ARRA-LOP Install Spec Rev D

REVISION No. D . CHANGE NO. .

378’ WHEC LUBE OIL PURIFIER REPLACEMENT

I-262-0001 ORIGINATED BY CWO J.A. McClain__________________. DATE 23Nov09 .

ORIGINATOR’S COMMAND USCG Surface Force Logistics Center .

DEPARTMENT / DIVISION 011/LRE-PL .

INTERNAL REVIEWER . DATE .

SWORB APPROVAL . DATE .

378’ WHEC LUBE OIL PURIFIER REPLACEMENT

1.0 SCOPE

1.1. The intent of this specification is to define the parameters involved in the replacement of the currently installed Alfa-Laval 65-25 Lube Oil Purifier with Government Furnished equipment on board Coast Guard 378’ WHEC cutters.

1.2. Government Furnished Property (GFE)

2.0 APPLICABLE DOCUMENTS

2.1. Document Availability – To obtain the referenced documents see section 6.1

2.2. Government Documents – The following specification and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Index of Specifications and Standards (DODISS) and supplements therein.

2.2.1. Commercial Specifications

a. American Society of Mechanical Engineers (ASME) B16.11, Rev -, 1/1/2005; Forged Steel Fittings, Socket-Welding and Threaded

b. American Society of Mechanical Engineers (ASME) B16.9, Rev 2003, 2/20/2003; Factory-Made Wrought Buttwelding Fittings

c. American Society for Testing and Materials (ASTM) F1387, Rev 99(2005), 6/1/1999; Standard Specification for Performance of Mechanically Attached Fittings

d. The Society for Protective Coatings SSPC-SP 2, Rev -, 11/1/2004; Hand Tool Cleaning

2.2.2. Military Specifications

a. MIL-G-24696, Rev SH; Gasket, Sheet, Non-Asbestos, 12/30/92

b. MIL-PRF-1149, Rev D; Gasket Materials, Synthetic Rubber, 50 and 65 Durometer Hardness, 6/10/98

c. MIL-STD-1627, Rev C; Bending of Pipe or Tube for Ship Piping System, 9/30/94

d. MIL-STD-1689, Rev Rev A, 11/23/1990; Fabrication, Welding and Inspection of Ships Structure

e. MIL-STD-2035, Rev Rev A, 5/15/1995; Nondestructive Testing Acceptance Criteria

f. MIL-T-16420, Rev K; Tube, Copper-Nickel Alloy, Seamless and Welded (Copper Alloys 715 &706), 9/16/88

g. MLCPAC Standard Specification 074, Welding and Allied Processes, 3/21/03

h. MLCPAC Standard Specification 085.1, General Requirements for Drawing Preparation, 3/1/00

i. MLCPAC Standard Specification 304.1, Shipboard Electrical Cable Test, 3/1/00

j. MLCPAC Standard Specification 304.2, Shipboard Electrical Cable Removal, Relocation, Splice, Repair and Installation, 3/1/00

k. NAVSEA Dwg 804-1385781, Pipe Hangers for Surface Ships (Superseding NAVSEA DWG. 810-1385781)

l. NAVSEA T9074-AS-GIB-010/271, Requirements for Non-Destructive Testing Methods

2.3. Other Government Documents – The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.3.1. USCG Commandant Instructions

a. COMDTINST M10360.3B, Coatings and Colors Manual, 6/12/01

b. Coast Guard Technical Publication 3262, Main Propulsion, Lube Oil SWBS 262

2.3.2. Drawings w/ Revision & title.

a. 378-FRAM-W 132-2, Rev A; 2ND & 3RD Deck Plating Aft

b. 378-FRAM-W 133-1, Rev B; 3RD Deck Plating & Framing Forward

c. 378-FRAM-E-133-1, Rev D; 2nd & 3rd deck Plating AFT

d. 378-FRAM-E-142-1, Rev E; 3rd deck plating & framing FWD

e. 378-FRAM-E-264-1, Rev E; Diagram L/O Transfer- Purification Sys.

f. 378-FRAM-E-264-2, Rev D; L/O Transfer & Purification Piping

g. 378-FRAM-E-264-3, Rev E; Lube Oil Transfer Purifier Piping L/M

h. 378-FRAM-E-264-5, Rev B; Connection L/O Tanks

2.3.3. Naval Ships Technical Manuals

a. Chapter 505, Piping Systems, 12/1/01

b. Chapter 635, Thermal, Fire and Acoustic Insulation

c. Chapter 074,V3,Gas Free Engineering.

2.3.4. OHSA Standards

a. 29 Code of Federal Regulation 1915 subpart B

2.4. Commercial Documents – The following documents form a part of this specification to the extent specified here. Commercial documents may be listed in the Department of Defense Index of specifications and Standards (DODISS)

2.4.1. American National Standards Institute (ANSI)/ National Conference of Standards Laboratories (NCSL)

a. ANSI/NCSL Z540-1-1994 DATED 1994, Calibration Laboratories and Measuring and Test Equipment – General Requirements.

2.4.2. American Society for Quality Control (ASQC)

a. ANSI/ASQC Z1.4-1993, DATED 1993, Sampling Procedures and Tables for Inspection by Attributes.

b. ANSI/ASQC Q9001-1994 – Quality Systems – Model for Quality Assurance in Design, Development, Production, Installation, and Servicing.

c. ANSI/ASQC Q9002-1994, DATED 1994 – Quality Systems – Model for Quality Assurance in Production, Installation, and Servicing.

d. ANSI/ASQC Q9003-1994, DATED 1994 – Quality Systems – Model for Quality Assurance in Final Inspection and Test.

2.4.3. American Welding Society (AWS)

a. AWS D1.1-96, DATED 1996, Structural Welding Code, Steel.

b. AWS D1.2-97, DATED 1997, Structural Welding Code, Aluminum.

2.5. Specification Order of Precedence – On the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

3.0 REQUIREMENTS

3.1. The Contractor shall provide all labor and material to accomplish the following in accordance with the General Requirements:

3.1.1. NOTE: A verification shipcheck by the Contractor prior to bidding is recommended to determine any major interference; familiarize existing piping routes and configurations; determine material specifications of affected piping and associated components; determine availability of piping and fitting materials; determine ways to isolate affected piping and components from the remainder of the system; and determine any other complications that may arise during the performance of this work item. Drawings referenced above roughly reflect existing shipboard configurations and arrangements of affected pumps and piping for repairs and/or replacements, respectively. Reference CG Drawings cited in this specification shall not be considered “as built” but provide Coast Guard’s best representation of existing shipboard configurations. Therefore, use these reference drawings for system orientation guidance only and for general location of the work area.

3.1.2. Personnel- All personnel shall be qualified as stated below

3.1.2.1- Project Manager- The designated project manager for any installation shall have documented experience of at least five years in marine repair including pipe fitting, steel fabrication, welding and electrical work. The contractor shall provide evidence of the qualifications prior to the acceptance of any project manager. Project manager shall not be changed without prior authorization of the contracting officer.

3.1.2.2- Other trades- Any other technician, welder, pipe fitter, and electrician shall be qualified by the industry they are employed for. Copies of certificates, licenses, and diploma’s shall be provided prior to the commencement of any work.

3.1.3. For bidding purposes, Contractor is also encouraged to contact Alfa Laval the original equipment manufacturer (OEM) of both the old and new units to discuss the installation, the operational testing or to answer any questions the Contractor may have. Contractor should question the manufacturer to understand the difficulty and scope of this work.

3.1.4. For installation, Contractor shall obtain the services of an OEM Technical Representative to supervise operational testing. OEM shall provide a statement at the conclusion of installation stating that the new purifier has been installed, tested, and is performing to Alfa-Laval standards.

3.1.5. The Contractor shall make an arrangement with the Contracting Officers Technical Representative (COTR) or Government Inspector to assist, identify, and locate affected piping and components.

3.1.6. In the presence of the COTR or Government Inspector, inspect and test all equipment and systems that will be disturbed during the performance of this work to document their original condition. Submit a Condition Found Report for all such equipment and systems noting any existing (pre-work) discrepancies in their operation.

3.1.7. Tag-Outs – Secure, isolate, and tag-out all affected mechanical, piping, and electrical systems in accordance with the General Requirements. All fluid that drains from the piping systems shall be cleaned up and removed immediately.

3.1.8. Interferences – The Contractor shall remove, modify, and protect all interferences to the work. All interferences that are removed shall be tagged to facilitate proper reinstallation. Ensure that all removed equipment is kept in a clean, dry, protected location. Obtain verification from the COTR or Government Inspector for the protective measures taken for equipment not removed. Known interferences include but not limited to insulation and lagging, structural structures, electrical components, miscellaneous piping, pipe hangers, and etc

3.2. Government Furnished Property/Material/Equipment – The contractor shall provide storage for the GFP/M/E when not in use, and safe handling when in use.

a. The storage area shall at a minimum be closed on all sides, dry, and locked when unattended.

3.3. Gas Free Certification

3.3.1. Methods and procedures:

a. Gas Free and certify by Marine Chemist the affected compartments in accordance with General Requirements2.3.3.c & 2.3.4.a. The affected compartments must be certified “Safe for Personnel – Safe for Hotwork” for the duration of work performed under this item.

b. Gas Free Certificates indicating the current status of each compartment shall be posted in Engineering Control Center (ECC) and at each open access to the compartments. Provide one copy to the COTR.

c. The concerned and affected compartments shall include but are not limited to Engine Room (5-192-01-E).

3.4. FIRE WATCH

3.4.1. Methods and procedures.

a. The Contractor shall provide and assign fire watch personnel for each hot work operation. Fire watch requirements shall be in accordance with NSTM Chap 074.

b. Fire watch personnel shall be trained to combat various class and type fires, and shall know the regulations, procedures and facilities for sounding an alarm, and shall carry them out in the event of a fire. One firewatch watchstander shall be permitted for up to 3 hotwork operations if the following criteria are met: (1) all hotwork operations are in the same compartment, and (2) all hotwork operations are visible from one vantage point. Fire watch personnel shall be on location prior to the start of hot work operation. Roving fire watches shall not be permitted. Fire watch personnel shall remain on station during the entire hot work operation. If it becomes necessary for the fire watch to leave the scene, hot work shall be halted and the person who was performing the hot work shall become the fire watch until relieved by a qualified fire watch. Fire watch personnel shall remain at the scene following completion of hot work for a minimum of 30 minutes or until the hot work area is cool to the touch and no smoldering embers remain.

c. The fire watch personnel shall be equipped with suitable Contractor furnished fire extinguishing equipment to combat and extinguish Class “A”, “B”, and “C” fires. Any discharged fire extinguishers shall be refilled/re-charged by the start of the next workday. Selection of fire extinguishing equipment shall be based on the nature and extent of the flammables or combustibles present during the hot work operations and fires that may occur. Fire watch personnel shall first attempt to extinguish fires only when obviously within the capability of the equipment available. In other cases the alarm shall be sounded

3.5. HOTWORK

3.5.1 Methods and Procedures

a.

Conduct all hotwork in accordance with MLC Std Spec 074. All welds shall be continuous, 100% efficient welds and as specified herein.

b.

Fabrication, welding, and inspection of piping joints shall be in accordance with NAVSEA S9074-AR-GIB-010, Class P-2. Weld joint design for butt or socket welding in accordance with MIL-STD-22.

c.

d.

Fabrication, Welding, and Inspection of cutter’s structures shall be in accordance with MIL-STD-1689.

3.6. EXISTING PURIFIER REMOVAL

3.6.1. Contractor shall remove and scrap the existing Purifier and all ancillary equipment not required for operation of new Government furnished Alfa Laval MAB-104 Purifier Unit.

3.7.

Drain all oil from the LOP and associated piping and properly dispose of this oil in accordance with all local, state, and federal laws and regulations.

3.7.1. Disconnect and tag all wiring and cable associated with Lube Oil Purifier Assy removal in accordance with MLC Std Specs 304.2. Prior to wiring removal/disconnection record wiring information for use in later reconnection. Retain electrical motor controller for reuse.

3.8.

The current LOP is:

Manufacturer: De-Laval Model Number: 65-25 estimated total weight: 1200 LBS

3.9. Disassemble parts as required to rig off cutter.

3.10. Remove all insulation and lagging of affected piping for repair to facilitate inspection and renewal.

3.11. Temporarily remove pipe hangers and supports located along the piping for removal. Discard deteriorated hangers and renew them.

3.12. Install caps or blank flange on the open piping immediately upon removal to prevent contamination.

3.13. The Contractor has the option to template pipe bends and fabrication from the removed piping, and discard removed piping after fabrication.

3.14. INSTALLATION OF NEW PURIFIER

3.14.1. Prior to loading new Purifier and all other GFE on board the Cutter, perform receipt inspection to identify any pre-existing evidence of damage.

3.14.2. Upon commencement of install, determine and provide to Coast Guard Inspector the intended load path to be followed to rig in purifier and all other GFE. Submit in proposal the lifting points to be used on both the ship structure as well as the Purifier components. Submit in proposal the level of disassembly of any GFE prior to loading onto Cutter. Shipping access routes and cuts are the responsibility of the Contractor, but shall be coordinated with the Coast Guard Inspector prior to accomplishment.

3.14.3. Obtain Alfa Laval foundation requirements for new GFE components and perform foundation design and modifications to fit new GFE components:

a. Alfa-Laval MAB-104, Oil Purifier, w/ feed & discharge pumps & piping.

b. Alfa-Laval 1762733-09, Motor Starter Panel

c. Alfa-Laval 176119080, MAWA 10 Alarm system

d. Alfa-Laval 17661750-08, HEATPAC 16 KW

3.14.4. Install foundations in accordance with MLPAC Std Spec 074. Existing deck plate is shown in section 2.3.2 a,b,c.

3.14.5. Contractor shall furnish all materials such as piping, fitting, designs, etc. (except Government-furnished material) required to complete piping modifications necessary to plumb new purifier to existing piping.

3.14.6. Contractor shall determine and furnish all cables, designs, etc. required to provide electrical power to GFE listed in section 1.2.1. to include any existing remote alarm capabilities.

3.15. PIPING CLEANLINESS AND TESTING

3.15.1 All new and modified piping shall be cleaned with lint free materials to achieve a level of visual cleanliness to be verified by Coast Guard Inspector before assembly.

3.15.2 All new and modified piping shall be operationally tested for a minimum of 30 minutes prior to inspection of the first joint by the CG Inspector with no leakage noted. No external leakage or permanent deformation is allowed. Repair and retest all leaks.

3.15.3 Correct all deficiencies and retest until correct. Provide a copy of all test data and results to the Coast Guard Inspector within 48 hours following completion of tests.

3.15.4 Flange gasket materials shall be synthetic rubber per MIL-PRF-1149 or synthetic rubber cloth inserted per HH‑P‑151 or non-asbestos sheet per MIL-G-24696. An alternate gasket material shall be man-made non asbestos compressed fiber gaskets of the same size as those removed. Suitable materials include but are not limited to Garlock 3200, Chesterton 195, Accord 533N, and John Crane 2160.

3.15.5 Flange bolting fasteners shall be monel fasteners in accordance with Federal Specifications QQ-N-281, Class “A” for bolts or studs, Class “A” or “B” for nuts. Do not use stainless steel fasteners on bronze flanges/valves.

3.15.6 Pipe bends shall be in accordance with MIL-STD-1627. Minimum pipe bend radius shall be five (5) times nominal pipe diameter.

3.15.7 Notifications & Inspections – The contractor shall be responsible for notifying the Contracting Officer at least seven (7) working days prior to said contractor being ready for any inspections or testing.

4.0 QUALITY ASSURANCE

4.1. General – The contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Coast Guard.

4.2. Records – The contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3. Calibration System – The contractor as well as any subcontractor’s, shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-1. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4. Responsibility for Inspection – The contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor shall provide space, personnel, and test equipment for the conduct of all inspection requirements The Coast Guard reserves the rights to verify or have performed any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.5. Responsibility for Compliance – All items shall meet the provisions of sections 3 & 4. The inspections set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.6. Inspection System – The contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Coast Guard.

4.6.1. Specifications currently in use.

a. ANSI/ASQC Q9001-1994 – Quality Systems – Model for Quality Assurance in Design, Development, Production, Installation, and Servicing.

b. ANSI/ASQC Q9002-1994 – Quality Systems – Model for Quality Assurance in Production, Installation, and Servicing.

c. ANSI/ASQC Q9003-1994 – Quality Systems – Model for Quality Assurance in Final Inspection and Test.

4.7. Classification of Inspection – Indicate the type of tests that shall be required under this specification, i.e. first article, production, or a combination thereof. The demonstration of quality, either by testing or limited inspection, is the key to enforcing the requirements of a contract.

4.8. Tests & Inspections – The inspections/tests required here and in subsection 3.15. are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the contractor to assure the quality of the item in question.

4.9. WELDING EXAMINATIONS – The Contractor shall perform the following weld examinations:

4.9.1. In the presence of the COTR or Government Inspector, visually inspect and conduct a dye penetrant (PT) weld inspection of all new piping and fittings welds in accordance with NAVSEA T9074-AS-GIB-010/271 and MIL-STD-1689. The COTR and the Contractor shall jointly determine whether a MT or PT test shall be used. Test acceptance standards shall be to Class III criteria in accordance with MIL-STD-2035(SH). Repair all weld deficiencies and retest

4.9.2. Provide a written report of nondestructive test findings to the COTR or Government Inspector.

4.10. Operational Testing

4.10.1. Refill lube oil system of any lost oil and perform initial start-up of new lube oil purifier with Alfa- Laval Technical Representatives guidance and instructions. Conduct a comprehensive operational test of the purifier and associated components.

4.10.2. Following the test, an inspection shall be made in the presence of the Coast Guard Inspector to ensure proper operation and balance and to determine whether all parts and components appear to be in their proper configuration

4.10.3. Witness and record the operation of all mechanisms and any unsatisfactory conditions encountered. Correct all defects, and retest until a satisfactory test is acquired.

4.10.4. Submit a written CFR of all tests and inspections to the Coast Guard Inspector and COTR within 48 hours.

4.11. Failure Responsibility – If the specified item fails to pass any inspection/test the contractor shall report the failure and the recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

4.11.1. General Statements

a. The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action.

b. The inspection/test shall be discontinued until all corrective action has been taken.

c. After all corrective actions have been taken the inspection/test shall be continued or repeated at the option of the Contracting Officer.

d. Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

e. All corrective actions shall be documented as part of the contractor’s inspection system and submitted for approval to the Contracting Officer.

f. Each corrective action report shall include, but not be limited to the cause of each defect, corrective action suggested, and the steps taken to prevent a recurrence of each defect.

4.12. Test & Inspection Reports – One copy of any required inspection, test or tolerance check shall be sent to the Contracting Officer.

5.0 COMPARTMENT RESTORATION

5.1. Upon completion of successful non-destructive testing, prepare all new and disturbed surfaces in accordance with SSPC-SP 2.

5.2. Feather the surrounding surfaces to obtain a 3-inch wide, smoothly tapered boundary from the existing paint to the prepared surface.

5.3. Prepared areas are to be inspected and verified by the COTR or Government Inspector prior to application of any coating.

5.4. SURFACE COATING

5.4.1. Coat all prepared surfaces to match surrounding surfaces in accordance with the applicable tables of COMDTINST M10360.3. The Contractor shall ensure that all prepared surfaces are dry and free of dirt, dust, grease, grit, or other contaminants.

5.4.2. Upon verification from the COTR or Government Inspector on all surface preparation, prime and coat the disturbed and prepared surfaces in accordance with COMDTINST M10360.3. For surfaces to be covered with insulation, apply primer coats only.

5.4.3. Coat all new and disturbed piping systems in accordance with COMDTINST M10360.3.

5.5. INSULATION AND LAGGING

5.5.1 All insulation and lagging disturbed in conjunction with this item shall be renewed in accordance with Coast Guard Dwg 378-FRAM-W 508-1, Dwg 378-FRAM-E 508-1 and NSTM Chapter 635.

5.6

RESTORATION

5.6.1 Restore all interferences to their original condition in accordance with the General Requirements.

5.6.2 Restore affected work areas to a clean condition.

6.0 NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Specification and Standards (DODISS Documents)

Standardizations Document Order Desk

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA. 19111-5094

215-697-1187 http://dodssp.daps.dla.mil/dodiss.htm

b. USCG Maintenance & Logistics Command Pacific (MLCPAC) Federal Building 1301 Oakland, CA. 94612 http://www.uscg.mil/mlcpac/vDiv/platform_support.asp

c. Naval Sea System Command (NAVSEA) 1333 Issac Hull Ave Washington Navy Yard, DC. 20376 http://www.navsea.navy.mil d.

Occupational Safety & Health Administration

200 Constitution Ave

Washington, DC. 20210 www.OSHA.org

6.1.2. Commercial Documents

a. American Society of Mechanical Engineers (ASME) P.O. Box 2300 Fairfield, NJ>07007 800-843-2763 http://www.asme.org/Codes/

b. American Society for Testing & Materials (ASTM)

1916 Race Street

Philadelphia PA. 19103-1187

215-299-5585

FAX 215-977-9679

http://www.astm.org/

c. The Society for Protective Coatings (SSPC) 40 24th street Pittsburgh, Pa. 15222 877-281-7772 http://www.sspc.org/contact.html

d. American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

212-642-4900 http://www.ansi.org/

e. American Welding Society (QAWS)

550 N. W. Lejeune Road

Miami FL. 33126

305-443-9353

FAX 305-443-7559

http://www.aws.org/w/a/