0310_A_(REV_A)_SWBD_Mods_Engine_Room_Vent_Inspect_and_Repair.doc

USS FRANK CABLE

AS-40

2 February 2017

SWITCHBOARD MODIFICATIONS ENGINE Room VENTILATION inspection & RePAIR(T-ALT AS40 12-016)”SPECIAL CONTROL SPACES”

1.0 ABSTRACT:

This item describes Engine Room ventilation inspection in support of the switchboard modifications.

2.0 REFERENCES:

2.1 MSC Drawing 501-4797066, AS 41, Engine Room Ventilation

2.2 MSC Drawing 115-4796405, AS 41, Miscellaneous Structural Vent Trunks & Plenums

2.3 MSC Drawing 501-4797064, AS 41, HVAC General Notes & Standard Details

2.4 MSC Drawing 501-4797065, AS 41, HVAC Misc. Details

2.5 MSC Drawing 803-7081122, General Technical Requirements (GTR)

2.6 2.1-004-All Lockout-Tagout, MSFSC Safety Management Procedures Manual.

2.7 MSC Drawing 512-8496026, USS Frank Cable, Engine Room HVAC Supply System Duct Replacement

2.8 Abs Steel Vessel Rules for Survey After Construction

2.9 MSC Drawing 512-8496066, HVAC Duct Replacement System Installation Operation Test Procedure

2.10 MSC Drawing 512-8496065, HVAC New Supply System Installation Operation Test Procedure

2.11 MSC Drawing 501-6341227, As-41, Installation Vent Watertight Closures Instl Halon 1301 Fire Extinguisher System

2.12 Military Sealift Fleet Support Command (MSFSC) Standard Work Item for Repetitive Repair Requirements Dated: 22 March 2010, Item No. 19, Motor and Ventilation Fan Repairs

2.13 Military Sealift Fleet Support Command (MSFSC) Standard Work Item for Repetitive Repair Requirements Dated: 22 March 2010, Item No. 04, Ventilation System Cleaning Requirements

2.14 NAVSEA Drawing AS40-800-7362894 Rev C, USS Frank Cable Nuclear/NonNuclear Interface Booklet.(FOUO)

3.0 ITEM LOCATION AND DESCRIPTION:

3.1 Locations/Quantity

3.1.1 Locations:

3.1.1.1 PIPE SHOP 1-106-0-Q

3.1.1.2 TEST LAB 1-109-1-Q

3.1.1.3 LAGGING SHOP 1-110-2-Q

3.1.1.4 MACHINE SHOP 2-98-0-Q

3.1.1.5 UPTAKE 2-123-0-Q

3.1.1.6 S.D. STOREROOM 3-110-0-A

3.1.1.7 MOORING STATION No. 5 3-110-1-Q

3.1.1.8 MOORING STATION No. 6 3-110-2-Q

3.1.1.9 ENGINE ROOM 7-110-0-E

3.1.2 Systems:

3.1.2.1 Supply S-3-110-1

3.1.2.2 Supply S-3-110-2

3.1.2.3 Supply S-3-122-3

3.1.2.4 Exhaust E-3-122-1

3.1.2.5 Exhaust E-3-122-2

3.1.2.6 Exhaust E-3-122-4

3.2 Item Description/Manufacturer’s Data

3.2.1 Bill of Materials

PC NO. QTY Description (See References 2.1, 2.2, and 2.11 for guidance)

3.2.2 Quantities given in the List of Materials are considered estimates. The Contractor shall provide these quantities and reasonable additional material in order to install a fully functional system that meets the requirements of this specification.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIALS/SERVICES

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material (GFM): None

4.3 Government Furnished Services (GFS): None

4.4 Government Furnished Information (GFI): None

5.0 NOTES:

5.1 The Contractor and Subcontractors must consult Military Sealift Command’s General Technical Requirements, (GTR’s), to determine applicability to this work item. The Contractor and all Subcontractors regardless of tier must comply with the requirements all applicable GTR requirements.

5.2 The Contractor and Subcontractors, regardless of tier, are advised to review other work items under this contract, to determine their effect on the work required by this item. Based on this review the Contractor shall plan and schedule work to minimize conflicts between work items.

5.3 THE CONTRACTOR AND ALL SUBCONTRACTORS SHALL CONTACT THE RADIOLOGICAL CONTROLS OFFICER (RCO) OR HIS DESIGNATED REPRESENTATIVE PRIOR TO PERFORMING ANY WORK IN NAVSEA 08 AREAS OF CONCERN AS OUTLINED IN REFERENCE 2.14, THE RADIOLOGICAL CONTROLS OFFICER (RCO) WILL DETERMINE IF THERE ARE SPECIAL REQUIREMENTS ASSOCIATED WITH THIS REQUIREMENT BASED ON ITS LOCATION AND WORK REQUIRED. THE RADIOLOGICAL CONTROLS OFFICER (RCO) SHALL CONTACT THE NUCLEAR SUPPORT FACILITIES PLANNING YARD (NSFPY) (CODE 2380.1 AT NORFOLK NAVAL SHIPYARD) IF HE HAS ANY QUESTIONS CONCERNING SPECIAL REQUIREMENTS.

5.4 The Contractor shall perform a ship check to retrieve accurate measurements and information before conducting work.

5.5 Materials not listed as Government Furnished (GFM) shall be furnished by the Contractor. The Contractor shall provide all labor and material required to accomplish this work item including but not limited to staging, space certification, contamination containment, full penetration welds, fire watches, removal and reinstallation of all interferences including insulation in way of repairs to effect a complete and finished end result.

5.6 Prior to initiating any work on the electrical system, de-energize and tag-out all sources of electrical power to the circuits involved in accordance standard electrical safety practices. Restore electrical power upon completion of all aspects of this work item.

5.7 All electrical work shall be performed in accordance with ABS, USCG, IEEE-45, and MIL-STD-1310(G) requirements.

5.8 New cable and/or mounting of equipment that requires welding or hot work performed in the service areas (from the interior or exterior) shall maintain the fire tightness to the satisfaction of the ABS surveyor and the MSCREP.

5.9 Any vacated penetrations or equipment removal from the service areas must be plugged and sealed for water tightness and fire tightness to the satisfaction of the ABS surveyor and the MSCREP.

5.10 Do not test any cable connected to a detector with a Megohm meter. Disconnect detectors before testing cables.

5.11 All welding shall be in accordance with the ABS Rules for Building and Classing Steel Vessels.

5.12 All disturbed surfaces will be repaired utilizing approved methods maintaining the water tight, fire tight, or smoke tight integrity of the bulkheads, decks or equipment.

5.13 All shipboard structure, hull insulation, sheathing, etc. damaged or disturbed by these modifications shall be repaired similar to the original or surrounding materials.

5.14 Minor deviations from the drawings are authorized if appearance, function and strength are not impaired.

5.15 Submit a Request for Deviation (RFD) to the MSC Representative for approval for any areas that appearance, function and strength are impaired.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 All work and testing shall be in accordance with the latest SOLAS regulations, ABS Rules for Building and Classing Steel Vessels, IEEE-STD-45, USCG Requirements, and to the satisfaction of and in the presence of the ABS Surveyor (if required), Manufacturer’s Representatives (as necessary), and MSC Representative (MSCREP).

6.2 All welding requirements shall be accomplished by certified welders and meet ABS and USCG requirements. All welders shall be certified to perform the type of welding required and documentation of such shall be current. Fire watches shall be posted by the Contractor during hot work.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Arrangements/Outfitting:

7.1.1 The Contractor shall design and make all necessary arrangements (temporary accesses, install padeyes and lifting gear, rigging path, etc.) to safely handle the Engine Room HVAC components and fixtures for inspection, using References 2.1 through 2.6 and 2.11 as guidance.

7.1.2 Remove all interference items necessary to accomplish the requirements of this Work Item. Mark, protect and properly store all interference items removed. Reinstall interference items and prove them operational when the requirements of this Work Item are complete.

7.1.3 Removals

7.1.3.1 Remove insulation using References 2.1, 2.3, and 2.5 as guidance.

7.1.4 Installation

7.1.4.1 Upon completion of cleaning and inspection, install or re-install insulation using References 2.1, 2.3, 2.5, and 2.11 as guidance.

7.2 Structural

7.2.1 Removals

7.2.1.1 Remove structural vent and plenum inspection covers using References 2.1 and 2.2 as guidance.

7.2.2 Installation

7.2.2.1 Re-install structural vent and plenum inspection covers using References 2.1 and 2.2 as guidance.

7.2.2.2 Install grounding straps on all fans re-installed using References 2.1 and 2.5 as guidance.

7.3 Mechanical/Fluids

7.3.1 Isolate and tag out the sections of vent systems being worked using References 2.1, 2.2, 2.6 and 2.11 as guidance and MSCREP-approved local tag out procedures.

7.3.2 Removals

7.3.2.1 For systems listed in paragraph 3.1.2: Remove and scrap all non-structural water tight supply duct on the third and second deck. Remove and scrap as required all non-structural watertight exhaust duct on the 2nd deck and third deck using References 2.1, 2.2, and 2.11 as guidance. Remove and scrap all non-structural Engine Room exhaust duct on the fourth deck and first platform using References 2.1, and 2.2, and 2.11 as guidance. The removals do not include structural duct or plenums as detailed by References 2.1 and 2.2.

7.3.2.2 Remove ventilation ducting and equipment using References 2.1, 2.2 and 2.11 as guidance as required to accomplish this work item.

7.3.2.3 Ducting selected for replacement as detailed in Reference 2.7 is covered by Work Item 308.

7.3.3 Modifications

7.3.3.1 None.

7.3.4 Installations

7.3.4.1 Replace non-structural duct removed according to paragraph 7.3.2.1: Install new water tight duct, baffles and divider plates on the third deck and above using Reference 2.1 and 2.11 as guidance. Install new Engine Room exhaust duct on the fourth deck and 1st platform using References 2.1 and 2.11 as guidance.

7.3.4.2 Note: Ducting selected for replacement as detailed in Reference 2.7 is covered by Work Item 308.

7.4 Electrical

7.4.1 Removals

7.4.1.1 Remove ventilation fans for systems listed in paragraph 3.1.2 through from ship to shop.

7.4.2 Accomplish the following:

7.4.2.1 Accomplish the requirements of Reference 2.12 to each electric motor listed in 3.1.2.

a. Dynamically balance each motor rotor with the impeller attached using Reference 2.12 for guidance.

b. Submit a report listing the results of 7.4.2.1 for each motor to the MSCREP.

7.4.3 Installation

7.4.3.1 Upon completion of all repairs, reinstall ventilation fans in their respective systems.

7.4.3.2 The Contractor shall verify fan rotation and direction of air flow for all affected ventilation systems to the satisfaction of the MSCREP.

7.5 Electronics:

7.5.1 None.

7.6 Cleanliness

7.6.1 Clean and gas free spaces as necessary in preparation for hot work. Clean and gas free affected enclosed spaces per local procedure as approved by the ship and/or MSCREP.

7.6.2 The Contractor shall, using References 2.1 and 2.13 as guidance, thoroughly cryogenically clean the interior surfaces of all Engine Room supply and exhaust systems. At the completion of the cleaning systems shall be free of all dirt, grease, lint, scale, rust and other foreign substance from their beginning to and including their weather deck terminus. Interior surfaces to be cleaned shall include vent ducts, structural ducts, plenums, terminus, louvers, dampers, trunks, screens, fan casing, fan blades, and registers. Cryogenic cleaning shall be accomplished using CO2 pellets (pellets shall not be larger than 1 micron), as well as appropriate nozzle and vacuum attachments suited for ventilation duct cleaning. Ducting selected for replacement as detailed in Reference 2.7 and Section 7.3.2.1 shall not be cleaned.

7.6.3 The Contractor shall clean the affected ventilation systems after completion of all work ensuring that no debris is present prior to starting the ventilation fans.

7.7 Preparation of Drawings/Documents:

7.7.1 Guidance Drawings - The Contractor shall provide drawings showing the details for repair or renewal of the wasted areas of the structural duct and plenums resulting from the wastage allowance inspection. These drawings shall detail renewals of the structural duct and plenums in accordance with ABS Steel Vessel Rules for Survey After Construction 7-A-4/29. The drawings shall detail area(s) to be cropped as well as repairs. A complete list of materials shall be included along with citations for weld procedures and tightness tests for ABS review.

7.7.2 Working Drawings - The Contractor shall provide drawings showing the results of the wastage allowance inspection of the structural duct, coamings, and plenums. These drawings shall detail as found thicknesses and recommended renewals of the duct and plenums in accordance with ABS Steel Vessel Rules for Survey After Construction 7-A-4/29.

7.7.3 Redline Drawings – None.

7.7.4 As-built Drawings

7.7.4.1 Contractor shall provide as-built drawings based off References 2.1 to 2.4 and the installed conditions.

7.7.4.2 As-built drawings shall be provided in AutoCAD 2004 and PDF (electronic format).

7.7.4.3 As-built drawings shall be provided to MSCREP and MSC Tech Library:

9276 3rd Ave., Bldg. LP-26

Norfolk, VA 23511

7.8 Inspections:

7.8.1 Inspect all structural duct, coamings, and plenums including baffles for wastage. Inspection shall be in accordance with ABS Steel Vessel Rules for Survey After Construction (Reference 2.8) 7-A-4/27. Acceptable wastage allowances for structural duct, coamings, and plenums including baffles shall be in accordance with ABS Steel Vessel Rules for Survey After Construction (Reference 2.8) 7-A-4/Table 1 as is applicable.

7.8.2 Welding and Brazing Inspection

7.8.2.1 The Contractor and MSCREP shall visually inspect new, modified, or repaired welds in accordance with ABS requirements.

7.8.2.2 The Contractor and MSCREP shall inspect all hot work prior to applying paint.

7.8.3 Painting Inspection

7.8.3.1 The Contractor and MSCREP shall conduct a joint inspection of areas disturbed by the installations. These areas are to be prepared and primed before final painting begins to ensure that protective measures are implemented.

7.8.3.2 The Contractor shall perform inspections after completion of each stage of surface preparation, each coat, and each stripe coat, to verify surface condition, dry film thickness (DFT), and space cleanliness, and before requesting final inspection by the MSCREP.

7.8.3.3 All painted areas shall be inspected prior to covering or insulating.

7.8.4 Other Inspections

7.8.4.1 The Contractor shall perform a preliminary inspection prior to calling out a formal inspection.

7.8.4.2 MSCREP shall inspect ventilation systems for cleanliness prior to placing the affected systems in service.

7.8.4.3 MSCREP shall inspect the paint and general condition of all affected systems, structures, arrangements, surrounding areas, etc.

7.9 Tests:

7.9.1 Tests shall be in accordance with GTR 3 (Reference 2.5), Reference 2.3, Reference 2.9, Reference 2.10, and as described herein to the satisfaction of the MSCREP.

7.9.2 Preliminary Tests:

7.9.2.1 The Contractor shall conduct preliminary tests on all completed work before calling for an official test.

7.9.3 Tightness Test:

7.9.3.1 The Contractor shall verify that all structural work, including any structural attachments or penetrations which would affect the tightness of the structure, is complete and ready for service.

7.9.4 Operational Test:

7.9.4.1 The Contractor shall perform an operational test of all new and modified systems and equipment. Operational test on all new and modified systems shall be per References 2.3, 2.9, 2.10, and GTR 3 (Reference 2.5). Operation of the new systems and equipment shall be performed to the satisfaction of the MSCREP.

7.9.4.2 Test and balance all new and modified ventilation systems in accordance with References 2.5, 2.9 and 2.10.

7.9.5 Completion Test:

7.9.5.1 The Contractor shall perform a completion test and provide documentation proving that all aspects of the work item have been completed. A completion test may include a series of functional, operational, and hydrostatic tightness tests. The Contractor shall demonstrate that the installation is USCG and ABS compliant and that the equipment installations are complete and ready for service.

7.9.6 Inspection and acceptance of work shall be by the MSC representative (MSCREP) and ABS Surveyor.

7.9.7 The Contractor’s quality assurance plan shall be invoked for all aspects of this Work Item.

7.10 Painting:

7.10.1 Clean and prepare the disturbed areas and apply primer and two topcoats of paint to all areas disturbed to match the surrounding areas per MSC GTR 7 (Reference 2.5).

7.10.2 The Contractor shall prepare the surface, and then paint the interior of the structural duct, coamings, and plenums with MIL-DTL-24441 polyimide paint in accordance with the paint manufacturer’s recommendations. Two coats of green primer, MIL-DTL-24441/29B (Formula 150 Type IV) and one topcoat of haze gray, MIL-DTL-24441/30B (Formula 151 Type IV) shall be used.

7.11 Marking

7.11.1 Contractor to reinstall or replace name plates for all affected areas and to stencil flow direction per MSC GTR 29 (Reference 2.5) for new and repaired ventilation and piping.

7.12 Manufacturer’s Representative: None additional

8.0 GENERAL REQUIREMENTS:

8.1 All areas involved in work or traversed by workmen or equipment shall be left clean and in good order.

8.2 All waste matter resulting from this work item shall be collected in suitable containers provided by the Contractor and shall be disposed of by the Contractor in strict compliance with current U.S. Government, state and local antipollution and public health regulations.

8.3 All required tests and inspections shall be performed to the satisfaction of the USCG, ABS, and MSCREP as applicable.

8.4 No items shall be left for ship’s force disposal.

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