0517_A_INSTALL_OILY_WATER_SEPERATOR_TALT_301_ARCTICROH20_REV1.docx

USNS ARCTIC

(T-AOE 8)

INSTALL OILY WATER SEPARATOR (OWS) UNIT

1.0 ABSTRACT

This item describes the removal of two (2) existing Oily Water Separators Heli-SEP Model 5000-OCD and installation of the Alfa Laval PureBilge Model No. 2505 Oily Water Separator, 90 kW heater module and feed pump unit in Main Machinery Room No. 1 Lower Level (7-455-01-E).

2.0 REFERENCES / ENCLOSURES

2.1 REFERENCES

2.1.1 MSC Drawing No. 505-8613401 Rev -, T-AOE-8 Oily Water Separator Installation Piping Mods

2.1.2 MSC Drawing No. 512-8613400 Rev -, T-AOE-8 Oily Water Separator Incidental HVAC Mods

2.1.3 MSC Drawing No. 180-8613402 Rev -, T-AOE-8 Oily Water Separator Arrangement & Structural Details

2.1.4 MSC Drawing No. 320-8613403, Oily Water Separator Electrical Mods

2.1.5 2.1-004-ALL Lockout-Tagout, MSFSC Safety Management Procedures Manual

2.1.6 PureBilge Bilge Water Cleaning System, Installation System Reference (Printed Feb 2017) Book No. 592108-02 V8

2.2 ENCLOSURES

2.2.1 Grounding Stud Installation

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Location: MMR 1 (7-455-01-E)

3.1.2 Quantity: One Unit

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 Lists of Materials of References 2.1.1 through 2.1.4.

3.2.2 Quantities specified in the List of Materials of References 2.1.1 through 2.1.4 are considered estimates. The contractor shall provide the exact quantities and additional material such as miscellaneous pipe fittings, elbows, caps, valves, pipe/duct/cable hangers, weld material, cable tags, etc., which are not included in the List of Materials of References 2.1.1 through 2.1.4, in order to install a fully functional system which meets the requirements of this specification.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Government Furnished Equipment (GFE)

4.1.1 One PureBilge 2505 Oily Water Treatment System, Alfa Laval, Part No. 589817-85

4.1.2 One Sludge Removal Kit, Alfa Laval, Part No. 589459-80

4.1.3 One Polishing Filter Block, Alfa Laval, Part No. 590033-80

4.1.4 One 90 kW Electric Heater Module (2.5 m3/h capacity), Alfa Laval, Part No. 5935036-80

4.1.5 One 2500 l/h Feed Pump Unit, Alfa Laval, Part No. 591252-80

4.1.6 One Frequency Converter Panel VFD, Alfa Laval, Part No. 591570-01

4.2.2 MSC Drawing 8613400, Sheet 2, List of Material Item #3, QTY 2, Air Filter Housing Coil End, Type C, Size 66 Coil.

4.2.3 MSC Drawing 8613400, Sheet 2, List of Material Item #1, QTY 2, Fan, Vaneaxial.

4.2.4 MSC Drawing 8613400, Sheet 2, List of Material Item #2, QTY 1, Cooling Coil

4.3 Government Furnished Services (GFS): None

4.4 Government Furnished Information (GFI): 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. 21 – Joiner Work GTR No. 23 – Piping GTR No. 24 – Manufacturer’s Representatives GTR No. 25 - Structure and Foundations GTR No. 26 - Interior Deck Coverings GTR No. 27 - HVAC GTR No. 28 – Electrical and Electronics Systems GTR No. 29 – Identifying Markings

5.3 Prior to initiating any work on the electrical system, de-energize and tag-out all sources of electrical power to the circuits involved in accordance with standard electrical safety practices (Reference 2.1.5). Restore electrical power upon completion of all aspects of this work item.

5.4 All Electrical work shall be performed in accordance with ABS, USCG, and IEEE-45, MIL-STD-1310(G) requirements.

5.5 If additional wireway or cable penetration material is required, the installing activity shall provide miscellaneous material to suit.

5.6 New cable and/or mounting of equipment that requires welding or hot work performed in the service areas (from the interior or exterior) shall maintain the fire tightness to the satisfaction of the ABS surveyor and the MSCREP.

5.7 Any vacated penetrations or equipment removal from the service areas must be plugged and sealed for water tightness and fire tightness to the satisfaction of the ABS surveyor and the MSCREP.

5.8 All welding shall be in accordance with ABS rules for building and classing steel ships.

5.9 All shipboard structure, hull insulation, sheathing, etc. damaged or disturbed by these modifications shall be repaired similar to the original or surrounding materials.

5.10 Minor deviations from the drawings are authorized if appearance, function and strength are not impaired.

5.11 Submit Request for Deviation (RFD) to the MSC Representative for approval for any areas that appearance, function and strength are impaired.

5.12 It is the responsibility of the contractor to determine the best routing of removed and added equipment, components, and material. For guidance, it is expected that removal of the inclined ladders between the MMR1 Lower Level and the MMR 1 Intermediate Level and between the MMR1 Intermediate Level and the MMR 1 Upper Level will be required and opening of a Bolted Equipment Removal Plate (BERP) between the MMR1 Upper Level and Elevator No. 7 (5-445-0-T) will then allow routing of large items to and from topside spaces.

5.13 Control and monitoring signal connections shall be verified by the installing contractor via continuity testing or other means prior to making any modifications, to ensure that the control system design intent is met.

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

7.0 STATEMENT OF WORK REQUIRED

7.1 Arrangements/Outfitting:

7.1.1 Removals

7.1.3 Installations

a. Install PureBilge 2505 Oily Water Treatment System and Skids, 90 kW Electric Heater Module, OWS Feed Pump, frequency converter panel, Sludge Removal Kit, and Polishing Filter Block provided as GFE in paragraphs 4.1 using Reference 2.1.3 as guidance.

7.2 Structural

7.2.1 Removals

a. Remove portions of the existing structural containment coaming for Oily Water Separators in Main Machinery Room No. 1 (7-455-01-E) using Reference 2.1.3 as guidance.

b. Remove existing structural foundations for OWS and Oil Content Monitors using Reference 2.1.3 as guidance.

c. Remove HVAC equipment foundations using Reference 2.1.3 as guidance.

7.2.2 Installations

a. Fabricate and install foundations for the new Oily @Water Separator, Electric Heater Module, Feed Pump Unit, and VFD Control Panel using Reference 2.1.3 as guidance.

b. Install modified containment coaming using Reference 2.1.3 as guidance.

c. Install grounding strap and studs in accordance using Reference 2.1.4 and Enclosure 2.2.1 as guidance.

d. Fabricate and install HVAC equipment foundations using Reference 2.1.3 as guidance.

e. Fabricate and install HVAC thermostat mounting using Reference 2.1.3 as guidance.

7.3 Mechanical/Fluids

7.3.1 Drain, isolate and tag out the sections of piping being worked using Reference 2.1.5 as guidance or MSCREP approved local tag out procedures.

7.3.2 Removal

a. Remove existing piping using References 2.1.1 and 2.1.2 as guidance.

b. Remove existing pressure gages for Oily Water Separator and Strainer using Reference 2.1.1 as guidance.

c. Remove existing HVAC fan 5-496-1, cooling coil, air filter, pressure gage, associated ventilation ducting, piping, incidental piping impacts, and associated hangers using Reference 2.1.2 as guidance.

7.3.3 Installations

a. Using the equipment installed in 7.1.2a integrate all necessary components to provide the form, fit, function of the new OWS Treatment System and supporting equipment using References 2.1.1, 2.1.2, 2.1.3, and 2.1.4 as guidance.

b. Install new OWS piping and components using Reference 2.1.1 as guidance.

c. Fabricate and install HVAC equipment foundations and hangers using References 2.1.2 and 2.1.3 as guidance.

d. Install new and replacement HVAC equipment, ducting, piping, and valves, including incidental piping impacts using Reference 2.1.2 as guidance.

e. Lag and insulate all new installed Recirc ducting and piping using Reference 2.1.2 as guidance.

7.3.4 Contractor shall dispose of all waste materials, after prior approval of the MSCREP. No items shall be left for ship’s force disposal.

7.4 Electrical

7.4.1 Removals

a. Remove cable 3S-4P(5-475-1), TNW-150 from Switchboard 3S to Power Panel 5-475-1 in MMR1 using Reference 2.1.4 as guidance.

b. Remove power cables associated with the Heli-Sep 5000 OWS No. 1 and No. 2 and Oil Content Meters in MMR1 using Reference 2.1.4 as guidance.

c. Remove the #2 OWS signal cables to and from the K-4LD10 Junction Box and the Machinery Control Console in Central Control Station (1-459-1-C) using Reference 2.1.4 as guidance. Update the Machinery Control System software to update the display to the Machinery Control Console monitor.

c. Remove signal wires associated with the Heli-Sep 5000 OWS No. 1 in MMR 1 to the K-4LD10 Junction Box using Reference 2.1.4 as guidance. Retain the wire tags to reuse for installing the new signal wires for the new equipment.

d. Remove signal wires associated with the Heli-Sep 5000 OWS No. 2 in MMR 1 to the K-4LD10 Junction Box using Reference 2.1.4 as guidance.

a. Disconnect cable GC15-4P-G, T3 from existing HVAC fan 5-496-1 motor. Reconnect cable GC15-4P-G, T3 to the replacement HVAC fan motor installed on Reference 2.1.2. If the existing cable is not long enough, use the junction box and cable provided in the Bill of Material to make the connection using Reference 2.1.4 as guidance.

a. Relocate light fixture in way of HVAC modifications using Reference 2.1.2 as guidance.

7.4.3 Installations

a. Install cable from Switchboard Number 5S to Power Panel 5-475-1 in MMR1 using Reference 2.1.4 as guidance.

b. Install the motor controller in MMR1 using References 2.1.3 and 2.1.4 as guidance. Install cable (5-475-1)4P-A(1) LSTSGU-4, from Power Panel 5-475-1 to the new HVAC fan 5-464-1 motor controller using Reference 2.1.4 as guidance.

c. Install the AQB-A101 25 Amp circuit breaker in Power Panel 5-475-1 in position B. Install cable (5-475-1)4P-B LS4OW-9, from Power Panel 5-475-1 to the new OWS Operator Panel using Reference 2.1.4 as guidance.

d. Install the AQB-A250 150 A circuit breaker in Power Panel 5-475-1 in position H. Install cable (5-475-1)4P-H LS4OW-100, from Power Panel 5-475-1 to the new OWS Heater using Reference 2.1.4 as guidance.

e. Install cable (5-475-1)4P-A(2), LSTSGU-4 from the motor controller to the new HVAC fan motor and cable K-(5-477-1)/(5-477-7)LSTSGU-4 from the motor controller to the new thermostat. Mount the temperature sensor in a convenient location adjacent to thermostat. Install cables from the thermostats to the chilled water solenoid valves using References 2.1.2, 2.1.3 and 2.1.4 as guidance. Install HVAC thermostats and cabling using References 2.1.2 and 2.1.4 as guidance.

f. After the new OWS equipment is placed, mount the Variable Frequency Drive on the I-beam adjacent to the equipment using References 2.1.4 and 2.1.6 as guidance. Install cable (5-590-5)/(5-488-6), 4G2,5 using References 2.1.4 and 2.1.6 as guidance.

g. Install cable K-(5-490-5)/4LD10, 2X-7 from the new Oily Water Separator equipment to the K-4KD10 Junction Box using References 2.1.4 and 2.1.6 as guidance. The RJ45 connector to cable K-(5-490-5)/4LD10, 2X-7 is provided in the BOM of Reference 2.1.4. The contractor shall coordinate the RJ45 connector installation with a subcontractor incorporating the signals into USNS Arctic’s Machinery Control System (MCS).

h. There are a number of Alfa Laval cables that are not provided or pre-installed. The contractor shall coordinate with the Alfa Laval Representative to insure these connections are made. See Table 1 and Figure 1 below. The cables for these connections have been called out in the BOM of Reference 2.1.4. A full listing of the cables with their connections and schematics are found in Reference 2.1.6.

Table 1: Cables and Connections Not Provided by Alfa Laval. Taken from Reference 2.1.6 sheets 63 and 64 of 156.

Figure 1: Oily Water Separator Electrical System Layout with Cables and Connections Highlighted that are Not Provided by Alfa Laval

i. The shipyard shall subcontract USNS Arctic MCS Control System OEM, to incorporate/program the signals from the new Oily Water Separator equipment into USNS Arctic’s MCS. All references to OWS 2 shall be removed and the three (3) OWS 2 signals shall be removed. All references to OWS 1 shall be modified to OWS and that the three OWS 1 signals shall be renamed OWS.

7.5 Electronics: None Additional

7.6 Preparation of Drawings

Provide As-Built “red-lined” markups of References 2.1.1, 2.1.2, 2.1.3, and 2.1.4 reflecting any deviations from the original plans. Redlined drawings are to be reviewed and approved by the local MSCREP prior to acceptance. Drawing number and sheet number must be legible in all submitted formats. Three hard copies - 11” X 17” or larger as required for clarity, and one electronically scanned copy of the following drawings showing all new and modified installation accomplished by this work item shall be provided. Drawings as a minimum shall include:

Machinery Arrangement One-Line Diagrams

7.7 Inspection/Test

7.7.1 Preliminary Tests

Contractor shall conduct preliminary tests on all completed work before calling for an official test. The Contractor shall work with the OEM and MSC to integrate and Commission the system as fully compliant with the OEM operational parameters and MSC requirements.

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 piping and structural work this means the shipyard shall notify the ABS surveyor to inspect completed 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.

7.7.4 Cable Insulation Resistance Test

a. 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.

b. Notify the MSCREP immediately if insulation values of equipment or cable are less than 1 Megohm (MΩ).

7.7.5 Enclosure Ground Test

Test new, modified, overhauled, or repaired electrical/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 Variable Frequency Drive and Alfa Laval OWS Equipment Commissioning.

As guidance it is expected that the contractor shall coordinate with the Alfa Laval Representative for the commissioning of the variable frequency drive to the feed pump motor and the operational acceptance testing of the new OWS equipment.

7.7.7 Clean and Flush All Piping

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

7.7.8 Hydrostatically test all new and modified piping for 30 minutes using test pressures defined in References 2.1.1 and 2.1.2. 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.

7.7.9 Following the cleaning and flushing and hydrostatic testing, disinfect new crossover piping from Oily Water Separator to new connection with existing Potable Water System.

7.7.10 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.

7.7.11 General Operational Test

In the presence of the ABS Surveyor and MSC Representative, verify that:

The OWS OEM representative will be required to attend the sea trial and ride the vessel to Norfolk, Virginia. This will allow a full test of the unit with no restrictions.

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.

7.7.12 Additional Operational Tests

Perform an operational test of each affected HVAC system to the satisfaction of the MSC representative (MSCREP).

Test and balance all new and modified ventilations systems in accordance with Reference 2.1.2.

Test all new and modified piping in accordance with References 2.1.1 and 2.1.2.

7.8 Painting

Clean and prepare the disturbed areas and apply two topcoats of paint to all areas disturbed to match the surrounding areas per MSC GTR 7.

7.9 Markings

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

7.10 Manufacturer’s Representative: Provide the services of an Alfa Laval authorized representative to commission the installation of the Oily Water Treatment System and supporting equipment.

8.0 GENERAL REQUIREMENTS: None additional

Approximate Welded Stud Location Use ¼” fillet weld Approximate Bolted Stud Location:

Locate at the middle of the panel’s depth.

Enclosure 2.2.1: T-AOE 8 Power Panel 5-475-1 Grounding Stud Installation

Shown above is guidance for the installation of a set of grounding studs in the enclosure for power panel 5-475-1 and on the bulkhead immediately adjacent. Connect the grounding studs with the grounding strap. All material provided by Reference 2.1.4.

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