WORK ITEM 74 Rev1 Hydraulic Steering Cooler Install.pdf

USCGC SPAR (WLB-225B) DRYDOCK AVAILABILITY 2012

TCTO06-037_56100_CKN_0811_225B

WORK ITEM 74 Rev1: Hydraulic Steering Cooler, Install

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to install a pair of hydraulic steering coolers to provide cooling for the hydraulic steering system, in the Steering Gear Room (1-102- 0-E).

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

N Heat Exchanger (37”x12” and 4” thick) ITT Model P7A-8-TK 2 $10,000.00

N Thermostatic Valve AMOT Model CM – Bronze Body 1-7/8” -12

2 $ 1,500.00

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 225B-WLB 256-001, Rev M; Seawater Cooling Sys Diagram Coast Guard Drawing 225B-WLB 505-1, Rev D; General Requirements for Piping Systems Coast Guard Drawing 225B-WLB 561-005, Rev -; Steering Gear Heat Exchanger Replacement Coast Guard Drawing 225B-WLB 671-001, Rev. E, Misc. Stowage Arrangement & Details Coast Guard Drawing 225B-WLB 561-001, Rev C, Steering Gear Hydraulics Diagram

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color

Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 0850 (SFLC Std Spec 0850), Jun 2009, General Requirements for Drawing Preparation Coast Guard Technical Publication (TP) 3555, 21-May-1996, Steering Gear Systems

OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative.

Not applicable.

3.1.3 Protective measures.

Not applicable.

3.1.4 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph

3.3.5 (Interferences):

• Piping and hoses.

• Electrical panel and cable trays.

• Control boxes and FF equipment.

3.2 Operational test - initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR.

3.3 Removals.

3.3.1 The Contractor shall disconnect and remove the hydraulic return piping for both pumps on the Steering Gear HPU, as shown on Coast Guard Drawing 225B-WLB-561-005.

3.3.2 Cap or blank off existing hydraulic connections, to minimize the risk of contamination.

3.3.3 Remove and dispose of the AFFF canister rack, as shown on Coast Guard Drawing 225B-WLB- 671-001.

3.4 Installations and modifications. The Contractor shall accomplish the following tasks, as shown on Coast Guard Drawing 225B-WLB-561-005:

3.4.1 Fabricate and install the heat exchanger foundation.

3.4.1 Locate and mount the heat exchangers on the foundation.

3.4.2 Install the hydraulic piping, valves and fittings connecting the Steering Gear HPU to each heat exchanger, as shown on Coast Guard Drawing 225B-WLB-561-005.

3.4.3 Install the auxiliary saltwater piping, valves and fittings from the ASW header to each heat exchanger and from each heat exchanger to the overboard discharge, as shown on Coast Guard Drawing

225B-WLB-561-005.

3.4.4 Fabricate and install the new AFFF canister rack as shown in the Coast Guard Drawing 225B-

WLB-671-001.

3.5 Temporary ASW connections . The auxiliary sea water (ASW) system is normally required to remain online import to provide cooling to the air conditioning condensers and the vessel refrigeration unit. The ASW system may need to be temporarily secured in order to connect the new ASW piping for the hydraulic oil heat exchanger to the existing ASW system. In the event that this system may need to be secured to accomplish this engineering change, the contractor may need to provide a temporary alternate source of ASW to equipment that normally uses this ASW import. The contractor shall work with the Coast Guard inspector and vessel Engineering Officer when necessary to determine if there will be a need for this requirement. The contractor shall determine the proper location and method to provide this temporary connection. Submit CFR and Change Orders for any additional work.

3.6 Air cooler removal and heat exchanger installation.

3.6.1 Using Coast Guard Drawings 225B-WLB 256-001 and 225B-WLB 561-001 as guidance, remove the existing air coolers and install the new GFE heat exchangers. Install the new salt water and over board discharge piping.

3.6.2 Contractor shall position new cooler, foundation and associated piping to minimize interferences and amount of disassembly needed to perform cooler maintenance (i.e., adequate pull space shall be provided to allow maintenance of one cooler while other cooler remains operational). Using the above noted Coast Guard Drawings as guidance, accomplish required piping removal/installation. Prior to removal Contractor shall chalk the sections of piping to be removed and obtain Coast Guard Inspector concurrence.

3.6.3 Air cooler removal. Disconnect the existing air coolers from the system. Turn over the coolers to the Coast Guard Inspector for final disposition. Cut off and grind smooth any brackets or studs used to hold the cooler.

3.6.4 New ASW piping to coolers. Install approximately 70 ft of new 1 ½ inch CuNi ASW piping to coolers as shown in attached detail figure..

3.6.5 New ASW piping from coolers. Install approximately 12 ft of new 1 ½ inch CuNi ASW piping from coolers. as shown in attached detail figure. The over board discharge is located in the Stern Thruster Room.

3.6.6 Plate heat cooler Installation. Install plate heat coolers as shown in referenced figure. The piping of ASW to and from coolers is combination of CuNi piping and flexible hydraulic hoses in accordance Tech Pub 3555. Contractor shall install bracket, hanging fixture and hardware for these coolers. Cooler dimension 37”x12” and 4” thick.

3.7 Design modification - The new plate cooler will be oriented fore and aft direction about 4 ft of the deck with piping connections facing the steering system.

3.8 Thermostatic Valves Installation – Install new GFE thermostatic valves in between hydraulic supply lines to coolers (steering return lines) and oil cooler inlet, with other leg to the sump (diverting position).

Contractor and CG Inspector should verify the direction of flow of these valves prior to install.

NOTE!

Thermostatic Valves are: Self Actuated Type; Model C; Threaded Connections; Stainless Steel;

Max Flow Rate of System 21gpm; Temp Setting 110F.

3.9 Piping Connections - Install new piping, valves and fittings as shown in reference figures. The Contractor shall mark all new proposed piping routes and obtain Coast Guard Inspector concurrence prior to proceeding with permanent modifications.

3.9.1 All new piping, takedown joints, fittings, valves, flexible connections gaskets, nuts and bolts required to complete the piping modifications above shall be in accordance with the piping system requirements contained on CG Dwgs 225B-WLB-505-001 and 225B-WLB-256-001.

3.9.2 Fabricate and install additional hangers needed to adequately support the newly installed piping in accordance with SFLC Std Spec 0000. Bulkhead or deck penetration (s) be shall be fabricated and installed in accordance with procedures and notes shown on SFLC Std Spec 0000.

3.9.3 Local Thermometers - In addition to the work shown in reference figure, install local temperature gages in each location to allow the ship to read the temperature of the inlet and discharge from the coolers.

3.9.4 Isolation Gasket Installation - Due to the dissimilar of metals on cooler system (Titanium plates and Copper-Nickel piping), isolation gasket kit should be installed on Steering Gear System Lube Oil Coolers to prevent galvanic corrosion.

3.10 Operational test – post repairs. After completion of work, the Contractor shall witness an operational test (by Coast Guard personnel) of all items or shipboard devices that have been disturbed, used, repaired, altered, or installed, to prove that they are in satisfactory operating condition. Submit a

CFR.

3.10.1 Hydrostatically test the newly installed ASW piping, hoses and connectors to 90 psig in accordance with the directions shown in reference 225B-WLB 561-1. Demonstrate that there is no leakage to the Coast Guard Inspector.

3.10.2 Operationally test the newly installed coolers. Demonstrate that there is no leakage to the Coast Guard Inspector.

3.10.3 Repair any leaks and retest in the presence of the Coast Guard Inspector.

3.11 Reassembly. Remake all connections. Refill the steering system with hydraulic steering oil to include the new install coolers.

3.12 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed exterior and interior surfaces to match existing adjacent surfaces, in accordance with COMDTINST M10360.3, Appendix A (Cutter and Boat Exterior Painting Systems) and Appendix B (Cutter and Boat Interior Painting Systems), respectively, and as applicable. Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

3.13 Label plate. The Contractor shall install a label plate to document satisfactory test completion in accordance with SFLC Std Spec 5000, Appendix B, Paragraph B2.9 (Label Plates).

4. NOTES

This section is not applicable to this work item.