Freedom Star NEW ITEM 205 SEA VALVES.pdf

• ITEM 205 SEA VALVES

ABSTRACT

It is the intent of this ITEM to open, clean and conduct a USCG & ABS inspection of the ship's sea valves.

REFERENCES / ENCLOSURES: ABS Rules Part 7, Chapter 6, Section 2/3.1.1.1

LOCATION / DESCRIPTION: Throughout the ship.

NOTES See Item Number (ITEM) 205 in Section B that requires pricing from all vendors.

STATEMENT OF WORK

In accordance with all regulatory body requirements, the Contractor shall provide all labor, materials and services to accomplish the intent of this ITEM. In addition, and at a minimum, the Contractor shall:

Furnish the necessary labor, material and equipment to open up, disassemble, clean, inspect, overhaul, and place in first class seaworthy and serviceable condition, all sea valves.

Furnish the necessary labor, material and equipment to open up, disassemble, clean, inspect, overhaul, and place in first class seaworthy and serviceable condition, the main engine, SSDG, and Bow thruster sea strainers. A total of Five (5) strainers.

Install blanks at the locations of all removed sea valves in order to prevent the intrusion of grit, water, paint, etc. during the hull surface preparation and coating.

Disconnect all electric motor driven valve actuators as required to disassemble the sea valves.

Note: The Chief Engineer or an individual appointed by him shall operate the valves before disassembly to demonstrate their initial, satisfactory operating condition.

Disassemble, clean, inspect, service, free-up, repair, adjust, reassemble, lubricate and place in good operating condition all parts forming the valve actuators. This will include the replacement of any normal wearing parts including the replacement of any seals or gaskets exposed during the disassembly for inspection. (Disassembly shall be required to the extent that a thorough inspection of all components can be made without the use of inspection aids such as mirrors and scopes). Upon completion of repairs to valves, re-connect the valve actuators to the respective sea valves and prove the proper operation of the actuators.

For all valves 12 inches and under: Tag all valves as to their location and orientation. Remove all valves to the shop. Completely disassemble and thoroughly clean all parts. Machine, grind, file, lap and/or polish all seating surfaces (bonnet faces, seats and discs, etc.) as necessary to remove any pits, scratches or other imperfections which will affect the valves ability to seal properly. At the Contractor's expense, replace any nut, bolt, washer, pin and any soft parts (to include O-rings and Buna inserts) using OEM or equal parts. Re-assemble the valve sufficient to perform a contact check of the valve and disc in the presence of the COR. Following a satisfactory contact check, coat the valve internals with Apexior, re-assemble all parts with new gaskets and packing and re-install the valve. The contact transfer line shall be of 360 degrees contact of uniform width covering one-third of the seating surface within the lower half of disc's seating surfaces for globe valves and of 360 degrees contact of uniform width the center fifty percent of the gate seating surface for gate valves and butterfly valves. Ensure the gates have clearance between the bottom of gate and valve bottom when valve is in a tightly closed position.

For valves over 12 inches: Perform the same work as defined for valves 12 inches and less, however, removal to the shop is not necessary. Removal of the valve from the sea chest and adjoining piping is necessary. Please note that additional valves of 12” and down to be replaced as noted in the valve Table on page 3. These valves have been identified to have improper materials for sea water.

Valves 2 inch and under are to be replaced by the Contractor with equal valves. New valves shall be supplied at no additional cost to the Maritime Administration. New valves shall be bronze, Monel trimmed, bolted bonnet style, using new gaskets and stainless steel or Monel bolting for installation.

To measure leakage after re-assembly, the contractor shall conduct a hydrostatic seat-tightness test of each valve using clean freshwater as the testing medium and apply the test-pressure as specified in Table I.

TABLE I. Test Pressure and Application

VALVE TEST PRESSURE PRESSURE APPLICATION

Test at (PSI)

System Operating Pressure

CHECK * 50 0 to 150 PSI Apply back test-pressure

STOP-CHECK * 100 150 PSI plus Hand wheel shall be in the open position

GATE * 150% of the maximum operating pressure of the system from which the valve was removed

* BUT

* not less than 50 PSI

Apply test pressure alternately on both sides of the disc with the opposite end open for inspection

ALL OTHER TYPES Apply test-pressure in the direction tending to open the valve

Maximum allowable seating force:

Use the values in Table II as the maximum allowable seating forces to be applied.

TABLE II. Maximum Allowable Valve Seating Force

Per Hand Wheel Diameter

HAND WHEEL DIAMETER

(inches)

VALVE SEATING FORCE*

(pounds)

0-2 90

3 98

4 106

5 112

6 118

7 121

8 124

9 127

10 130

11 133

12 135

14 138

16 141

18 144

21 147

24+ 150

*Total tangential force on rim

Allowances:

If no leakage occurs after three minutes of pressurization, the test may be discontinued. However, if there is any visible leakage, the test shall be discontinued the valve reseated and tested again, this may be done up to three times to ensure complete seat contact for the test if after three attempts to reseat the valve does not eliminate all leakage the valve shall be reworked at the contractor’s expense until a satisfactory test of the sea valve results in zero leakage in a three minute time period as indicated above is achieved.

Final inspection:

After undocking, each valve shall be inspected for leaks in the presence of the Chief Engineer and the COR. If a sea valve is found to be leaking, it shall be the responsibility of the contractor to repair the condition to the COR’s satisfaction at no additional cost.

Butterfly valves employing buna or other soft parts shall require a hydrostatic test to determine their integrity in lieu of a contact check.

Hammer test and examine all shell fastenings securing the various valves and their appurtenances, such as pads, nipples, studs, spool pieces, spuds, flanges, etc., to the hull.

Remove for inspection all sea valve waster spools for visual inspection. Spools suitable for re-use shall be grit blasted, internally and externally and shall be sent to a specialty shop for heavy, hot-dip galvanizing of the sleeve. Spools excessively wasted shall, upon funding by Delivery Order, be re-fabricated by assembly of a new flange and sleeve, again shall be sent out for heavy, hot-dip galvanizing.

Replace and restore insulation that has been removed or damaged. Clean, prepare, prime and paint disturbed areas to match surrounding.

Perform a satisfactory hydrostatic test on all valves in the presence of the COR and the regulatory bodies following overhaul. All valves shall be hydrostatically tested before re-installation in the piping.

Note: When deck drain overboard valves are removed, rain on deck will leak into engine room. These need to be blanked.

LOCATION

ENGINE ROOM

FRAME POSITION(P-

S-CL)

SIZE

(inch)

TYPE FUNCTION ITEM

42 PORT 2 GATE A/C COOLING WATER OVERBOARD Replace

43 PORT 12 BUTTERFLY HIGH SEA SUCTION

43 PORT 6 CHECK PORT MAIN ENGINE OVERBOARD Replace

43 PORT 6 GATE PORT MAIN ENGINE OVERBOARD Replace

43 PORT 4 GATE FIRE & BALLAST OVERBOARD Replace

43 PORT 4 CHECK FIRE & BALLAST OVERBOARD

45 CL 12 GATE PORT LOW SEA SUCTION Replace

45 CL 12 GATE STBD LOW SEA SUCTION Replace

45 CL 2 GATE PORT LOW SEA CHEST VENT Replace

45 CL 2 GATE STBD LOW SEA CHEST VENT Replace

45 CL 1 GLOBE PORT LOW SEA CHEST BLOW DOWN Replace

45 CL 1 GLOBE STBD LOW SEA CHEST BLOW DOWN Replace

45 STBD 3 Ball valve with locking lever SEWAGE OVERBOARD Replace

48 STBD 6 CHECK STBD MAIN ENGINE OVERBOARD Replace

48 STBD 6 GATE STBD MAIN ENGINE OVERBOARD Replace

60 PORT 3 GATE P & S GENERATOR OVERBOARD Replace

60 PORT 3 CHECK P & S GENERATOR OVERBOARD Replace

63 PORT 2 GATE GEAR & CP COOLER OVERBOARD Replace

64 PORT 4 GATE PORT DECK DRAIN OVERBOARD Replace

64 PORT 4 WAFER CHECK PORT DECK DRAIN OVERBOARD Replace

64 STBD 4 GATE STBD DECK DRAIN OVERBOARD Replace

64 STBD 4 WAFER CHECK STBD DECK DRAIN OVERBOARD Replace

BOW THRUSTER ROOM

FRAME POSITION(P-

S-CL)

SIZE

(inch)

TYPE FUNCTION ITEM

12 STBD 2.5 GATE BOW THRUSTER OVERBOARD Replace

12 STBD 2.5 CHECK BOW THRUSTER OVERBOARD Replace

12 PORT 8 BUTTERFLY BOW THRUSTER EXHAUST

14 PORT 2.5 GATE BOW THRUSTER SEA SUCTION Replace

14 PORT 2 GATE BOW THRUSTER SEA CHEST VENT Replace

14 PORT 1.5 GATE REEFER COOLING PUMP SEA SUCTION Replace

STERN THRUSTER ROOM

FRAME POSITION(P-

S-CL)

SIZE

(inch)

TYPE FUNCTION ITEM

64 STBD 2.5 GATE STERN THRUSTER OVERBOARD Replace

66 CL 2.5 GATE STERN THRUSTER SEA SUCTION Replace

66 CL 1 GATE STERN THRUSTER SEA CHEST BLOW DOWN Replace

66 CL 2 GATE STERN THRUSTER SEA CHEST VENT Replace

74 CL 1 * STERN THRUSTER CASING VENT Replace

PERFORMANCE CRITERIA / DELIVERABLES

Satisfactory hydrostatic test of all valves.