fan room deck gauging described in Section 100.5 of this work package.

000.1.1.3 WP-26 Drydocking (Reference 3)

Included in WP-26 is the requirement to blast to SSPC-SP-10 and recoat all of the vessel’s ballast tanks. Visual and UT inspection of tank interiors in this work package shall take place will these tanks are in an uncoated condition after blasting. Coating of the newly-expanded Sewage Holding Tank shall be performed in accordance with Section 600.2.

000.2 BID REQUIREMENTS

000.2.1 Costs

The Contractor shall include in their bid the following costs:

1. The cost of the effort to complete the work described in this specification.

000.2.2 Documentation

The Contractor shall include in their bid the documentation listed in Reference 1 and the following:

1. None additional.

100 HULL STRUCTURE

100.1 SEWAGE TANK EXPANSION

Complete the scope of work required by Reference 7 to increase the holding capacity of Sewage Holding Tank 4-64-0. This work will require the removal of the port and starboard bulkheads of the existing sewage tank and the installation of new transverse bulkheads at Frame 67 within the vessel’s double bottom.

Perform the testing required in Section 900.2.3 prior to performing surface preparation. After testing is complete, prepare the interior of the modified tank in accordance with Section 600.2.2 of Reference

2. Coat the tank in accordance with References 2 and 6.

100.2 BERP INSTALLATION

Complete the scope of work required by Reference 8 to install a BERP on the outboard bulkhead of Fan Room 03-67-1. Coordinate with the work required by Reference 4.

4 Rev 1

100.3 STRUCTURAL RENEWALS

100.3.1 Forepeak Ballast Tank 4-0-0

Reference 5 calls for the renewal of stiffeners within Fore Peak SW Ballast Tank 4-0-0 at Frames 5.5, 6.5, and 7.5 between the header plate at 8’-6” ABL and the side stringer at 16’-0” ABL on both Port and Starboard sides. These stiffeners are currently constructed from 5”x3”x5/16” structural L-shapes.

Remove the existing stiffeners. In lieu of a direct renewal of these stiffeners, replace them instead with 6”x4”x3/8” stiffeners similar to those on Frames 5, 6, and 7. Structural details for this area of the vessel can be found in Reference 11.

Perform all testing required by Section 900.2.1 prior to surface preparation and application of coatings required in Section 600.2 of Reference 2.

100.3.2 #2 Fuel Oil Tank 4-32-0

Reference 5 calls for the renewal of plating and stiffeners forming the centerline girder within the #2 Fuel Oil Tank between frames 32 and 36. Reference 12 contains structural details for this area of the vessel. Renew the 15.3-lb (3/8”) web plating, the 40.8-lb (1”) flange plating, and the 3/8” gussets that make up the centerline girder between the oil tight bulkhead at frame 32 and the nontight bulkhead at frame 36.

100.4 BILGE WELL RENEWALS

Renew all bilge wells listed below. Structural renewals shall include the four sides, bottom, cover, and any tank boundary insert plating the comprises the bilge well. Renew all piping and foot valves within the bilge wells up to either the first joint or the penetration of bilge well plating.

TABLE 100.4-1 BILGE WELLS TO BE RENEWED

Location Suction Pipe Size

Piping Detail Structural Detail

Bow Thruster Room 4-16-0 2” Reference 18, Detail 17-D Ref. 11, Plan 52-A & Elev. 52-D Dry Stores 3-44-4 2-1/2” Reference 18, Detail 17-D Ref. 19, Det. 43-B & Det. 46-B Laundry 3-54-2 2” Reference 18, Detail 17-D Ref. 19, Det. 45-B & Det. 46-B Passage 3-40-2 3” Reference 18, Detail 17-D Reference 19, Detail 45-B Generator Room 3-64-0 Forward Centerline

4” Reference 18, Detail 19-D Reference 13, Plan 47-A

Generator Room 3-64-0 Aft Port

4” Reference 18, Detail 19-D Reference 13, Plan 47-D

Generator Room 3-64-0 Aft Starboard

4” Reference 18, Detail 19-D Reference 13, Plan 47-D

Engine Stores & Pump Room 3-90-0

4” Reference 18, Detail 17-D Reference 20, Det. 40-A & Det.

51-B

Winch Room 2-99-0 Starboard 2” Reference 18, Detail 17-D Reference 20, Detail 50-E Winch Room 2-99-0 Port 2” Reference 18, Detail 17-D Reference 20, Detail 50-E

Test renewed bilge well plating in accordance with Section 900.2.1 to prior to applications of any coatings. Prepare and coat newly installed bilge well plating and piping in accordance with Reference 6.

100.5 INSPECTIONS

100.5.1 Joint Inspection with ABS

5 Rev 1

Within the first 10% of the period of performance, Contractor shall perform a joint walkthrough with the attending ABS Surveyor and the Owner’s Representative to identify suspect areas throughout the vessel that are not identified for inspection or replacement elsewhere in this work package or other work packages. Submit to Owner’s Representative a detailed plan to gauge all suspect areas in accordance with recommendations from attending ABS Surveyor.

100.5.2 ABS SLEP Report Areas

Reference 5, the ABS Service Life Extension Program (SLEP) report for Ronald H. Brown, contains recommendations for critical areas of the vessel to be periodically inspected. Coordinate a joint inspection of the following areas identified in the report with the Owner’s Representative and the attending ABS Surveyor. Remove any paint, insulation, or interferences necessary to complete this inspection. Large interferences, such as equipment removals or access cuts, shall be the subject of a CFR. Prepare and deliver to Owner’s Representative a report detailing the findings of the inspection, including any repair recommendations. Replace all removed interferences after inspection and any necessary repairs are completed.

Areas to be surveyed include (See Reference 5):

All areas identified in Table 51.: Recommended Fatigue Inspection Periods. Monitor for signs of cracking via visual and NDT inspection.

Main Deck plating in Access 3-44-2 shown on Page 7-44. Provide further UT gauging in the identified area.

02 Deck plating shown on Pages 7-45 and 7-46. Provide further UT gauging around the suspect area.

Port and starboard side shell plating, items 12 and 13 in Table 53. Provide additional thickness gauging around the suspect area.

Main Deck plating, item 14 in Table 53. Provide additional thickness gauging around the suspect area.

All areas identified in Table 54. Perform visual inspection for buckling, cracking, or other material damage.

100.5.3 Generator Room Deck Inspections

Reference 1 describes the requirement to repower the vessel, including removal of all generators, auxiliary equipment, and their respective foundations. Inspect within 1 week of equipment removal the deck underneath all removed equipment. Inspect all other accessible areas of both the lower and upper Main Generator Room. Provide at least one (1) UT shot per two (2) square feet of deck.

100.5.4 Air Handler Deck Inspections

Reference 4 describes the requirement to renew air handlers throughout the vessel. Upon removal of each air handler, inspect the deck plating underneath and surrounding the existing foundation. Provide a minimum of one (1) UT shot per square foot of deck and at least two (2) UT shots of each air handler’s condensate drain piping per linear foot.

200 MAIN PROPULSION SYSTEM

200.1 REMOVALS

No items.

200.2 INSTALLATIONS

No items.

6 Rev 1

300 ELECTRICAL POWER PLANT

300.1 REMOVALS

No items.

300.2 INSTALLATIONS

No items.

400 COMMAND, COMMUNICATIONS, AND NAVIGATION

400.1 REMOVALS

No items.

400.2 INSTALLATIONS

No items.

500 AUXILIARY SYSTEMS

500.1 REMOVALS

No items.

500.2 INSTALLATIONS

No items.

600 OUTFIT AND FURNISHINGS

600.1 REMOVALS

No items.

600.2 INSTALLATIONS

No items.

700 SCIENTIFIC MISSION SYSTEMS

700.1 REMOVALS

No items.

700.2 INSTALLATIONS

No items.

800 INTEGRATION AND ENGINEERING

Reference 1 provides requirements regarding regulatory body inspections and requirements for certificates and other documentation associated with regulatory body certification processes.

Reference 1 provides requirements pertaining to schedule, drawings development and revision, material control, engineering, estimates, purchase technical specifications, technical documentation, signage, paint schedule, test memorandums, instruction books, equipment identification, and spare parts.

7 Rev 1

800.1 DOCUMENTATION

No items.

800.2 TRAINING

No items.

900 TESTING AND COMMISSIONING

900.1 STAGE 1 – SHOP INSPECTIONS AND FACTORY ACCEPTANCE TESTS

No Stage 1 tests are required for this work package.

900.2 STAGE 2 – CONSTRUCTION INSPECTIONS AND TESTS

900.2.1 ABS-Required Testing

Perform any testing required by the attending ABS surveyor to inspect the quality of modifications and renewals within this work package. Testing may include, but is not limited to, airbox testing, UT gauging, dye penetrant testing, magnetic particle testing, “soap and blow” testing, and fire hose testing. Testing shall be performed in the presence and to the satisfaction of the attending ABS Surveyor and Owner’s Representative.

900.2.2 Plating Inserts

All inserted plating shall be subject to, at a minimum, fit up inspection, back gouge inspection, and airbox testing in the presence of the attending ABS Surveyor and Owner’s Representative.

900.2.3 Sewage Holding Tank Pressure Test

Upon completion of structural modifications, perform a static pressure test to working pressure of the Sewage Holding Tank at 95% capacity with fresh water. Under no circumstances shall seawater be introduced to this tank. The length of time to hold pressure and allowable pressure drops shall be determined by the attending ABS Surveyor.

900.3 STAGE 3 – OPERATION AND PERFORMANCE TESTS

No Stage 3 tests are required for this work package.

900.4 STAGE 4 – DOCK TRIALS

No Stage 4 tests are required for this work package.

900.5 STAGE 5 – SEA TRIALS

No Stage 5 tests are required for this work package.