0210_A_1A_and_1B_Boiler_Repairs.docx

USS MOUNT WHITNEY

(LCC-20)

MACHINERY, PROPULSION RFP N32205-16-R-4601

Amend 005, 09 Jun 2016

1A and 1B BOILER REPAIRS

1.0 ABSTRACT

1.1 This item describes the repair/renewal of refractory, coping and brickwork in 1A and 1B boilers using materials and procedures in accordance with ABS and manufacturer recommended standards and as approved by the MSCREP.

2.0 REFERENCES:

2.1 NAVSEA Main Boiler Technical Manual S99221-AL-MMO-020

2.2 Drawing 4692826, Refractory Arrangement and Details

2.3 NAVSEA Tech Manual S9221-C1-GTP-010/020 Repair and Overhaul of Main Propulsion Boilers

2.4 NAVSEA Tech Manual S9074-AQ-GIB-010 248, Requirements for WeldingAmend005

2.5 NAVSEA Tech Manual S9086-GY-STM-010, NSTM 221, BoilersAmend005

2.6 NAVSEA Tech Manual S9074-AR-GIB-010/278, REQUIREMENTS FOR FABRICATION WELDING AND INSPECTION FOR MACHINERY, PIPING AND PRESSURE VESSELSAmend005

2.7 NAVSEA Tech Manual S9086-RK-STM-010 Chapter 505 Piping SystemsAmend005

3.0 ITEM LOCATION/ DESCRIPTION

3.1 Location: Boiler Room 8-76-0-E1.2

3.2Item Description/Manufacturer's Data: 1A & 1B Boiler:

3.2.1 Foster Wheeler Inc, Type V2M, 600 PSI, Main Propulsion Boiler. Amend 005

4.0 GOVERNMENT FURNISHED EQUIPMENMT/MATERIAL/SERVICES:

None

5.0 NOTES

5.1 The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTR's including but not limited to GTR's 1 through 7,22,23,27 and 29.

5.2 The contractor and all subcontractors, regardless of tier are advised to review other work items under this contract to determine their effect on the work required under this work item. The contractor should reference work items including, but not limited to work items. Many of the definitions relating to performance of this work item are found in Work item 001 (General requirements).

5.3 This work item shall be accomplished in conjunction with other MTW ESLP items specified in this work package specifically the 200 series regarding propulsion machinery.

5.4 The USS Mount Whitney is known to have a considerable amount of asbestos. Additionally, it is known that the coating systems may contain lead. The contractor should expect this condition and factor in removal and remediation time requirements into his overall planning schedule. Costs associated with unexpected hazardous waste remediation and removal shall be attributed to Work Item 023, rather than to the individual work items. Wastes removed in the course of the work package accomplishment shall be removed from the ship, handled and disposed of in accordance with Work Item 023 of this work package. Contractor shall be responsible to follow all international, national and US Federal regulations in the containment and removal of these wastes as encountered.

5.5 The Contractor is expected to use best management practice to identify and dispose of all hazardous waste. Every effort shall be made to minimize the disturbance, removal and handling of hazardous wastes in the accomplishment of the work package.

5.6 Template all undimensioned work from ship and equipment.

5.7 Contractor shall refer to Reference 2.2 inspection report as guidance.

5.8 Care should be taken to provide material of like type to the fire clay brick, mortar and cast refractory already found in the boiler to prevent reaction between refractory types and to provide for like expansion and material properties.

5.9 Contractor is to provide a schedule for initial light off period as to prevent damage and allow for the installed refractory to properly set.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 All work conducted shall be to ABS and manufacturer recommended standards and approved by the MSCREP.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Provide the services of a firm specializing in marine boiler refractory and brick repairs to accomplish work required in this item.

7.2 Temporarily remove all interference in way of removing and installing the burner fronts. Reinstall equal to existing when new upon completion of work.

7.3 Open, inspect and certify gas free “safe for men” 1A and 1B boiler furnace. Close up with CFM new “ASBESTOS FREE” gaskets upon completion of work.

7.4 Open 1A and 1B boilers to gain access to burner throats and the boiler floor.

7.5 1A Boiler work:

7.5.1 Using Refs 2.1 thru 2.7Amend005 for guidance, remove and replace steel deck brickwork and support. Remove and replace the steel furnace deck using anchored floors. Rebrick deck when complete. All new joints shall be 1/16” or less thick.

7.5.2 Upper Rear Wall Refractory: Remove and replace castable refractory between the upper rear wall tubes. For Bidding purposes and estimating labor, assume 10 bags (50 lbs bags) of castable to be applied.

7.5.3 Rear Wall Refractory: Remove and replace castable refractory of the rear wall. For Bidding purposes and estimating labor, assume 10 bags (50 lbs bags) of castable to be applied.

7.5.4 Side wall refractory: Renew the side wall refractory, coping and screen tubes refractory using reference 2.1, Plan D-9. Renew the entire coping length thickness to ensure strength and proper anchoring to S-clips. Install expansion joints correctly per Plan D-9. For Bidding purposes and estimating labor, assume 30 bags (50 lbs bags) of castable to be applied.

7.5.5 Inner boiler casing has light rust and loose flaking paint. For bidding purposes, provide mechanical cleaning of 30 sq mtrs and preserve with two coats of high heat resistant aluminum paint (TT-P-28 or equal) in the inner casing, to include all lower headers.

7.5.6 The boiler outer casing requires preservation. For bidding purposes, provide mechanical cleaning of 25 sq mtrs and preserve with two coats of high heat resistant aluminum paint (TT-P-28 or equal) using Refs 2.1 and 2.4 for guidance.

7.6 1B Boiler:Amend 005

7.6.1 Using Refs 2.1 thru 2.7Amend005 remove and replace steel deck brickwork and support. Remove and replace the steel furnace deck using anchored floors. Rebrick deck when complete. All new joints shall be 1/16” or less thick.

7.6.2 The inner casing supports by the screen wall header has multiple cracks, corroded and requires replacement. For bidding purposes, provide for the replacement of approximately 1 sq. mtr of inner casing supports using Refs 2.1 thru 2.7Amend005

7.6.3 The desuperheater nozzle inlet flange raised face seating surface requires minor resurfacing. Resurface the desuperheater inlet flange using guidance provided by References 2.1 thru and 2.7.

7.6.4 There is a 4 inch crack in the inner casing just above the screen wall header located at the rear area of the boiler. Grind out the crack and weld repair using References 2.1 thru 2.7 as guidance.

7.6.5 There is a 3 foot crack in the inner casing just above the sidewall header. Grind out the crack, and weld repair using References 2.1 thru 2.7 as guidance.

7.6.6 There is a 12 inch crack in the inner casing above the screen wall header. Grind out the crack and weld repair using References 2.1 thru 2.7 as guidance.

7.6.7 There are (2) broken studs and (2) incorrect fasteners on the steam drum belly plate support bracket. Grind off and weld repair the broken studs using References 2.1 thru 2.7 as guidance. Replace incorrect fasteners using References 2.1 thru 2.7 as guidance.

7.6.8 The stack has (4) 1/8 inch holes at the economizer outlet expansion joint. Weld repair the holes using References 2.1 thru 2.7 as guidance.

7.6.9 There is a 4 inch crack, along with (4) 1/8 inch holes and severe corrosion at the stack’s first expansion joint, located (6) feet above the economizer. Weld repair the cracks and holes using References 2.1 thru 2.7 as guidance.

7.2.10 Open and inspect the boiler main steam stop valve (1-MS-lB) and the main steam stop bypass valve. Provide condition report to MSCREP.

7.2.11 Open and inspect the boiler Auxiliary steam stop (1-AS-lB) and bypass valve. Provide condition report to MSCREP.

7.2.12 Measure all handhole seats. For bidding purposes, contractor shall machine/resurface a minimum of (24) handhole seats in the side wall, rear wall, screen wall and superheater headers using References 2.1 thru 2.7 as guidance. Please note: Contractor shall provide handhole seat resurfacing equipment along with qualified boilermakers to accomplish this resurfacing.

7.6.13 Using Refs 2.1 thru 2.7 for guidance, remove and replace the castable refractory of the rear wall brickwork between the rear wall tubes. For Bidding purposes and estimating labor, assume 20 bags (50 lbs bags) of castable to be applied.

7.6.14 Using Refs 2.1 thru 2.7 for guidance, remove and renew the screen wall coping and screen tubes refractory IAW reference 2.1, Plan D-9. When repairs are made to castable refractory, renew the entire thickness and length in the affected area to allow proper strength and s-clip anchoring. For Bidding purposes and estimating labor quantity, assume 20 bags (50 lbs bags) of castable to be utilized.

7.6.15 Using Refs 2.1 thru 2.7 for guidance, remove and replace castable refractory between the upper screen wall tube joints where they meet the steam drum. For Bidding purposes and estimating labor, assume 5 bags (50 lbs bags) of castable to be applied

7.6.16 Inner boiler casing has light rust and loose flaking paint. For bidding purposes, provide mechanical cleaning of 30 sq mtrs and preserve with two coats of high heat resistant aluminum paint (TT-P-28 or equal) in the inner casing, to include all lower headers.

7.6.17 The boiler outer casing requires preservation. For bidding purposes, provide mechanical cleaning of 25 sq mtrs and preserve with two coats of high heat resistant aluminum paint (TT-P-28 or equal) using Refs 2.1 thru 2.7 for guidance.

8.0 GENERAL REQUIREMENTS: None Additional