0702_A_Firemain_Straub_Coupling_Install.doc

USNS LEWIS B. PULLER

(T-ESB-3)

RFP No. NXXXX-X-XX-XXX

MACHINERY, AUXILIARY SYSTEMS

May 11, 2016

ITEM NO. 702

Category “A”

MSC/N757/SJB

FIREMAIN STRAUB COUPLING INSTALLATION (TALT T-ESB-16-009/012)

1.0 ABSTRACT:

1.1 This item describes the removal and replacement of the existing failed Dresser 38 couplings in the Firemain system with Straub couplings. Additionally, this work item includes the installation of a 6” NPS isolation valve in the fire main serving the forecastle, forward of frame 97.

2.0 REFERENCES:

2.1 COMSC INSTRUCTION 4700.16, MSC General Technical Requirements.

2.2 MSC Drawing No. 803-7080703, Preparation of Computer Aided Design (CAD) Drawings

2.3 NAVSEA Drawing, 521-8468146 Firemain System Diagram

2.4 NAVSEA Drawing, 635-8468287, Insulation Schedule Pipe and Vent

2.5 Straub Coupling Installation Guide for Straub Open Flex Coupling

2.6 NAVSEA Drawing 631-8393784, Paint Schedule

2.7 NAVSEA Drawing 631-8452132, Paint Code Matrix

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location:

3.1.1 Service Trunk (5-97-2)

3.1.2 Auxiliary Machinery Room (6-108-0)

3.2 Item Description/Manufacturer’s Data:

3.2.1 Material/Components:

3.2.1.1 Existing Couplings:

· Firemain nine (9) each 12” NPS Dresser, Style 38 Coupling, (W&O Part no. 541107.820)

· Firemain one (1) each 6” NPS Dresser, Style 38 Coupling, (W&O Part no. 541107.700)

3.3 Contractor Furnished Material (CFM):

3.3.1 The contractor shall provide the exact quantities and additional material, such as weld materials, insulation, paint, cable hangers, pipe hangars, etc., which are not included as Government Furnished Material (GFM).

3.3.2 Contractor shall supply all materials to make two manifolds and valve fasteners including:

1. 4” NPS Boss connection, CuNi 90/10, W&O P/n: 695120.600 or equivalent, Quantity: One (1) each

2. 4” NPS Flange, CuNi 90/10, 150#, Commercial, W&O P/n: 689100.600 or equivalent, Quantity: Three (3) each

3. 4” NPS Flange, CuNi 90/10, 150#, BLIND, Commercial, W&O P/n: 689180.600 or equivalent, Quantity: One (1) each

4. 4” NPS Pipe, CuNi 90/10, Quantity: Eight (8) feet

5. 12” NPS Flange, Blind, CuNi 90/10, 150#, Commercial, Quantity: One (1) each

6. 2-1/2” NPS Hose Globe Valve (Type B), 250#, NAVY, W&O P/n: 412371.450 or equivalent, Quantity: Four (4) each

7. 2-1/2” NPS Pipe, CuNi 90/10, Quantity: Six (6) feet

8. 2-1/2” NPS Flange, CuNi 90/10, 250#, NAVY, Socket Weld, W&O P/n: 689240.450 or equivalent, Quantity: Four (4) each

9. Garlock G-9900 Gaskets

10. Pressure gage, 0-200 psi, Quantity: Two (2) each

11. All fasteners for manifold and valves, Galvanized Grade A Nuts, and Galvanized Grade B Bolts

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE): None.

4.2 Government Furnished Material (GFM):

4.2.1 VALVE: One (1) each 6” NPS Gate Valve, lugged, bronze body with monel trim and, rising stem, 150#, Buna Liner, W&O Part No. 052104.700 or equal.

4.2.2 Flange: One (1) each 6” Flange CUNI 90/10 ASTM B-369, 150#, Commercial, Slip-on, W&O Part No. 689140.700 or equal.

4.2.3 Straub Open Flex Coupling: Nine (9) each, 12” Straub-Open- Flex SS 316, Hinged & two Piece with T-Insert includes Fire Fence.

4.2.4 Straub Open Flex Coupling: One (1) each 6” Straub-Open- Flex SS 316, Hinged & two Piece with T-Insert includes Fire Fence.

4.3 Government Furnished Services (GFS): None.

4.4 Government Furnished Information (GFI): None.

5.0 NOTES:

5.1 The ship’s force will provide access to any required spaces.

5.2 The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR), Reference 2.1, to determine applicability to this work item. In performance of this item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs including but not limited to GTRs 1 through 3, 7, 22, 25, 26, and 29.

5.3 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.

5.4 Welding shall be in accordance with ABS requirements. The weld size shall be in accordance with ABS Steel Vessel Rules, Part 3, Chapter 2, Section 19.

5.5 This ship contains High Voltage (HV) electrical systems. The contractor and subcontractors shall obey all posted and verbal instructions regarding safety and exclusion from High Voltage areas. At no time shall a contractor or subcontractor approach, work on, or enter a High Voltage area without proper authorization.

5.6 Contractor shall maintain firefighting capability at all times during modifications.

5.7 Port Engineer Contact Information:

Larry Cameron

Port Engineer

USNS Lewis B. Puller (T-ESB 3)

757.443.2167 Office

757.763.8582 Cell

Email:Lawrence.cameron@navy.mil

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 Work accomplished per this Work Item shall be in accordance with ABS/USCG Rules and Regulations

7.0 STATEMENT OF WORK REQUIRED:

7.1 General Guidance Notes:

7.1.1 This work item does not necessarily identify all interferences or boundaries. The Contractor is responsible for the identification and resolution of all interferences and boundaries affecting the accomplishment of this work item. The Contractor shall temporarily remove, relocate, alter, and reroute all interferences, mechanical, electrical, furnishings, insulations and/or misc. equipment to facilitate the completion of this work item. All interferences shall be reinstalled using contractor furnished hardware, fasteners, gaskets, seals, O-Rings, etc.

7.1.2 Contractor shall arrange for and provide the services of a Straub OEM authorized Technical Representative (note para 7.10) to be present during the beginning of the task; during the installation of Straub Couplings; and during hydro and final op-testing; to ensure the proper installation methods are employed by the contractor. The OEM Tech rep shall deliver to the job site, any required special installation tools as detailed in the installation instructions at the start of the task and turn the tools over to the ship once all work is complete.

7.1.3 Contractor shall require the Straub Tech Rep to document and sign off on each coupling installed and provide a signed copy to the Chief Engineer and Port Engineer at completion of all testing for this work item. The Straub rep shall not depart until the system has been certified by ABS/USCG regulatory bodies.

7.1.4 Contractor shall provide gas free engineering/chemist services and firewatch for all hot work evolutions in this work item.

7.1.5 Contractor shall provide all rigging services to get all materials to the Service Trunk.

7.1.6 Contractor shall provide for 24/7, around the clock, shifts while the firemain system is taken down in the forward house and forecastle until pancake blanks and gate valve are installed, and firemain pressure has been established to forward house and forecastle.

7.1.7 This Work Item is ordered sequentially from start (prefabrication and staging) to finish (re-establishing firemain pressure throughout system) and shall be followed as presented. If these sequential steps cannot be followed or any deviation is made, the Port Engineer and Chief Engineer must be notified.

7.2 Prefabrication and Staging:

7.2.1 Contractor shall prefabricate two manifolds from 4” NPS pipe. Each manifold shall have two (2) each 2-1/2” NPS Globe hose valves on one side and a 4” NPS Flange connection on the opposite side. The manifold body shall be made from 4” NPS CuNi 90/10 pipe. See Paragraph 3.3.4 for material required. Each manifold shall be equipped with a pressure gage. See Detail A-4 of Appendix A for a rough sketch of a 2 hose valve connection manifold.

7.2.2 Prior to any work on the Firemain system, contractor shall pre-stage all materials and prefabrications at worksites prior to isolating the forward firemain system. Contractor shall stage all locations where hotwork will be done, to reduce time delay of firemain system being offline.

7.2.3 Contractor shall work around the clock (24/7), all shifts to minimize impact to safety of ships crew while firemain is down.

7.2.4 Contractor shall provide for all “Christmas Tree” temporary firemain services and hoses. Adequate hoses shall be staged on the Mission Deck and Flight Deck outside the forward house. Contact Chief Engineer and/or Port Engineer for specific locations. Contractor shall coordinate with port operations to use shore connections for firemain/sea water.

7.3 Firemain takedown:

7.3.1 All firemain lockout/tag out efforts shall be coordinated with the Chief Engineer and Port Engineer.

7.3.2 Isolate system via valves (5-49-1), (5-47-2) and (5-57-23) then drain system. Ensure firemain piping has been drained completely before beginning hotwork.

7.3.3 Contractor shall coordinate with Chief Engineer to isolate 12” NPS Firemain via valve 5-93-2 in Service Trunk (5-57-2). Install hard blank or pancaking on discharge side of valve (5-93-2).

7.3.4 Contractor shall coordinate with Chief Engineer to isolate 12” NPS Firemain header via valve 5-57-1 in Pump Room (5-57-0).

7.3.5 Temporary shore connection in 12” NPS Firemain riser:

7.3.5.1 Contractor shall install a 4” NPS boss (Item 1 of Paragraph 3.3.2)connection to the existing 12” NPS firemain riser on the A2 level of Stairtower (A1-91.5-2). See Detail A-1 in Appendix A. The connection shall be approximately 60” above the deck and installed to face forward.

7.3.5.2 Maintain minimum distance off 12” NPS riser for flange connection. Contractor shall install prefabricated manifold assembly to 4” NPS flange using new gaskets. Connect temporary shore firemain hoses to valve hose connections. Ensure manifold is properly supported.

7.3.6 Installation of 6” NPS Isolation Valve:

7.3.6.1 Contractor shall locate existing flanges in the 6” NPS firemain riser to the forecastle shown in Detail A-2 of Appendix A. This piping section is located in the Auxiliary Machinery Room (6-108-0) on the Tank Top Level.

7.3.6.2 Contractor shall cut sufficient amount of 6” NPS firemain piping to accommodate the 6” NPS gate valve and 6” NPS flange (GFE). Weld in the slip on flange, install valve with new gaskets.

7.3.6.3 Contractor shall remove and retain the blind shore connection flange located at the forward interface station on the aft end of the forecastle (Mission deck frame 97, see Detail A-3 of the Appendix). Install new prefabricated two valve manifold with new gaskets. Connect shore firemain hoses to flanges. Ensure manifold is properly supported.

7.3.7 Test the system:

7.3.7.1 Contractor shall charge the firemain risers at both charging manifolds. Inspect all mechanical joints for leaks. Report any leaks to the Chief Engineer and/or Port Engineer.

7.3.8 Contractor shall remove all temporary firemain stations and hoses on the Mission Deck and Flight Deck.

7.4 Replace Dresser Coupling with Straub:

7.4.1.1 Ensure system is tagged out and drained prior to removing couplings.

7.4.2 Removal:

7.4.2.1 Remove all insulated covers on the Firemain system if any remain over couplings.

7.4.2.2 Temporarily disconnect heat trace power supply from the junction boxes surrounding the Firemain system. Loosen cable slack around the couplings.

7.4.2.3 Removal and Replacement shall be one Dresser coupling for one Straub coupling. Remove nine (9) 12” NPS and one (1) 6” NPS existing Dresser Couplings in the Firemain system located in the service trunk between frames 57 – 96 (10 each total). Clean and prepare the existing pipe for installation of the Straub Open Flex Couplings using reference 2.5 and Straub OEM Tech Rep instructions as guidance.

7.4.3 Installation:

7.4.3.1 Install nine (9) each 12” NPS and one (1) each 6” NPS Straub Open Flex Couplings for the Firemain system as per Straub Installation Instructions Reference 2.5 and Straub OEM Tech Rep instructions. Replacement shall be one–for–one.

7.4.3.2 Any pipe hangars damaged and requiring replacement will be subject of contract modifications.

7.4.3.3 Do not install Fire Fence over couplings until satisfactory completion of hydrostatic testing.

7.5 Reestablish Firemain System:

7.5.1 Remove the pancake and restore the 12” firemain cutout valve 5-93-2.

7.5.2 Upon completion of the installation, re-establish firemain by aligning firemain valves 5-93-2 and new 6” NPS gate valve.

7.5.2.1 Reconnect the heat trace power supply to junction boxes after satisfactory completion of hydrostatic testing.

7.6 Testing:

7.6.1 The contractor shall conduct all testing using reference 2.1 as guidance.

7.6.2 The contractor shall, in the presence of ABS surveyor, hydro test all new/disturbed piping to 169 psi in accordance with reference 2.3. No leaks allowed.

7.6.3 Contractor shall perform elevated NDT (PT - liquid penetrant dye) on each root pass and a 5X visual on each final pass weld.

7.6.4 Test the heat tracing system for continuity and for proper function.

7.6.5 All testing shall be accomplished to the satisfaction of the Chief Engineer and/or MSCREP.

7.7 Painting and Insulation:

7.7.1 Prepare, prime and paint all new and disturbed areas to match the surrounding surfaces using contractor–supplied paint. This includes any decks, bulkheads, lagging and all adjacent space coatings that have been damaged by heat from welding. Surface preparation and paint coating application requirements are provided in reference 2.6 and 2.7.

7.7.2 Repair all insulation removed during work. Match to surrounding areas with same type insulation.

7.7.3 Install Fire Fence insulation over each coupling and secure in accordance with manufacturer’s requirements.

7.8 Markings:

7.8.1 The contractor shall make and install label plates in accordance with 2.1, using reference 2.4 as guidance for the new 6” NPS Firemain Cutout valve to the Forecastle. See Chief Engineer and/or Port Engineer for valve locator number.

7.9 Preparation of Drawing:

7.9.1 Use Reference 2.3 as working drawings to accomplish the requirements specified in this work item.

7.9.2 Use reference drawing 2.3 to create actual working drawings. Contractor shall submit additional working drawings to reflect installation requirements, if found missing on the reference drawing.

7.9.3 Submit working drawing to MSCREP for review and approval. Working drawings shall be submitted within 2 weeks after contract award notification.

7.9.4 Maintain red-lined mark ups of approved working drawings, to reflect all installations, modifications, and any changes accomplished.

7.9.5 All submitted drawings shall be reviewed by MSCREP prior to final acceptance. Submit red-lined drawing (final) to MSC Rep for review and approval.

7.9.6 After MSCREP acceptance of the red-lined drawings, contractor shall submit drawings to American Bureau of Shipping (ABS) for regulatory review and approval, for compliance with all applicable ABS requirements and USCG regulations. Contractor shall receive ABS “stamped” approved drawings, and respective approval letters, and submit deliverables to the MSCREP.

7.9.7 See also GTR 5 concerning drawing requirements and deliverables.

7.10 Manufacturer’s Representative:

7.10.1 Straub USA

2901 Harding Ave.

National City CA 91950

P.O.C. Elliot LeGros Phone: 619-336-0400

8.0 GENERAL REQUIREMENTS: None.

APPENDIX A

DETAIL “A-1”

12” NPS firemain riser on the A2 level of Stairtower (A1-91.5-2). 4” NPS stab in with boss shall be 60” above the deck, on forward side of riser.

DETAIL “A-2”

6” NPS Firemain riser that serves the forecastle. Located on the Tank Top level of Auxiliary Machinery Room (6-108-0).

DETAIL “A-3”

Forward Interface Station shore connection for firemain temporary services to the forecastle, located between Frame 96-97 on the Mission Deck.

DETAIL “A-4”

Guidance sketch of prefabricated manifold. Flange connection, pipe and body are to be 4” NPS. Hose valves, flanges and associated pipe to hose connections are to be 2-1/2” NPS. Typical 2 places.

702-1