Sxx_51700_JAH_0915_378W_BOILER_SHELL_RENEWAL_modified_updated_-_no_5_year_cert.pdf

Sxx_51700_JAH_0915_378W_BOILER_SHELL_RENEWAL

WORK ITEM 1: Boiler Shells; Renew

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew the boiler shells of the

No. 1 and No. 2 Boilers with new government furnished boiler shells.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION MANUFACTURER PART

NUMBER

NIIN QTY

N ***Fire Tube Heating Boiler (Stbd) Johnston Boiler Company 509S-4PC-LH 01-507-1318 1 ea.

N ***Fire Tube Heating Boiler (Port) Johnston Boiler Company 509S-4PC-RH 01-484-5291 1 ea.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 378-FRAM-E 221-1, Rev -, Steam Heat Boiler Control Panel(Supercedes

715-Wpg

Coast Guard Drawing 378-FRAM-E 517-3, Rev -, Steam Heat Boiler Assy & Sect (Supercedes

715-Wpg-

Coast Guard Drawing 378-FRAM-E 517-4, Rev -, Auxiliary Boiler Retro-Fit Combustion Sys.

Boiler

Coast Guard Drawing 378-FRAM-E 517-5, Rev -, Auxiliary Boiler Retro-Fit Combustion

System Syste

Coast Guard Drawing 378-FRAM-E 517-6, Rev -, Auxiliary Boiler Retro-Fit Combustion

System Insta

Coast Guard Drawing 378-FRAM-E 320-19, Rev -, As Built Electrical One-Line Dia

Coast Guard Drawing 378-FRAM-W 234-13, Rev -, Spec Drawing FT4A-2/A-6 Gas Turbine

Enclosure

Coast Guard Drawing 378-FRAM-W 251-1, Rev -, Propulsion Diesels Plenum Air Intake Filter

A&D

Coast Guard Drawing 378-FRAM-W 534-1, Rev -, Steam Condensate System Diag

Coast Guard Drawing 378-FRAM-W 534-2, Rev -, Steam & Condensate System in Machinery

Space Arrgt

Coast Guard Drawing 378-FRAM-W 801-1, Rev -, Booklet of General Plans

Coast Guard Drawing 378-FRAM-W 111-1, Rev -, Shell Expansion Forward

Coast Guard Drawing 378-FRAM-W 111-2, Rev -, Shell Expansion Aft

Coast Guard Drawing 378-FRAM-W 508-1, Rev -, Insulation Schedule

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3273, Manufacturer's Instruction Book, SWBS Group(s)

517-529

Coast Guard Technical Publication (TP) 4681, Auxiliary Boiler Retro-Fit Combustion System –

Micro2000

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

NAVSEA Dwg 804-5959214, Insulation, Piping

ASTM International (ASTM) F683, 2008, Standard Practice for Selection and Application of

Thermal Insulation for Piping and Machinery

Naval Ship's Technical Manual (NSTM) Chapter 635, Jul 1998, Thermal, Fire and Acoustic

Insulation

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP

3), 2004, Power Tool Cleaning

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of qualified Tech Rep, who is familiar with the Technical Marine Service, Inc. (TMS) Boiler Control, Fuel-Air Mixture, and Exhaust Gas Monitoring

System, to accomplish the following tasks – on site:

Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

Assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

3.1.2.1 The Contractor shall ensure that the Tech Rep is a certified representative of Technical Marine

Service, Inc.

3.1.2.2 The Contractor shall submit the name of the Tech Rep to the COTR at the Arrival Conference.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec

0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following:

Sheathing

Bulkhead insulation

Pipe hangers

Pipe insulation

Electrical wireways

Vent Plenum steel bulkhead

Vent Plenum insulation

Upper Vent Plenum ventilation louvers

Soft patches

Hot well tank

Steam pipes

3.2 Boiler Shell Renewals. The contractor shall perform the following work:

3.2.1 The Contractor shall provide all labor, material and equipment including crane services (except the

Government-Furnished Property/Material, GFM) to accomplish the removal of the existing boiler shells and the installation of the new GFM boiler shells in accordance with Coast Guard Technical Publication

(TP) 3273, Manufacturer's Instruction Book, SWBS Group(s) 517-529. The contractor is required to provide a system with certain operational capabilities, within certain parameters. The details required to reach this desired state are NOT specified in complete detail, and are the responsibility of the contractor.

A verification shipcheck by the Contractor prior to bidding is recommended to determine any major interference, piping routes, etc. during removal and installation of equipment, piping, and components.

CG Dwg FRAM-W 234-13, FRAM-W 251-1, and FRAM-W 801-1 may be used as guidance.

NOTE

The GFM being provided consists of new boiler shells. The shells are not lagged and do not have attachments installed. The Contractor shall reinstall the attachments and install new fasteners, gaskets and lagging on the new boiler shells. Current insulation blankets on boilers may be reused.

The access route for the boilers will be through the Main Gas Turbine Plenum Air Intake and

Boiler Flat.

3.2 .2 In the presence of the Coast Guard Inspector, The Contractor shall inspect all affected equipment and systems (including those subject to interference/removal) to document original condition. Submit a

CFR for each affected space noting any discrepancies in equipment and system operation.

3.2.3 The Contractor shall develop a routing and access plan. Considerations shall include disruption of services, safety, and shop fabrication versus onboard fabrication. Shipping access routes and cuts are the responsibility of the Contractor, but shall be coordinated with the Coast Guard Inspector prior to accomplishment. Contractor shall submit routing and access plan, including all access cuts, via CFR 24 hours prior to making any structural modifications to the vessel. This plan must be approved by the COR.

Previous boiler installations on other 378 Class vessels have used access cuts through the Main Gas

Turbine Air Intake Plenums, however, this route is just a suggestion, and the contractor is still responsible for the best possible route to accommodate this task. Information concerning plant lay out may be found in the drawings associated with this specification item. All interferences affected by work shall be replaced or renewed to initial condition.

3.2.3.1 Any padeyes used in the rigging plan – both new and existing – shall be tested with the test force applied in the same direction as the expected working load is normally applied.

3.2.3.2 The following proof loads will be used in testing all padeyes. Padeyes shall be sized in accordance with the diameter of the stock directly above the hole or eye of the padeye. A dynamometer shall be installed in the test lead immediately adjacent to the padeye to record the actual test load being applied. Supply a copy of the dynamometer calibration certificate to the Coast Guard Inspector. The test proof loads below are static loads. Dynamic loads will not be used.

Padeye Size Working Load Proof Test Load

1/2" 2,000 lbs. 3600 lbs.

3/4" 5,800 lbs 8,700 lbs

1" 9,800 lbs 14,700 lbs.

3.2.3.3 Conduct dye penetrant weld inspection on all padeye welds. Dye penetrant weld inspections shall be in accordance with NAVSEA T9074-AS-GIB-010/271. Test acceptance standards shall be in accordance with MIL-STD-2035. Repair all weld deficiencies and retest until correct.

3.2.3.4 After inspection and testing, prime and paint all new padeyes with one coat of epoxy paint.

Repair any disturbed insulation and touch up paint in accordance with SFLC STD SPEC 6310 to match surrounding area. Affix a label plate, inscribed with the test load and date tested adjacent to each padeye. All padeyes installed by the contractor shall remain in place at the end of the contract unless removal is required to facilitate reinstallation of equipment.

3.2.4 In the presence of the Coast Guard Inspector, The Contractor shall inspect Main Gas Turbine

Enclosure, Air Intake Plenum and Boiler Flat to verify cleanliness and condition prior to starting work and after completion of work.

3.2.5 In the presence of the Coast Guard Inspector, The Contractor shall inspect and inventory all GFM before work begins to ensure that all material has been furnished and submit a CFR. The Contractor shall be responsible for GFM lost or damaged while in his custody. Contractor shall turn over to the

Coast Guard Inspector all technical documentation, manual, and information upon completion of testing.

3.3 Structural removals. The contractor shall perform the following work:

NOTE

The Contractor shall remove and reinstall structural items as required to accomplish the work in this item. The Contractor in their determination of the necessary cutout may use information contained in referenced drawings and tech pubs.

3.3.1 The Contractor shall plug, cover, or blank flange all open piping prior to and during work.

3.3.2 The Contractor shall fabricate and install new padeyes in the Engine room, Main Gas Turbine Air

Intake Plenum and supports as required.

3.3.3 The Contractor shall set up a staging platform inside the Main Gas Turbine Air Intake Plenum for aid in removing and reinstalling of the new boiler shells.

3.3.4 The Contractor shall mark sections of the bulkhead and any required structural sections for approval by the Coast Guard Inspector prior to commencing rip out.

3.3.5 The Contractor shall crop out the structural sections as required to remove the boiler shells. The cutout bulkhead should be saved for re-welding during restoration.

3.3.6 The Contractor shall remove the turbine intake squirrel cage and the turbine dog house as required to remove the boiler shells. Cover and protect the turbine intakes to ensure no contamination enters the turbines during this work. Remove the turbine intake covers upon completion of this work and reinstall the squirrel cage and dog house.

3.4 Mechanical removals and installations. The contractor shall perform the following work:

3.4.1 The Contractor shall remove the existing No.1 and No. 2 boiler shells through the determine route and access as describe in section 3.1 and section 3.2. Boiler weight: empty 5600 lbs, full 8440 lbs.

3.4.2 The Contractor shall install temporary caps or other suitable plugs on open piping upon removal to protect the system from contamination if installation is not immediately done. Contractor shall maintain a plug log and submit to the Coast Guard Inspector upon completion of all work.

3.4.3 The Contractor shall Remove all attachment pipes and gages, and all necessary equipment from the boiler. Use the old boiler as a template, remove to the dockside to verify the rout and access plan. The attachments include: piping connections, combustion controls, water level controls and alarms, feed connections, steam connections, exhaust gas connections, chemical sampling connections, blow down connections, burner assembly, blower assembly, gage glass assembly, and any other attachments to the main boiler shell.

3.5 Boiler Installation. The contractor shall perform the following work:

3.5.1 The Contractor shall install the new No. 1 and No. 2 boiler shells in accordance with Coast Guard

Technical Publication (TP) 3273, Manufacturer's Instruction Book, SWBS Group(s) 517-529 and all drawings mention in the References.

3.5.2 The Contractor shall supply all material (except the Government-furnished material) to accomplish the replacement of the boiler.

3.6 Hydrostatic testing. The contractor shall perform the following work:

NOTE

Previous boiler installations on various WHEC Class vessels have demonstrated that the new boiler shells may have tube leaks or plugged tubes. The new boiler shells will be tested after installation to ensure that the boilers are ready for operation.

3.6.1 The Contractor shall disassemble the new boiler shells as required to conduct hydrostatic tests on each boiler. Blank any flange connections on the boiler shell using blank flanges and gaskets in preparation for hydrostatic testing.

3.6.2 The Contractor shall hydrostatically test each boiler shell by filling the boiler shell with clean fresh water (water temp shall be between 70 to 120 F) with outlets and sight glass valves closed. Apply pressure to 1.5 the working pressure or 225 psi. Hold this pressure for 10 minutes and check for leaks.

Inspect for leaks. Neither external leakage nor permanent deformation is allowed. Conduct the hydrostatic test in the presence of the Coast Guard Inspector. Submit a CFR. Contractor shall reroll any tubes found to be leaking; the re-rolling shall be the subject of a contract modification.

3.6.3 The Contractor shall repair and retest all leaks. Conduct this second hydrostatic test in the same manner as the first test. Demonstrate that no tubes leak and that all repairs have been completed satisfactorily. Conduct the hydrostatic test in the presence of the Coast Guard Inspector.

3.6.4 The Contractor shall drain the water from the boilers and dispose of the water in accordance with all federal, state, and local regulations. Each boiler contains approximately 350 gallons of water. If contractor elects to drain this water to the bilge, contractor will be responsible for conducting an oily waste offload equal to the number of gallons drained into the bilge.

3.7 Boiler reassembly. The contractor shall perform the following work:

3.7.1 The Contractor shall attach all components that were removed from the old boiler casings to the new GFM boiler casings. Remove the blank flanges and install the proper assemblies at each location using new gaskets and fasteners.

3.8 Combustion Control Tech. Rep. The contractor shall perform the following work:

3.8.1 The Contractor shall provide the services of a Technical Marine Service, Inc. (TMS) Boiler

Control, Fuel-Air Mixture, and Exhaust Gas Monitoring System boiler control technician in accordance with paragraph 3.2 to adjust, set, calibrate and ensure the automatic controls on each boiler are reinstalled and functioning as designed.

3.9 The TMS Technical Representative shall test operate each of the boiler operating controls. Adjust the linkage to the firing rate motor and the damper. Verify proper operation of water levels, steam pressure switches and controls.

3.9.1 Verify the setting of each of the boiler safety valves.

3.10 Foundation preservation. The contractor shall perform the following work:

3.10.1 The Contractor shall power tool clean the boiler and equipment foundations in accordance with

SSPC-SP 3.

3.10.2 The Contractor shall paint the foundations with 2 coats of epoxy paint to match the existing in accordance with SFLC Std Spec 6310.

3.11 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.)

3.12 Acceptance testing. The contractor shall perform the following work:

3.12.1 The Contractor shall notify the Coast Guard Inspector no later than 24 hours prior to any testing.

This procedure will assure assignment of qualified test witnesses.

3.12.2 Test Performance – All acceptance tests shall be performed in the presence of the Coast Guard

Inspector. Provide a written report to the Coast Guard Inspector of all test results within twenty four hours of test completion.

3.12.3 With the aid of ship's force, the Contractor shall fill each boiler to operating level with distilled water. The contractor will provide approximately 1500 gallons of distilled water to be added to the ship's feed water tanks to fill each of the boilers for operation. Coordinate filling the feed tanks and the boilers with the ship's force.

3.12.4 The Contractor shall conduct an operational test of each new boiler installation. Operate each boiler for a minimum of twenty-four (24) hours, cycling through all firing rates. Inspect all connections and repair any leaks. The Coast Guard crew will operate all equipment.

3.12.5 The Contractor shall 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.

3.13 New insulation installation. The Contractor shall reinstall existing insulation material over the new boiler shells and install new insulation over exposed pipe surfaces. If the existing material is disturbed and unusable, renewal of boiler shell insulation shall be the subject of a contract modification. All KTR provided insulation, including associated pipe hangers, valves, fittings, and flanges, shall be in accordance with details in NAVSEA Drawing 804-5959214; select appropriate insulation materials and thicknesses for the application and temperature ranges specified in ASTM F683, Tables S1.1, S1.2, and

S1.4. Paint the newly installed insulation system, in accordance with SFLC Std Spec 6310, using the system specified for “Insulation Surfaces, Fiberglass Sheet/Closed Cell PVC Foam” in Appendix B

(Cutter and Boat Interior Paint Systems).

4. NOTES

This section is not applicable to this work item.