WP-30 Tank Level Indication Modifications V1.pdf

Abstract This modification package describes the scope of work to modify the tank level indicating (TLI) system.

At the conclusion of this work package, all TLI sensor inputs listed in this work specification will be ready for Alarm Monitoring System (AMS) integration in order to display real time and historically logged tank level information at AMS workstations and remote panels located at the ballast and fuel oil manifolds.

Note: This work specification addresses the removal and replacement of existing sensor inputs and distribution cabling. WP-01 addresses AMS integration, distribution, processing, and display.

Primary elements of this Work Package include:

Remove existing transducers Qty (37) and cabling up to the first termination point outside the tank and TLI body, usually a junction box or an existing PLC/RIO cabinet.

Restore, modify, or replace supporting structure, piping, cable glands, flanges, bushings, or tank entry point required for new sensor installation.

Install Qty (37) new pressure TLIs and distribution cabling in the same locations as those removed

Remove existing transducer Qty (1) and distribution cabling in the Sewage Tank up to the first termination point outside the tank and TLI body.

Install Qty (1) new ultrasonic transducer and distribution cabling in the Sewage Tank.

In accordance with WP-01, remove and replace new, the remainder of the system equipment

(distribution cabling, processing units, and displays) and integrate sensor inputs into the new Alarm Monitoring System (AMS) for end-to-end distribution, processing, and display.

Calibrate and perform post-installation acceptance testing.

Provide as-built installation drawings.

Revisions

WP-30 TANK LEVEL INDICATION

SYSTEM MODIFICATIONS

NOAAS Ronald H. Brown | Rev 1

PREPARED FOR: PREPARED BY: ORGANIZATION DATE:

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

Jim Courville ECS Federal 12 October 2020

CHECKED BY: ORGANIZATION DATE:

Steve Laverty ECS Federal 15 December 2020

APPROVED BY: ORGANIZATION DATE:

CONTRACT #: - Jamie LeCompte NOAA -

Section Rev Description Date All References 000.1.3 400.1 400.2

Initial Release Added Ref 8 (TLI TM) Added (Waiting on Atlantis/Revelle info) Added existing TLI data in Ref 8 Added existing mounting arrangement details

15 Dec 2020 23 Jun 2021 23 Jun 2021

WP-30 Tank Level Indication System Modifications NOAAS Ronald H. Brown

15 December 2020 ii Rev 1

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: Potable Water System Modifications, ECS, WP-06, 22 SEP 2020

4. Work Package: NOAA Ship Ronald H. Brown Midlife Refit, WP 10: Sewage System and Drain

Replacement, ECS

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

6. Drawing: Booklet of General Plans, Art Anderson Associates, RB-085-001, 4 NOV 2010

7. Drawing: Machinery Control System Block Diagram, NAVSEA, 6932730, Rev. F, 15 NOV

8. TANK LEVEL INDICATORS, AGOR-24 CLASS TECHNICAL MANUAL

1 Rev 1

000 GENERAL REQUIREMENTS

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 item shall be carried out as part of this work item and shall be reinstalled and restored to original condition. All affected mechanical and electrical components shall be tested to the Owner’s satisfaction after reinstallation.

000.1 NOTES

000.1.1 General Technical Requirements

Reference 1 contains general design, production, and documentation requirements relevant to the work described in this 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.

000.1.2 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.

000.1.2.1 WP-01 Repower (Reference 2)

The Contractor is responsible for integrating the performance requirements of Reference 2 with the requirements of this modification package to achieve an integrated and properly functioning system.

Alarm and Monitoring System Upgrades will distribute, process, display, and integrate transducer inputs.

000.1.2.2 WP-06 Potable Water System Modifications (Reference 3)

WP-06 describes the installation of new RO units and the expansion of the p/s water tank capacities.

Execution of this work package shall be coordinated with WP-06.

000.1.2.3 WP-10 Sewage System and Drain Replacement (Reference 4)

WP-10 describes the modification to the Sewage. Execution of this work package shall be coordinated with WP-06.

000.1.2.4 WP-26 Drydocking (Reference 5)

WP-26 describes the requirement to drydock the vessel. TLI removals and installations described within this work package shall be performed while the ship is in drydock. Execution of this work package shall be performed in conjunction with WP-26.

2 Rev 1

000.1.3 Transducer Selection

New transducers shall be integrated with the new Alarm, Monitoring System (AMS), Reference 2.

Recommended manufacturer for the pressure transducers is Marcon, P XDCR, 4-20mA, and Flowline Ultrasonic, 4-20mA, for the Sewage Tank (or approved equal). Each model TLI should be selected to utilize at least 70-75% of its’ scale range for the tank it is installed in to ensure good readout resolution/accuracy).

000.2 BID REQUIREMENTS

The scope of work in this WP is recommended to be completed by the same system supplier as the bulk of the AMS system in order to integrate transducers into the AMS.

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 REMOVALS

No items.

100.2 INSTALLATIONS

No items.

200 MAIN PROPULSION SYSTEM

200.1 REMOVALS

No items.

200.2 INSTALLATIONS

No items.

300 ELECTRICAL POWER PLANT

The Contractor shall utilize the power supply and processing units as described in Reference 2 for power to the TLI sensors and processing and display of the data.

400 COMMAND, COMMUNICATIONS, AND NAVIGATION

400.1 REMOVALS

The intent of this work package is to have all TLI cabling replaced with new cables. No existing cabling in the TLI system will be reused. Cable replacement must be coordinated with WP-01 to ensure compatibility during integration with the AMS. The Contractor shall remove, and discard tank level indicator transmitters, cables, and system components associated with Table 400.1-1. Existing TLI electronics used for routing and processing pressure transducer I/O sensor analog inputs are

3 Rev 1 addressed in WP-01 and with the Alarm, Monitoring, and System (AMS) vendor furnished information.

The contractor shall conduct the following removals:

Remove existing TLI’s Qty (37) and cabling up to the first termination point outside the tank and TLI body, usually a terminal box or an existing PLC/RIO cabinet. See Reference 6 for tank locations and Reference 8 for existing TLI arrangement and mounting details.

Remove existing transducer Qty (1) and distribution cabling from the Sewage Tank to first connection point (j-box) outside the tank.

The sensor terminal/junction boxes shall be retained and inspected for reuse.

Visually inspect the remaining system terminal boxes and provide a report of the condition found to the Owner.

Inspect all existing cable glands, bushings, flanges, support structure, and TLI piping and provide a report of the condition found to the Owner.

TABLE 400.1-1 TANK LEVEL INDICATORS FOR REMOVAL / INSTALLATION

Tank Quantity Transducer Type Fuel Oil #1 Stbd Tank Level 1 GEMS 36000 SERIES Fuel Oil #1 Port Tank Level 1 GEMS 36000 SERIES Fuel Oil #2 CL Tank Level 1 GEMS 36000 SERIES Fuel Oil #3 Stbd Tank Level 1 GEMS 36000 SERIES Fuel Oil #3 CL Tank Level 1 GEMS 36000 SERIES Fuel Oil #3 Port Tank Level 1 GEMS 36000 SERIES Incinerator Fuel Oil Tank Level 1 GEMS 36000 SERIES Fuel Oil #4 Stbd Tank Level 1 GEMS 36000 SERIES Fuel Oil #4 Port Tank Level 1 GEMS 36000 SERIES Fuel Oil #5 Stbd Tank Level 1 GEMS 36000 SERIES Fuel Oil #5 CL Tank Level 1 GEMS 36000 SERIES Fuel Oil #5 Port Tank Level 1 GEMS 36000 SERIES Fuel Oil #6 CL Tank Level 1 GEMS 36000 SERIES Fuel Oil Service Tank Stbd Tank Level 1 GEMS 36000 SERIES Fuel Oil Service Tank Port Tank Level 1 GEMS 36000 SERIES EDG Fuel Oil Day Tank Level 1 GEMS 36000 SERIES Ballast Peak Tank Level 1 GEMS 36000 SERIES Ballast #1 Tank Level CL 1 GEMS 36000 SERIES Ballast #2 Stbd Tank Level 1 GEMS 36000 SERIES Ballast #2 Port Tank Level 1 GEMS 36000 SERIES Ballast #3 Stbd Tank Level 1 GEMS 36000 SERIES Ballast #3 CL Tank Level 1 GEMS 36000 SERIES Ballast #3 Port Tank Level 1 GEMS 36000 SERIES Ballast #4 Stbd Tank Level 1 GEMS 36000 SERIES Ballast #4 Port Tank Level 1 GEMS 36000 SERIES Ballast #5 Stbd Tank Level 1 GEMS 36000 SERIES Ballast #5 Port Tank Level 1 GEMS 36000 SERIES Ballast #6 Stbd Tank Level 1 GEMS 36000 SERIES Ballast #6 Port Tank Level 1 GEMS 36000 SERIES Potable Water Stbd Tank Level 1 GEMS 36000 SERIES

4 Rev 1

Tank Quantity Transducer Type Potable Water Port Tank Level 1 GEMS 36000 SERIES Lube Oil Tank Level 1 GEMS 36000 SERIES Oily Waste CL Tank Level 1 GEMS 36000 SERIES Waste Oil CL Tank Level 1 GEMS 36000 SERIES Z-Drive Lube Oil Tank 1 GEMS 36000 SERIES Anti-Roll Tank Level 2 GEMS 36000 SERIES Sewage Tank Level 1 Ultrasonic

400.2 INSTALLATIONS

The Contractor shall install thirty-seven (37) new pressure transducers and one (1) ultrasonic transducer in the Sewage Tank as listed in Table 400.1-1. All tank level indicators are to be protected by 0.1A fuses. Typical installation and connection figures are provided below to aid the contractor with the understanding of the scope of this work specification and in the development of its own detailed design drawings.

Figure 400.2-1 Typical Tank Level Indicator Installation (Top Mount)

The contractor shall conduct the following:

Existing TLI’s are mounted to tank entry points with a GEMS bracket or Flange arrangement.

Modify as necessary the existing mounting and tank entry arrangement at the tanks to accept the selected new TLI’s. Reference 8.

Provide and install new (or reuse pre-existing with Owner’s approval) replacement gaskets, cable glands and bushings, pipe, stuffing tubes.

Provide and install new cables from the transducer sensor heads to the first termination point. Coordinate with WP-01 (Reference 2), Repower to ensure compatibility with AMS integration.

Provide and install new tank level pressure transducers. New sensor supports inside the tanks shall be fabricated and installed as required (Reference 1). Transducers shall be installed a maximum of 4" above the lowest point of the tank in locations similar to the removed transducers. All transducers shall be appropriate for the location of installation (sea water, fuel oil, etc.). In addition to pressure transducers, the Contractor shall provide, install, and integrate one (1) ultrasonic tank level transducer in the sewage tank. The sewage

5 Rev 1 tank sensor shall be located between 8 and 16 inches off center line on either side between the forward bulkhead at Frame 64 and the aft bulkhead at Frame 67. Exact location to be determined by Owner.

The Contractor shall consider maintenance and access to all sensors. Tank level sensors must be capable of being removed from the tank without draining or entering the tank.

Figure 400.2-2 Typical Tank Level Indicator Connections

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.

6 Rev 1

700 SCIENTIFIC MISSION SYSTEMS

700.1 REMOVALS

No items.

700.2 INSTALLATIONS

No items.

800 INTEGRATION AND ENGINEERING

The AMS shall contain software that allows for calculation of tank volumes for non-linear tank shapes.

The tank levels and volumes shall be displayed on the CMCS monitors and levels on local instruments at the tank valve headers. Reference 1 provides requirements regarding regulatory body inspections and requirements for certificates and other documentation associated with regulatory body certification processes.

A tank level indicating system shall be provided. The tank level transmitters shall be pressure transducer type with the exception the sewage tank which shall be ultrasonic. All transducers listed in Table 400.1-1 shall be integrated into the centralized machinery control system as described in Reference 2. Readouts, HMI’s, and level alarms for these tanks shall be located remotely at the site where filling and emptying is controlled for each tank and also in the MCSC in accordance with Reference 2.

The Contractor is responsible for calibration of TLI and correlation with tank tables for volume calculations, values shown are developed from T&S booklet and existing AMS calibration sheets.

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.

800.1 DOCUMENTATION

All documentation shall be revised to the as-built condition at the conclusion of Sea Trials. Technical documentation necessary for this modification package, in accordance with the documentation requirements in Reference 1, shall include, at the minimum:

Drawings of the new TLI system components including physical arrangements, dimensions, circuit diagrams, terminal layouts, layout diagrams, and parts lists.

Installation and working drawings for TLI system installations.

Installation, operation, and technical manuals for the TLI system. These should be part of the integrated machinery manuals required as part of the Siemens scope of supply in the Alarm and Monitoring System Upgrades work specification.

Regulatory compliance documentation.

Spare parts and special tools lists.

Test procedures.

Completed and signed test reports.

Commissioning and calibration/configuration data.

800.2 TRAINING

No items.

7 Rev 1

900 TESTS AND TRIALS

The Contractor shall prepare, commission, and test the system and all modified or disturbed equipment in accordance with ABS and USCG requirements and Reference 1. The testing shall be witnessed by the Owner, and regulatory bodies where required. The Contractor shall conduct testing in conformance with Contractor-developed test memorandums approved by the Owner and meeting the test program requirements of Reference 1.

900.1 STAGE 1 – FACTORY ACCEPTANCE TESTS

There are no Stage 1 tests for this work package.

900.2 STAGE 2 – CONSTRUCTION INSPECTIONS AND TESTS

Stage 2 testing will at a minimum include:

All electrical cable affected (new or existing) by the modifications in this work package shall be tested for insulation resistance (meggering) in accordance with ABS (American Bureau of Shipping) and USCG (United States Coast Guard) requirements.

All disturbed tanks shall be leak tested in accordance with ABS and USCG requirements.

900.3 STAGE 3 – OPERATION AND PERFORMANCE TESTS

Operation and Performance Tests shall demonstrate proper operation and performance of installed, modified, and disturbed equipment described in this work specification with respect to design functions, features, and capabilities as identified in the equipment instruction books (operating manuals), USCG regulations, and ABS Rules. Operational testing shall also be performed in conformance with manufacturer recommendations and guidelines. Contractor engineering personnel intimately familiar with all hardware and firmware/software design features of the system shall conduct the post-installation operation tests with a fully installed, calibrated, and AMS integrated system. The Owner shall have one or more representatives witness all the testing.

900.4 STAGE 4 – DOCK TRIALS

A Dock Trial shall be performed to verify that the TLI system is operating satisfactorily. This testing shall include all manufacturer-recommended testing and at a minimum:

All tank level outputs from the TLI system shall be calibrated and correlated with tank tables for volume calculations.

Tank levels and Low-High value alarms will be verified by stimulating the pressure at the tank level transducer using a manometer or other means to demonstrate accurate levels are displayed on HMI’s.

900.5 STAGE 5 – SEA TRIALS

A Sea Trial shall be performed to verify that the TLI system operates satisfactorily with the vessel motions in a seaway. This testing shall include all manufacturer-recommended testing for Sea Trials including demonstration of time delays and averaging.

000.1.3 Transducer Selection