0941_A_FW_Stern_Tube_Lub_System_Install_TALT_403__Rev_2_V6_SA.doc

USNS CHARLES DREW

(T-AKE 10)

DOCKING AND UNDOCKING

N32205-18-R-4252

21 DECEMBER 2017

ITEM NO. 941

Category "A"

N756/SA

FRESHWATER (CLOSED LOOP) STERN TUBE LUBRICATION SYSTEM T-ALT 403

1.0 ABSTRACT:

1.1 This item describes the requirements for a Shipyard to install a NEW Freshwater (Closed Loop) Stern Tube Lubrication System designed by WARTSILA Defense.

2.0 REFERENCES/ENCLOSURES:

2.1 References:

2.1.1 MSC Drawing 530-8498002 Rev – Fresh Water (Closed Loop) Stern Tube Lubrication System Installation Dated 8NOV2017.

2.1.2 WARTSILA Drawing H79352-01 REV C – GA 744 TYPE A8 SEAL.

2.1.3 WARTSILA Drawing H74985-02 REV 2 – GA of 750 MOD 712 TYPE MD SEAL.

2.1.4 WARTSILA Drawing US30305-01 Rev 2 – Proposal Stern Tube Modification for 744 Type A8 Seal.

2.1.5 Manchester Head Tank Dwg 302516 (Modified).

2.1.6 Point Eight Power Drawing 2888.

2.1.7 MSC Dwg 320- 8387094, Electrical System One Line Diagram.

2.1.8 MSC Dwg 531- 8387092, Distilled Water Transfer System Diagram.

2.1.9 NASSCO Dwg 471-351-4982, Stern Tube Installation and Chocking (Welding Sequence Schedule).

2.2 Enclosure:

2.2.1 Enclosure 1 - Drawing for the Aft seal adapter plate.

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity:

3.1.1 Location:

-Head Tank – Cargo Hold 5 (2-75-0).

-Motor/Pump, Strainer Bedplate – Shaft Alley (5-79-0).

-Plate Heat Exchanger – Shaft Alley (5-79-0).

- Aft Stern Tube adapter plate and seal – Exterior of the hull at the Stern Tube.

3.1.2 Quantity: 1ea, Freshwater (Closed Loop) Stern Tube Lubrication System.

3.2 Item Description/Manufacturer’s Data: Water Circulation Package, Closed Loop. MFG: WARTSILA UK LTD.

3.2.1 Per Ref 2.1.1 Bill of Materials (Contractor Furnished):

Note:

The electrical parts kit shall be provided by Custom Panel and Controls under separate WARTSILA DEFENSE contract.

-Wartsila Piping Components Parts Kit: WDI002115-002 –QTY 1 Kit

Note:

This parts kit contains the following parts listed in the bill of materials on reference 2.1.1.

a. Provide Items 1 through 12 listed in the bill of materials on reference 2.1.1 sheet 1.

b. Provide Items P1 through P6, V-1 through V-9 and F-1 through F-64 listed in the bill of materials on reference 2.1.1 sheet 18.

Note:

The quantities of piping and fittings will be adjusted as needed to support routing the FW (CLS) supply and return piping in the overhead down the port side of the ship. P1 from LOM on sheet 18 is being provided as GFM.

3.2.2 In addition to the quantities listed for piping additional 1.5-inch 316 SST piping will be provided to replace the stern tube vent line from the isolation valve at the stern tube to the connection to the of the return piping.

3.2.3 In addition to reference 2.1.1, installation shall include all miscellaneous material (structural foundations, piping, pipe collars, hangers, studs, fasteners, angle iron, cable ties, rubber grommets, etc.).

3.2.4 Provide material in reference 2.1.1 with all ABS Heat Trace markings and serializations. Material recommendations identified in reference 2.1.4 shall be either AH36/DH36. The plate will be a minimum of 2.5 inches (63.5mm) prior to machining. Refer to Enclosure (1) and paragraph 7.1.3 Figure 1 for dimensional and bolt circle requirements.

3.2.5 Install hull penetrations and overboard fittings Refer to Reference (1) and paragraph 7.3.2 Figure 2.

3.2.6 Provide a fabricated fitting identified in paragraph 7.3.2 Figure 3 for FW supply connection to Aft Seal. Material shall be SS316.

4.0 GOVERNMENT-FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE):

None.

4.2 Government Furnished Material (GFM):

4.2.1 WARTSILA provided material under separate Contract;

· Aft Seal H79352-01 - 620 MOD 610 A8 Seal, 1ea.

· Rope Cutter – PAAG255431; 1 EA

· Carrier Assembly for Inboard – H74985-02/4 1 EA

· Face Assembly for Inboard Seal, H74985-02/05 1 EA

· Inboard Seal Overhaul Kit, WLP001326-001, 1 EA

· Fwd Seal H74985-02 – 750 MOD 712 MD Seal, 1ea w/face and carrier assemblies.

· Motor/Pump Bedplate with Duplex Strainer, Controller w/breaker box, Ball Valves, and Simplex Strainers, 1ea.

· Pump Duplex Controller, w/junction box, RTU Enclosure and all necessary contactors, relays, PWR Transformers, PWR Supply, PWR Modules, Relays, Breakers, DIN Rails, Terminal Boxes, and Cables.

· Heat Exchanger, 1ea.

· Flow Meters, 2ea, 1-1/2” NPS Flanged, Rosemount 680DF0153SAINTPE5m5.

· Flow Meter, 1ea, 1/2” NPS, Flanged, Rosemount 680DF0053SAINTPE5m5.

· Flex Hose Assy, PC42 of reference 2.1.1, ½” ID W-1/2” NPS nipple CONN, SAE 100R1 TY A1, 316SSL END CONN.

· Sight Glass, 1” NPS, Flanged, GEMS 61000 Series with Ball Valves 1” NPS, 150#, Flanged, 316SSL, ASTM A351, VALTROC Series 180-1” or Equal.

· Gauges, Temperature and XMTR 0-200F (Commercial), REOTEMP Model DM-4M-040-D43-RC-HT-AU, 4-20mA output or equivalent.

· Gauges, Pressure 0-100psi, WARTSILA DWG H79807-01.

4.3 Government Furnished Services:

None

4.4 Government Furnished Information (GFI): 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 GTRs.

5.2 The contractor and all subcontractors regardless of tier are advised to review the other work items under this contract to determine their effect on the work required under this work item.

5.3 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.

5.4 THE T-AKE CLASS ELECTRICAL COLOR CODING DOES NOT FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK, AND WHITE. ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED AND PROVEN OTHERWISE. TEST ALL ELECTICAL CABLES TO ENSURE THEY ARE DE-ENERGIZED PRIOR TO WORKING ON THE ITEM.

5.5 Provide all labor and material required to accomplish this work item including but not limited to rigging, staging, space contamination containment, removal and reinstallation of all interferences including insulation in way of repairs or modifications to complete this Work Item.

5.6 All welding shall be in accordance with ABS requirements for building and classing steel ships. Welding Sequence requirements are outlined in reference 2.1.9 for the welding of the Aft Stern Tube Seal adapter plate to the hull and stern tube flange.

5.7 Gas free and certify safe for Hot work the following spaces; Shaft Alley (5-79-0), Propulsion Motor Room (5-75-0), Cargo Hold 5 (2-75-0), Passage between Cargo Potable Water Tanks (3-80.5-2/3-79-2) and Distilled Water Tank (3-79-0)and Void (6-83-0) port side of stern tube.

5.8 Vacuum tests shall be accomplished on all watertight penetrations and witnessed by ABS, Chief Engineer, and the MSC Rep.

5.9 All interferences and reinstallations are the responsibility of the Contractor.

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional.

6.1 WARTSILA is the OEM and designer and shall oversee or be available or on station during installation, testing and trials as well as the N7 MSC Rep.

6.2 Accomplish all work in accordance with American Bureau of Shipping (ABS) Regulatory Body rules and regulations and to the satisfaction of the MSC Rep.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Arrangements and Outfitting:

7.1.1 Tag-Out all required systems and equipment. Drain and dispose of any liquids in accordance with all federal, state, and local regulations.

a. Remove interference such as handrails, ladders, deck grating etc as required.

b. Gas free and certify safe for Hot work the following spaces; Shaft Alley (5-79-0), Propulsion Motor Room (5-75-0), Cargo Hold 5 (2-75-0), Passage between Cargo Potable Water Tanks (3-80.5-2/3-79-2),Distilled Water Tank (3-79-0) on 3rd Deck and void (6-83-0) port side of stern tube.

7.1.2 Provide the services Original Equipment Manufacturer (OEM) Representative WARTSILA Defense Inc. to oversee the installation of the Freshwater Closed Loop System (FW CLS); Forward Stern Tube seal with modifications for FW CLS and the NEW Aft Stern Tube Seal installation identified in the paragraphs below.

7.1.3 Provide the services of a Quality in place Machining vendor for machining services of the Stern Tube Face and Aft Seal Ring for new Aft Seal mounting.

a. Machine the existing welds for the removal the existing split ring cover plate.

b. Machine the Stern Tube Flange and stern tube boss for the fitting and welding of the Aft Seal Foundation Plate.

7.1.4 Provide machining services (in-house) or of a machining services of a Quality Machining vendor for the machining of the new Aft Seal Foundation Plate.

a. Machine the raw AH-36/DH-36 plate for the Aft Seal Foundation Plate to the design provided in Enclosure 1 and Figure 1; and to the dimensions provided by the OEM representative and MSCREP.

b. Drill / tap the Aft Seal Foundation per drawing. Bolt holes shall be drilled and tapped for 16-M24x3 fasteners.

c. Hole depth and bottom tape to be accomplished as per enclosure 1 and verified before install

7.1.5 Contractor provide services for the preparation of the propeller hub to be fitted for the Aft seal.

a. Drill / tap propeller hub using template provided by WARTSILA Defense. Bolt holes shall be drilled / tapped for 16-M24x3 fasteners.

b. Hole depth and bottom tape to be accomplished per reference 2.1.2 and verified before install.

7.1.6 Provide the services of Custom Panel and Controls to calibrate and wire of all flow meters, pressure gauges, temperature transducers, and terminations to motor controller prior to installation in the FWCL system.

7.1.7 Provide the services of GE Energy to electrically connect all terminations to the DAU and update all MIMIC Screen software.

7.1.8 All structural foundations, ladders, bedplates, Pipe Hangers/supports, identified herein as well as in reference 2.1.1. shall be manufactured/provided by the Contractor.

7.1.9 The existing 6” Strainers, reducing station, gauge board, and drain pan from SW Firemain currently mounted in Shaft Alley portside shall remain. The System will supply water to the FW CLS heat exchanger

7.1.10 The SW System will also remain as an emergency SW lubrication system if upon failure of the NEW Freshwater Closed Loop System should fail aft of the SW connection to the heat exchange.

7.1.11 Open and inspect the strainers and separators in the firemain between the root valves off the fire main to the connection to the 1-1/4 - inch SW supply to the FW CLS heat exchanger. Provide condition report.

7.1.12 Notify MSCREP prior to removal of Vidmar cabinets located adjacent to Pyrotechnics Storeroom (2-77-0). VIDMAR’s will be removed permanently for New Head Tank, per reference 2.1.1 detail “Plan 59-B”. Studs shall be ground flush with adjacent deck.

7.1.13 Prime and paint to match surrounding areas with Ships Force provided paint.

7.2 Structural:

7.2.1 Head Tank installation:

a. The pre-fabricated Head Tank shall be placed on a foundation and permanently located on 2nd Deck, Cargo Hold 5 starboard side, adjacent to Pyrotechnics Storeroom (2-77-0) in according with reference 2.1.1. MSCREP and Wartsila Rep will determine exact location.

b. Inspect the interior of the Manchester head tank for damage and to determine if there is a pipe inside the tank from the 1-1/4 inch vent connection.

c. Ladder and platform shall be located adjacent to head tank as per reference 2.1.1.

d. Head Tank dimensions are 36” Diameter X 86” Tall as per reference 2.1.5.

e. Prep, prime and Touch-up painted surfaces to match surrounding.

f. All valves leading to or from the head tank will be positioned to allow reach from the ladder or the deck.

7.2.2 Motor/Pump and Strainer Bedplate Foundation:

a. Fabricate motor/pump bedplate foundation in accordance with reference 2.1.1.

b. Prepare existing deck grating and structural longitudinal(s) for installation of newly fabricated foundation.

c. Installation The location of the Motor/Pump and strainer will be outboard of the heat exchanger and shall be oriented as identified in reference 2.1.1.

d. Motor/pump bedplate with strainer shall be hard mounted to NEW foundation and secured with fasteners.

e. Foundation shall support motor/pump bedplate and additional for maintenance of units. The bedplate shall be mounted in a way that does not interfere with normal maintenance of the motor/pump, strainer, and valves. Pressure and temperature indicators will be orientated to allow visibility when looking aft.

f. Reconfigure deck grating around motor/pump assembly and heat exchanger as well as install handrails for safety once motor/pump bedplate are installed and mounted. Modify the existing ladder to allow continued access.

g. Fabricate and install drain pan under NEW motor/pump and strainer bedplate. Drain pan shall be mounted providing adequate space between motor/pump bedplate to maintain drain cleanliness and support maintenance. The pump and strainer skid drain line will be connected with a 1.5” inch SST piping. The piping shall be tied into the existing drain line to the shaft alley bilge, upstream of SW-V-219. Note: Drain pan from existing 6” strainers in shaft alley (5-79-0) ties into bilge drain upstream of SW-V-219.

7.2.3 Heat Exchanger Installation:

a. Fabricate heat exchanger foundation in accordance with reference 2.1.1.

b. Prepare existing deck grating and structural longitudinal(s) for installation of newly fabricated foundation.

c. Installation shall be oriented as identified in enclosure 1 “Simplified N7 Closed Loop”.

d. Heat Exchanger shall be hard mounted to NEW foundation with fasteners.

e. Heat Exchanger foundation shall be mounted in a way that does not interfere with normal maintenance.

Fabricate and install drain pan under new heat exchanger. Drain pan shall be mounted providing adequate space between the heat exchanger to maintain drain cleanliness and support maintenance of the heat exchanger plates. Two 1/2 –inch drain holes will be installed in the drain pan (one forward and one aft of the heat exchanger) connecting to the 1.1/2 inch line identified in 7.2.2 g. The combined drains from the pump skid and heat exchanger shall be tied into the existing drain line to the shaft alley bilge, upstream of SW-V-219.

Note:

Drain pan from existing 6” strainers in shaft alley (5-79-0) ties into bilge drain upstream of SW-V-219.

7.2.4 Aft Seal Installation:

a. The existing Split Ring cover plate attachment welds will be machined for its removal.

b. Machine the stern tube face in accordance with Figure 1 and enclosure 2.2.1. Machining shall include chamfering edges. Chamfering shall include the inner diameter of the Aft Seal Ring and inner diameter of the stern tube flange areas to meet welding requirements. Dimension identified are approximations. Onsite MSCREP will validate and oversee machining efforts.

c. No less than 10mm at 45 degree Chamfer will be machined for the weld locations.

d. Once stern tube flange face has been machined to the dimensional requirements of the MSCREP and the aft edge of the outer diameter of the stern tube flange has chamfer installed to allow of matching of the aft seal foundation plate; ring/install NEW Stern Tube Aft Seal Foundation plate.

e. Ensure TDC of NEW Stern Tube Foundation plate matches the NEW Aft Seal mounting ring. Aft Seal Mounting ring shall be aligned to allow future TDC for bearing measurements. In addition, the FW supply connection of the aft seal shall be BDC.

Figure 1 – Stern Tube Face Machining Requirements

f. Alignment of Stern Tube Foundation Plate shall meet the following; Max runout WRT bearing area 0.000” +/-0.003”. A “fitup” inspection of the Aft Seal Foundation Plate by ABS, MSCREP will be conducted prior to welding.

g. Weld NEW Stern Tube Aft Seal Foundation plate using welding sequence in reference 2.1.9. Root welds shall be applied to both inner and outer machined chamfered edges prior to final weld passes.

h. Verify the fit-up of the stern tube bearing retaining ring. Ensure the stern tube bearing retaining ring clears the interior welds for the Aft Seal Foundation Plate. Remove any obstructions to the fitting of the retaining ring. Ensure the retaining rings bolts do not protrude beyond the aft edge of the Aft Seal Foundation Plate.

i. Inspect, verify, and document NEW stern Tube face to bearing area bore. Face machine seal area if outside tolerance. Unless otherwise stated in the above references, surface finish criteria Ra 3.2 or better. Perform Magnetic Particle “NDT” Tests of newly installed welds. ABS, MSCREP shall witness.

j. Prior to installation of aft seal, stern tube coatings shall be applied to inside stern tube including the retaining ring and NEW stern tube foundation ring as stated in WI 903.

k. Once Propulsion shaft is installed as stated in WI 903, install the aft seal IAW reference 2.1.2.

l. Press up Propeller on propulsion shaft taper as stated in WI 903, validate the required length between NEW Stern Tube Face and Propeller Hub. Criteria 235mm +/-2mm. If required, shaft position shall be adjusted at the coupling to meet overall length requirements.

Note:

Removal of the propeller may be required to achieve the required criteria above of 235mm +/- 2mm.

7.2.5 Fwd Seal Installation:

a. WARTSILA shall assist SY in removal and repair existing seal components and replace with modified seal for the FW application.

b. WARTSILA shall install new modified fwd seal and components to meet the requirements of this design. Components were procured under separate work item.

7.3 Mechanical/Fluid:

7.3.1 All pipe shall be isolated with rubber grommets to eliminate chaffing. Installation shall and meet ABS Surveyor inspection requirements.

7.3.2 Aft Seal supply piping:

a. Supply piping penetration through Hull shall be presented to ABS prior to welding or cutting for prior approval. Wartsila and MSCREP shall determine exact location of penetration thru hull plating just forward of void (6-83-0) bulkhead.

b. Piping penetration shall meet the requirements of Figure 2. Shell plating is 24.5mm thick, GR A STL.

Figure 2 – Piping Penetration through Shell Plating

c. Per reference 2.1.1, install 1-1/2” SS316 SCH 160 piping and fitting from aft seal thru penetrating hull plating to shaft alley (5-79-0). Termination beyond the hull plating shall be flanged where SS piping continues inside the skin of the ship.

d. Supply piping run from shaft alley penetration bulkhead external to the Ship shall be protected from debris or damage once installed. Install a guard around the Newly installed FW Supply Piping, from penetration outboard FWD of frame 83 to Aft seal piping connection.

e. Prime and paint all piping, welded areas and covering with the same paint process being used on the hull.

f. Fabricate fitting identified in Figure 3 below. Fitting shall be used to connect FW Supply piping to BDC mounting ring on Aft Seal.

Figure 3 – Aft Seal FW Supply Fitting (SS316)

g. Provide the location of the hull penetration for the FW supply piping, length of pipe on the exterior, the location and dimensions of the covering from the hull penetration to stern tube.

h. Install NEW 1.5 inch piping run in the shaft alley per this Work Item.

i. Piping shall run from New motor/pump, strainer assembly and heat exchanger through bulkhead forward of frame 83 port side. The bulkhead penetration for the FW supply piping and the FW piping entering the shaft alley will, as much as practicable, be located just under the existing LO piping run already located in the shaft alley.

j. After the piping enters the shaft alley it will run to a location just beneath the existing LO piping. Use exiting or install new hangers to satisfy hanger requirements.

k. The piping will then turn running aft following beneath the existing LO piping. Ensure the NEWLY installed piping does not interfere with the overhead crane.

l. At the aft bulkhead of the space the piping will penetrate the NT bulk head in the area of the already existing ballast pipe.

m. The piping will continue through the following two NT bulkheads at approximately the same level.

n. Between NT bulkheads three and four the piping will be lowered with either 90 or 45 degree elbows prior to penetrating the fourth and fifth bulkhead.

o. After penetrating the fifth bulkhead the supply piping will turn down penetrating decks and entering the area to the port side of the shaft. Ensure the piping does not block access to the manhole access cover located aft of the fifth NT bulkhead.

p. The piping will be ran port side of the shaft to align with the skin valve and to support installation of the 1/2 inch line for the control station for the FWD seal FW cooling. Piping in the area of shaft will have spool pieces installed to support shaft removal.

q. Flanges shall be placed at each fitting (elbow for example). Flanges shall be placed on straight runs so that pipe length of no more than six (6) feet.

7.3.3 Fwd Seal Return Piping:

a. Install NEW 1.5 inch piping run in the shaft alley per this Work Item.

b. Install new 1.5 inch 316 SST piping replacing the installed 1.25 inch stern tube vent piping between the valve located at the stern tube to the connection for the FW return piping run in the shaft alley.

c. Install a flanged 1.5 inch 316 SST Tee to connect to the NEWLY installed vent/return piping The Tee will provide connections for the vent line to continue to the third deck and for the connecting the FW return piping.

d. Install 1.5 inch flanges ball valve off the tee in the FW return. Install the vent isolation valve per reference 2.1.1 outside of the steering gear room.

e. The return piping will be ran to the port side of the void to parallel the NEWLY installed supply piping.

f. The piping will be installed through the five NT bulkheads in a similar manner and location as the supply piping.

g. The FW return piping will run near the installed supply piping located on the port side of the shaft alley.

h. The piping will be mounted with existing or new pipe hangers as required.

i. In the forward part of the shaft alley (after the CLS supply piping turns to exist the shaft alley) will run forward and fittings installed to allow the return piping to exit the space at existing locations previously identified in reference 2.1.1.

j. The piping in the overhead of the shaft alley will not interfere with the operation of the overhead crane.

k. Piping in the area of shaft will have spool pieces installed to support shaft removal. Flanges shall be placed at each fitting (elbow for example). Flanges shall be placed on straight runs so that pipe length of no more than six (6) feet.

7.3.4 Emergency SW piping supply:

a. Install emergency SW piping connection to NEW FW return piping just “below” FWD seal return with isolation ball valve (flanged). Ball valve shall be normally closed, marked, and labeled.

b. Emergency SW supply shall run from existing SW Fire Main, starboard side in shaft alley (5-79-0) downstream of existing SW FM relief valve SW-V-216 and SW stern tube supply.

c. Existing vent piping from FWD seal leading to passage 3-79-01 shall be modified IAW with work item. The vent piping above the split with the FW CLS return piping will remain and have an isolation valve installed per reference 2.1.1.

d. Replace the existing valves on the SW system on the bottom of the stern tube and install ½-inch sample valve IAW reference 2.1.1 on the existing salt water piping near the stern tube.

7.3.5 Head Tank piping:

a. Install NEW FW supply, NEW Distilled water Supply to Head Tank, FW return, vent, and supply piping in accordance with reference 2.1.1.

b. Head Tank shall be fitted with SURESITE Site Glass and Switch modules for High and low level alarms and isolation ball valves as per reference 2.1.1.

c. The head tan TLI will be positioned to allow it to be visible from the port side looking inboard. (The position of the ladder blocks the view of the TLI if TLI is facing aft.)

7.3.6 Pump/Motor and Strainer Bedplate piping:

a. Install NEW piping in accordance with reference 2.1.1.

7.3.7 Heat Exchanger piping:

a. Install NEW piping in accordance with reference 2.1.1.

b. SW overboard piping from heat exchanger shall be run overboard and adjacent to heat exchanger between longitudinal stiffeners, away from welds, and existing external ICCP Coating System. Penetration will be 1 or 2 feet away from bulkhead leading to shaft alley. MSCREP and Wartsila REP will determine exact location.

c. Provide the exact location of the hull plating penetration referenced from the first frame forward and the first longitudinal inboard of the penetration.

7.3.8 Distilled Feed Water to Head Tank:

a. Supply or feed water to the Head tank shall run downstream of Distillate hydrophore tank in motor propulsion room (5-75-0), 4th deck to ½” flanged connection on head tank as per reference 2.1.1.

b. Install 2ea 1/2" NPS isolation ball valves, 1ea at hydrophore connection in motor propulsion room (5-75-0) and 1ea at head tank in fan room (2-75-2).

7.3.9 Vortex Flow Meters, Temperature/Pressure Gauges, and Tank Level indication:

a. Install NEW Vortex flow meters, temperature/pressure gauges, transducers, and tank level indicators (calibrated) in accordance with reference 2.1.1.

b. Vortex flow meters, pressure and temperature gauges, Tank Level indication (4-20mA) shall be connected to DAU20 unless GE Energy Rep sees otherwise. SY Contractor shall run cable to and from sensor(s) to appropriate DAU.

c. Ensure the MCCS setting for the identified pressure gages in reference 2.1.1 is 0-87.02 psi over a 4-20mA signal.

d. Ensure the 1.1/2 inch flow meters are set to have an output of 0-50 gpm. This will be programmed at the flow meter itself.

e. GE Energy Tech Rep shall update the IO Schedule spreadsheet to quantify sensor location, DAU, equipment description, sensor type, module type, channel number etc. and provide the Chief Engineer and MSC Rep the updated copy in excel format.

7.4 Electrical:

7.4.1 All Electrical work shall be performed in accordance with IEEE Std 45 requirements.

7.4.2 All wiring/connections/cable runs, etc shall be installed in accordance with reference 2.1.1.

7.4.3 Motor Controller shall be mounted on the forward bulkhead off the centerline outboard of the Pump/Motor/Strainer Bedplate in Shaft Alley (5-79-0).

NOTE:

Since Custom Panel and Controls LLC is the OEM, the OEM shall make all connections of cabling to the motor controller cabinet and all system sensors.

7.4.4 Signal Cabling shall be run to/from DAU 20 unless otherwise directed by the MSCREP. DAU 20 is located in Propulsion Motor Equipment Rm (3-75-1) as identified in reference 2.1.1. GE Energy shall be make connections to DAUs.

7.4.5 Supply Power shall be provided from Power Panels P418 and P415 (480VAC) as per reference 2.1.1.

7.5 Electronics:

None.

7.6 Preparation of Drawings/Documents:

7.6.1 Contractor shall provide structural, Electrical, and Piping “As Built” drawings.

7.6.2 As Built drawings shall be provided in Autocad and Pdf format (electronically).

7.6.3 As Built shall be provided to the MSCREP from references 2.1.1. OEM shall provide all necessary piping, electrical, and structural diagrams for Shipyard bidding purposes.

7.7 Inspections and Testing:

7.7.1 All deck/bulkhead collars and penetrations shall be air tested. No leakage allowed. All tests shall be performed prior to installing lagging/insulation and applying paint to any disturbed surfaces.

7.7.2 WARTSILA OEM Technical Representative shall Torque fasteners in accordance with all applicable references. MSCREP / ABS shall witness.

7.7.3 Connect NEW fresh water cooling water union to the Aft Seal. Fill the system with Distilled water and perform a hydrostatic test. Criteria, Hydrostatic test pressure 30psi (2bar) for 15 minutes. Leakage rate shall not exceed 1.8 Liters per hour. MSCREP, Chief Engineer, and ABS shall witness hydrostatic tests.

7.7.4 Perform operational check of NEW system. MSCREP, Chief Engineer, and ABS shall witness testing. To include:

7.7.5 Operate the system for a minimum of four hours during which the strainers will be cleaned when pressure differential alarms occur or every thirty (30) minutes or longer if PD alarms continue or strainer continue to have debris. Record the system pressures, flow rates, and make-up water usage during testing of the FW CLS.

7.7.6 Complete SOVT of all alarms and set points. Provide results of SOVT testing.

7.8 Painting, labeling and Markings:

7.8.1 Clean, prime, and paint all new and modified surfaces to match surrounding surfaces in accordance with GTR 7.

7.9 Marking:

7.9.1 Label all new piping/valves with service and direction of flow in accordance with GTR 29.

7.9.2 Place welded hull numbering to the FW CLS heat exchanger overboard IAW direction of the N7 Rep.

7.10 Manufacturers Representative:

7.10.1 Contractor shall provide the following OEM Technical representatives:

Propulsion Shafting and FWCL;

Wartsila Defense Inc.

Scott Miller

3617 Koppens Way

Chesapeake, VA 23323

Office: 757-966-5420

Fax: 757-558-4831

Cell: 757-927-4422 MCCS Software and DAU Connections;

GE Energy

David Thornton

Phone: 804-955-0015

610 Epsilon Drive

Pittsburgh, PA 15238

Phone: 804-955-0015 FWCL Electrical Connections and Calibration;

Brian Perry / Matt Werling

Custom Panel and Controls LLC

2697 International Parkway, Pkwy 4 Suite 180 Virginia Beach, VA 23452

Office: 757-226-0522

8.0 GENERAL REQUIREMENTS: None additional.

62.5mm before machining

Chamfers for fitting

Chamfers for Welding

941 - 2

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