0618-RevB_A_Smoke_Stack_Indicator.docx

USNS RAPPAHANNOCK

(T-AO 204)

OUTFITTING

STACK SMOKE MONITOR REPLACEMENT (T-ALT 0914)

1.0 ABSTRACT

This item describes the modifications necessary for the replacement of Stack Smoke Monitoring System onboard the ship. This includes arrangement modifications, structural modifications, electrical modifications and piping modifications.

2.0 REFERENCES

2.1 MSC Drawing No. 085-8497598 T-AO STACK SMOKE MONITOR REPLACEMENT, OUTFITTING MODIFICATIONS

2.2 MSC Drawing No. 185-8497599 T-AO STACK SMOKE MONITOR REPLACEMENT, POWER SYSTEM MODIFICATIONS

2.3 MSC Drawing No. 320-8497600 T-AO STACK SMOKE MONITOR REPLACEMENT, POWER SYSTEM MODIFICATIONS

2.4 MSC Drawing No. 551-8497601 T-AO STACK SMOKE MONITOR REPLACEMENT, LP AIR MODIFICATIONS

2.5 MSC Drawing No. 803-7081122 MILITARY SEALIFT COMMAND GENERAL TECHNICAL REQUIREMENTS (GTRs)

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location: Various

3.2 Item Description/Manufacturer's Data

3.2.1 Material/Components, including specific quantities and manufacturer make and model numbers, necessary to accomplish work required by this work item, are included in the List of Material of References 2.1 through 2.4 above.

3.2.2 Quantities specified in the List of Material of References 2.1 through 2.4 are considered estimates. The contractor shall provide the exact quantities and additional material such as fittings, weld material, pipe hangers, etc., which are not included in the List of Material of References 2.1 thru 2.4.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES: None

5.0 NOTES

5.1 The shipyard 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.

5.2 In performance of this Work Item, the shipyard and subcontractors regardless of tier must comply with the requirements of all applicable General Technical Requirements (GTRs) including but not limited to GTRs 1 through 6 and the following GTRs:

GTR No. 7 – General Painting GTR No. 3 - Test, Inspections, Trials and Certificates GTR No. 22 – Insulation and Lagging GTR No. 23 – Piping GTR No. 24 – Manufacturer’s Representatives GTR No. 25 - Structure and Foundations GTR No. 28 – Electrical and Electronics Systems GTR No. 29 – Identifying Markings

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0 STATEMENT OF WORK REQUIRED

7.1 INSTALLATONS:

7.1.1 Install two (2), new, flanged Knife Gate Valves, blind flanges, and sensor mounts on each of the Fwd and Aft Auxiliary Boiler Stack Smoke Monitors mounting flanges located in the Engine Room, 4-60-0 using Reference 2.1 as guidance.

7.1.2 Install two (2), new, flanged Knife Gate Valves, blind flanges, and sensor mounts on each of the Port and Starboard Ship Service Diesel Generator Stack Smoke Monitors mounting flanges located in the Engine Room, 4-60-0 using Reference 2.1 as guidance.

7.1.3 Install two (2), new, flanged Knife Gate Valves, blind flanges, and sensor mounts on each of the Port and Starboard Main Engine Stack Smoke Monitors mounting flanges located in the Casing, 4-60-0 using Reference 2.1 as guidance.

7.1.4 Install two (2), new, flanged Knife Gate Valves, blind flanges, and sensor mounts on the Emergency Diesel Generator Stack Smoke Monitors mounting flanges located in the Emergency Diesel Generator Room, 06-96-0 using Reference 2.1 as guidance.

7.1.5 Install two (2), new, flanged Knife Gate Valves, blind flanges, and sensor mounts on the Incinerator Stack Smoke Monitors mounting flanges located in the Incinerator Room, 1-84-2 using Reference 2.1 as guidance.

7.2 STRUCTURAL:

7.2.1 Removals

a. Remove Stack Smoke Monitor Control Cabinet Door as required to fit new 15” Panel PC in Engine Room 4-60-0 using Reference 2.2 as guidance.

b. Remove Joiner Bulkhead Panel as required to fit new 10.4” Display in Chart Room 07-67-0 using Reference 2.2 as guidance.

7.2.2 Installations

a. Install angle iron for 10.4” Display foundation in Engine Room Control Station 2-92-0 using Reference 2.2 as guidance.

7.3 Mechanical/Fluids

7.3.1 Removals

a. Remove two (2) existing Ball Valves and attached flanges on each of the Fwd and Aft Auxiliary Boiler Stack Smoke Monitors located in the Engine Room, 4-60-0 using Reference 2.1 as guidance.

b. Remove two (2) existing Ball Valves and attached flanges on each of the Port and Starboard Ship Service Diesel Generator Stack Smoke Monitors located in the Engine Room, 4-60-0 using Reference 2.1 as guidance.

c. Remove two (2) existing Ball Valves and attached flanges on each of the Port and Starboard Main Engine Stack Smoke Monitors located in the Casing, 4-60-0 using Reference 2.1 as guidance.

d. Remove two (2) existing Ball Valves and attached flanges on the Emergency Diesel Generator Stack Smoke Monitors located in the Emergency Diesel Generator Room, 06-96-0 using Reference 2.1 as guidance.

e. Remove two (2) existing Ball Valves and attached flanges on the Incinerator Stack Smoke Monitors located in the Incinerator Room, 1-84-2 using Reference 2.1 as guidance.

f. Remove one (1) Pressure Regulator and one (1) Reducer fitting on the Emergency Diesel Generator Stack Smoke Monitors LP Air piping located in the Emergency Diesel Generator Room, 06-96-0 using Reference 2.4 as guidance.

g. Remove one (1) Pressure Regulator and one (1) Reducer fitting on the Incinerator Stack Smoke Monitors LP Air piping located in the Incinerator Room, 1-84-2 using Reference 2.4 as guidance.

h. Remove portion of existing LP Air piping using Reference 2.4 as guidance.

7.3.2 Installations

a. Install new LP Air copper tubing using Reference 2.4 as guidance.

b. Install new flexible hoses and fittings using Reference 2.4 as guidance.

c. Install new Compressed Air Filter/Regulators and fittings using Reference 2.4 as guidance.

d. For T-AO 187, 188, 189: Incinerator Room and EDG: Tie in LP air with in space. Approximately 20 feet 1’ CS schedule 40. Fittings: “T” (2 each), 90 deg (2) and isolation valve (qty 1).

7.4 Electrical

7.4.1 Removals

a. Remove equipment and cabling using Reference 2.3 as guidance.

7.4.2 Installations

a. Install equipment and cabling using Reference 2.3 as guidance.

7.6 Preparation of Drawings: None Additional

7.7 Inspection/Test

7.7.1 Preliminary Tests

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

7.7.2 Completion Test

The Contractor shall conduct a completion test that verifies that all aspects of the work item have been completed. For compartments, this means all equipment, electrical, overheads, etc. is installed and tested and proves the compartment is complete and ready for service. A completion test may include a series of functional, operational, and structural tightness tests. For structural work this means the shipyard shall notify the ABS surveyor to inspect completed structural work.

7.7.3 Welding Test

Visually test new, modified, or repaired welds in accordance with ABS rules. All results of the weld inspection to be reviewed for approval by MSCREP and ABS surveyor. Welds shall be per ABS 4-6-2/5.5.4.

7.7.4 Cable Insulation Resistance Test

Perform an end to end continuity and electrical insulation resistance test on new, modified, overhauled, or repaired system cables in accordance with Institute for Electrical and Electronic Engineers (IEEE) Standard 45, Recommended Practice for Electric Installations on Shipboard. Notify the MSCREP immediately if insulation values of equipment or cable are less than 0.1 ohm (Ω).

7.7.5 Enclosure Ground Test

Test new, modified, overhauled, or repaired electronic equipment enclosures for continuity and resistance of the grounding path. The resistance of the grounding path between the equipment enclosure and a ship structural member shall not exceed 0.1 ohm.

7.7.6 Clean and flush all piping affected by this work item by using a service fluid or medium approved by the MSCREP.

7.7.7 Hydrostatically test all new and modified piping for 30 minutes at 150% of the design pressures. No leaks are permitted. After satisfactory completion of hydrostatic and tightness tests, the systems shall be tested for proper operation and unobstructed flow. Visually inspect welded, brazed, and new mechanical joints for leaks.

7.7.8 Structural Tightness Test

New, repaired, and modified ship’s structures designated as watertight shall be tested to ensure tightness. Verify that all structural work including any structural attachments, which would affect the tightness of the structure, is complete and ready for service. Structural integrity and tightness shall be considered satisfactory if no bubbles develop in the leak indicator solution. System design data is provided below.

7.7.9 Operational Test

In the presence of the ABS Surveyor and MSCREP, verify that:

All work has performed satisfactorily and to the specific instructions and requirements of the work item, manufacturer, and regulatory bodies.

The equipment, material, machinery, or system including all flows, levels, temperatures, loads, and alarms complies with manufacturer’s parameters.

The equipment, material, machinery, or system performs its intended purpose.

7.8 Painting: Paint all new and disturbed surfaces to match surrounding surfaces.

7.9 Insulation: All lagging and pipe insulation installed during this installation shall be installed to match the surrounding areas in accordance with Reference 2.5, Supplemental Requirements, Section S1.

7.10 Markings: Install name plates, notices, and markings for all new and modified systems in accordance with GTR No. 29.

7.11 Manufacturer’s Representative: None additional

8.0 GENERAL REQUIREMENTS

8.1 Disposal of Equipment/Cleanup HAZMAT: All listed equipment and material removed shall be disposed of in accordance with the applicable list of removals table as shown on the appropriate drawing. All other scrapped material and any material classified as Hazardous Material (HAZMAT) shall be disposed of in accordance with Federal regulations and EPA guidelines as appropriate.

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