EPD_Adaptive_Force_Package_Work_Item_Plastic_Tank_install_RADAR_TLI_and_PUMP_CONTROL_with_TRICOLD_POWER_5_DEC_2016.doc

EPF CLASS

(EPF 1, 2, 3, 4, 5, 6 and others after delivery)

05 December 2016

iNSTALL vage tli on Plastic portable POTABLE WATER TANK AND FLAT RACK MOUNTED PUMP and SHIP INSTALLED brominatoR motor control with

1.0 ABSTRACT:

This item is to install a tank level indicating (TLI) system, remote read and controls for the skid mounted pump and ship’s installed brominator pumps. The system will consist of four parts:

- Installation of a VAGEFLEX Series 60 TLI on top centerline 3” Top Outlet provision of the flat rack mounted (separate work item) plastic - portable potable water tank(s) (P-PPWT).

- Provide an integrated remote displace of the tank level on the motor controller of the flat rack mounted tank (separate work item). To include relay to interrupt a 28 VDC circuit routed to the flat rack mounted water pump and ship’s installed brominator pumps’ controllers.

- Modifications of the brominator pump motor controller will allow the operation of the pump to fill the PPWT without timing out, as well as operate with the timer for normal bromination. The installation will consist of a three position controller (PPWT-Off-Timer), installation of a control relay and additional wiring for the two circuits for control power.

-Modifications of the flat rack mounted water pump motor controller circuit to have an additional cutout that interrupts timer and manual operation of the water pump.

-Installation of 220VAC Receptacles to power TRICOLD Freezers in Helo parking area This work will mainly encompass the following: electrical welding, pipefitting and painting.

2.0 REFERENCES/ENCLOSURES:

2.1 References:

2.1.1 MSC Drawing No. 803-7081122, Military Sealift Command General Technical Requirements (GTRs)

2.1.2 Drawing No. PCF01-00716 – Portable Tank Drawing

2.1.3 Schematic of ship installed Brominator Pump Control Circuit

2.1.4 MSC Drawing No.8497294 – EPF Adaptive force Package 5,025 Gal water storage –Tank and Piping Diagram

2.1.5 MSC Drawing No.8497294 – EPF Adaptive force Package 5,025 Gal water storage Electrical Diagram

2.1.6 MSC Drawing No.8497093 – Power Mods AFP Village

2.1.7 MSC Drawing No.8497094 – AFP Power Foundation Mods

2.1.8 IEEE 45 RECOMMENDED PRACTICE FOR ELECTRICAL ON SHIPBOARD

2.2 Enclosure:

2.2.1 Technical Manual for Village Marine RO Unit

2.2.2 Modular Interface Panel (MIP) Drawings

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity

3.1.1 Location: TBD

3.1.2 Quantity: NONE

3.2 Item Description/Manufacturer's Data:

3.2.1 System characteristics and criteria in accordance with references 2.1.1 – 2.1.6 and supporting enclosures will be used to support contractor material purchases, installations and testing of the tank TLI and Motor Controller modifications.

3.2.2 The contractor shall perform a review of this work item, drawings, schematics and enclosures to determine the effort required for the items to be procured and assembled; provide accurate measurements and information for additional equipment and material needed to complete the work; and provide redlines to diagrams provided by MSC before conducting work.

3.2.3 Estimated quantities of materials are provided from the reference diagrams. The Contractor shall provide these quantities and reasonable additional material in order to install the identified systems that meet the requirements of the specifications.

3.2.4 Additional material/components necessary to accomplish the work required by this work item, such as stuffing tubes, pipe hangers, mounting hardware, weld material, paint, etc. are not required to be included in the Bill of Material, and shall be provided by the Contractor as needed.

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):

4.3.1 MSC will provide schedule of availability to perform work checks for the P-PPWT locations, conduct the install on board an EPF and complete testing.

4.3.2 Controlled access to the base with proper clearance.

4.4 Government Furnished Information (GFI): None

4.5 Due the nature of the testing, coordination between MSC and the contractor must be pre-arranged when filling and emptying the tank, when working on top of or inside the tank during install and testing onboard EPF.

4.6 The work for assembling, initial testing and preparation will be conducted at on a Government Installation. The contractor will be responsible for coordination of loading the system onboard with the ship’s crew and initial hook ups and installations.

5.0 NOTES:

5.1 SAFETY OF PERSONNEL AND EQUIPMENT IS PARAMONT AND WILL NOT BE COMPROMISED. AT NO TIME WILL SHORT CUTS BE TAKEN CIRCUMVENTING STANDARD SAFETY PROCEDURES SUCH AS TAGOUT/LOCKOUT, ELECTRICAL SAFETY AND HOTWORK PROCEDURES OR FOR PERSONNEL WORKING ON TOP OF THE TANK. SAFETY IS A MUST.

5.2 THIS WORK WILL BE ON A PORTABLE POTABLE WATER SYSTEM. AS SUCH THE TANK WILL BE CLEANED IAW REF 2.1.1 SECTION 11.1.3. THIS CAN BE DONE IN CONJUNCTION WITH THE FILL TESTING ONCE ABOARD THE SHIP, IF RE-ENTRY OF THE TANK IS REQUIRED THE TANK WILL BE CLEANED IAW 11.1.3 AGAIN.

5.3 The contractor and all subcontractors, regardless of their tier must consult Military Sealift Command’s General Technical Requirements, (GTR’s), to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors, regardless of their tier, must comply with the requirements of all applicable GTR’s including but not limited to GTR’s 1 through 7, 23, 25, 28 and 29. The contractor and all subcontractors, regardless of their tier, are advised to review other work items under this contract, included but not limited to work items 009, 010, and 015, to determine their effect on the work required under this work item. Based on this review the contractor should plan and schedule work to minimize conflicts between other repairs ongoing during the same time frame. Many of the definitions relating to the performance of this work item are found in Work Item 001.

5.4 The reference 2.1.2-2.1.3 will be used for the construction, material estimating and updated for the actual install.

5.5 Any welding, grinding, chipping and drilling will take special precautions to avoid any damage or contamination to the tank or any of the system components.

5.6 All dimensions and quantities as shown in diagrams are approximate.

5.7 Deviations from the diagrams are authorized if the appearance, function and/or strength are not impaired.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 All work and testing shall be in accordance with References 2.1.1 and 2.1.4, and to the satisfaction of, and in the presence, of the MSC Representative (MSCREP).

6.2 All welding requirements shall be accomplished by ABS certified welders and meet ABS and USCG requirements. All welders shall be ABS certified to perform the type of welding required, and documentation of such shall be current and available upon the request of the MSCREP. Fire watches shall be posted by the Contractor during all hot work if conducted at a government facility or onboard the ship.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Arrangements/Outfitting:

7.1.1 The Contractor shall design and make all necessary arrangements (scaffolding, ladders, lifting gear, rigging, etc.) to safely assemble the components and load the Portable Potable Water System aboard an EPF.

7.1.2 Before initial work starts, the contractor shall verify that the tank is clean and not damaged and the container frame is not damaged, specifically the locking corners.

7.2 Structural:

7.2.1 Removal: None.

7.2.2 Installation: Install foundations and supports for the VAGE TLI, remote indicator and the motor control circuit electrical enclosure(s).

7.2.3 Components will be accessible between the lower container frame and the mid-point of the tank.

7.2.4 Install additional wiring and supports on the P-PPWT as needed to support the VAGE TLI and associated wiring and control boxes.

7.3 Mechanical/Fluids:

7.3.1 Removal: None.

7.3.2 Installation: Install fitting in the plastic tank (9) to support the installation of the VAGE TLI.

7.4 Electrical:

7.4.1 The electrical installation will be fed from an 120 VAC and 28 VDC, 30-amp service from the EPF MIPs through a disconnect switch to the components on the PPWT. The 120 VAC supply to the VAGE TLI and supporting systems will be provided from the 120 VAC identified in Reference (2.1.5). The 28 VDC will be connected from the MIP through a 25ft cable that will be attached to the P-PPWT at a disconnect switch.

7.4.2 The electrical installation on the P-PPWT will provide power to the VAGE Series 60 TLI, the remote indicator and relay(s) to operate the flat rack mounted pump and brominator pump control power circuit when in the PPWT mode.

7.4.3 The major components will include the VAGE TLI, TLI remote read out, a 28 VDC relay controlled by the TLI output, a three position switch, an electrical enclosure for the connections 28 VDC on the PPWT, 28 VDC controlled 120 VAC relay for the brominator pump control circuit, fuses and leads connecting the three position switch to the motor controller.

7.4.4 Individual components and terminals will be covered to avoid exposure to electrical contact from a person.

7.4.5 All electrical components and enclosures will be NEMA 4 rated.

7.4.6 All connections inside the enclosures will be covered to prevent electrical contact with the operator.

7.4.7 The single 28 VDC to 120 VAC relay will be located to in the flat rack mounted controller to stop the water pump regardless of the operational mode.

7.4.8 The three position switch will allow the operation of the brominator pumps in Three Modes: PPWT - OFF - Timer.

7.4.8.1. PPWT Mode - The PPWT position will allow operation of pump when the TLI indicates the tank level is between the low level and high level. If the TLI detects either a low/high level the 28 VDC circuit will be interrupted for the brominator pump motor controller relay shutting down the pump.

7.4.8.2. Off Mode – The pumps cannot be operated. The OFF MODE will disable both the PPWT and Timer Modes. This feature is installed to allow only one pump be operated at a time when in PPWT Mode or Timer Mode.

7.4.8.3. Timer Mode – Operation of the bromide pump will be controlled by the 60 minute timer and used when the brominator is aligned for normal operation. In the event the PPWT is reading a low level/high level the timer mode can be used to put water in or take water out the PPWT until the TLI reads between the low and high level readings. HOWEVER, OPERATING IN THE TIMER MODE TO REMOVE WATER BELOW THE LOW LEVEL SET POINT FROM THE PPWT MAY CAUSE THE PUMP TO RUN DRY.

7.4.9 The 28 VDC wiring from the flat rack mounted system will be ran along the piping that connects the risers on the mission bay to the brominator pumps. A connector will be installed at the riser to allow the 28 VDC circuit to be disconnected when the PPWT is removed.

7.4.10 Conduct electrical wiring checks per Reference 2.1.1, 2.1.4, 2.1.6, and 2.1.7 prior to operating the systems.

7.5 Electronics: None.

7.6 Preparation of Diagrams:

7.6.1 As-built diagrams

7.6.1.1. Contractor shall provide As-built diagrams based on Reference 2.1.2.

7.6.1.2. As-built diagrams shall be provided in AutoCAD 2007 and PDF (electric format).

7.6.1.3. As-built diagrams shall be provided to:

MSCREP AND MSC Technical Library

9276 3rd Ave, Bldg LP-26

Norfolk, VA 23511-2914

7.7 Inspection/Test:

7.7.1 The TLI and electrical system will be visually inspected to meet References 2.1.1-2.1.3.

7.7.2 Calibrate the TLI to verify that the tank level indicates the amount of water that is in the tank. The read out will be in gallons. Set the high level cutout at ~4,900 gallons and low level at cut out at ~250 gallons.

7.7.3 Align electrical power to the flat rack mounted system with the disconnect switches open. Place the flat rack mounted pump in the off position, and both three positon switches in the OFF Mode, close brominator pumps controller breaker and verify pumps do not start. Close the Skid mounted disconnect switch and verify no pumps start.

7.7.4 Test the flat rack mounted pump in both operational modes.

7.7.5 Place one of the two three position switch from OFF MODE to TIMER Mode and verify the pump does not start. Set the time for 10 minutes and verify pump operates for ~10 minutes. Once timer has ran out repeat the test for the other brominator pump.

7.7.6 Verify that the TLI is no longer reading a low level. Place one of the two three ways switches

7.7.7 Close brominator inlet valve and verify that pump starts and recirculates back to the tank. Operate for 10 minutes and inspect for leaks. During testing Record suction and discharge pressure readings.

7.7.8 Place the controller from manual to auto operation and verify the pump stops. Open the brominator inlet valve and close the bypass valve.

7.7.9 Set timer switch for 10 minutes. Verify the pump starts and operate for 10 minutes discharging back to the tank. During the test record suction and discharge pressure readings.

7.7.10 Allow pump to run for the full 10 minutes and the pump shuts down after the timer runs out.

7.7.11 Remove water after testing is complete by operating the pump in manual.

7.7.12 Measure total operating current of the system and provide to the MSCTECH.

7.7.13 Once delivered the tank will be cleaned, piping flushed, surge busters installed and disinfected per Reference 2.1.2.

7.7.14 Provide a measured weight of the system prior to delivery to the ship. This can be conducted by using a certified truck scale.

7.7.15 Test TRICOLD Electrical Power per notes in Ref. 2.1.6 and 2.1.7

7.8 Painting: Painting of the newly constructed supports and any disturbed areas on the container platform will be provided by the contractor to prevent future rusting and to match the color of the container platform. Painting will be conducted in accordance with Reference 2.1.1.

7.9 Markings:

7.9.1 Install nameplates, valve labels and markings for all piping and valves on the container platform. Paying close attention to flow direction and Brominator system isolation valves.

7.9.2 Provide a schematic of the piping per installation to include valve numbers and matching valve labels in paper, electronic and photo engraved. The photo engraved will be mounted to the system next to the electrical enclosure.

7.9.3 Provide a schematic of the electrical system per installation in paper, electronic and laminated copy. The laminated copy will be placed inside the electrical enclosure.

7.9.4 Install placard showing total weight of the portable potable water system, and total weight including 5,000 gallons of water.

8.0 GENERAL REQUIREMENTS:

8.1 The systems will be weather protected until they are either ready for installation or directed for delivery to a different location.

8.2 All materials and equipment shall be furnished by the Contractor. The Contractor shall provide all labor, services and material required to accomplish this work item, including but not limited to ventilation and gas free certification, scaffolding and repairs to affect a complete and finished end result.

8.3 The contractor shall retrieve accurate measurements and information before conducting work and provide any additional information for the drawings, develop Bill of Material for incidental material for the install (see section 3.2.4) and provide a schedule for completing the work to MSC prior to work starting.

8.4 The contractor shall provide all ABS approved Welder certs, material certs and welding procedures to the MSCREP and ABS Surveyor prior to commencing of work required to accomplish this specification item.

8.5 The Contractor shall verify the weight of installed material applicable to this work item including all hardware per 7.7.12. The Contractor shall provide the recorded weights to the MSCREP.

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