0956_A_TAKE CCSI OVERHAULING SEA VALVES (5YR) (2).docx

USNS LEWIS AND CLARK

(T-AKE 1)

OVERHAULING SEA VALVES (5YR)

ABSTRACT

The work item describes the requirements to examine, service and test the ships sea chests, sea valves and their attachment to the hull during the Special Survey.

REFERENCES/ENCLOSURES

References MSC Drawing 801-8388177, Docking Plan MSC Drawing No. 163-8193708, List of Closeable Exterior Shell Penetrations MSC Drawing No. 256-8194714, Central Seawater Cooling System Diagram ABS Rules for Survey After Construction, Part 7, Chapter 4, Section 1, Drydock Surveys (Commercially Available) Enclosure Sea Valve List

ITEM LOCATION/DESCRIPTION

Location/Quantity Locations: See Enclosure 2.2.1 Quantity 42 valves below scantling draft (9.75M) 40 valves above scantling draft (9.75M)

1.1 Item Description/Manufacturer’s Data: See Enclosure 2.2.1 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE: Valves to be replaced.

SC-V-101

SC-V-110

SC-V-150

SC-V-151

OW-V-128

OW-V-040

MD-V-37

MD-V-86

SC-V-100

SC-V-111

SC-V-152

TV-V-37

TV-V-39

TV-V-41

TV-V-43

SW-V-211

WD-V-122

WD-V-123

WD-V-124

WD-V-131

WD-V-132

DD-V-011

CH-V-52

FM 5-65-3

FM 5-65-18

SW-V-041

SW-V-1

SW-V-04

SW-V-33

MD-V-024

BW-V-07

FM COV 4-75-2

FM COV 5-36-2

DB-V-002

FM COV-5-61-4

SW-V-241

CH-V-52

WD-V-120

NOTES

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 including but not limited to GTRs 1 through 7, 22, 23, 24, 28, and 29.

The contractor and all subcontractors regardless of tier are advised to review other work items under this contract, including but not limited to Work Items 023, 901, 913 and 915, to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

THIS SHIP CONTAINS HIGH VOLTAGE (HV) ELECTRICAL SYSTEMS. OBEY ALL POSTED AND VERBAL INSTRUCTIONS REGARDING SAFETY AND EXCLUSION FROM HIGH VOLATGE AREAS. AT NO TIME APPROACH, WORK ON, OR ENTER A HIGH VOLTAGE AREA WITHOUT PROPER AUTHORIZATION.

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 ELECTRICAL CABLES TO ENSURE THEY ARE DE-ENERGIZED PRIOR TO WORKING ON THE ITEM.

QUALITY ASSURANCE REQUIREMENTS: None additional.

2.0 STATEMENT OF WORK REQIRED

With ship’s force assistance, tag out required equipment and systems.

Examine, service and test the vessels sea chests, sea connections, sea suction and overboard valves and their attachments to the sea chest or hull using ABS, USCG, IMO and manufacturer requirements using References 2.1.1 through 2.1.4 and Enclosure 2.2.1 for guidance.

2.1.2 Temporarily open the sea chest suction grates and provide staging for inspection. Temporarily remove deck plating in way of sea valves and hull attachments to facilitate their inspection. Temporarily rope off the areas to prevent accidental injury. Restore upon completion of all repairs.

2.1.3 In the presence of ABS and/or USCG, externally examine all sea chests, sea valves and their attachment to sea chests, including expansion pieces in sea water cooling and circulating systems. Internally exam all sea chests, sea connections and spool pieces.

Shell fastenings securing the various valves, and associated parts such as pads, nipples, spuds, spool pieces, studs and flanges are to be hammer tested and examined in the presence of ABS and/or USCG.

Temporarily open the main sea water strainers and remove their strainer baskets/plates. Thoroughly clean and inspect the strainers and their components.

Inspect all associated valve actuators and reach rods. Exercise them, both locally and remotely. Grease all joints and gear boxes. Replace all missing or deteriorated pins. For bidding purposes assume 10 pins will require renewal.

Accomplish the following maintenance to the ship’s sea suction and overboard valves shown in References 2.1.1 through 2.1.3 and Enclosure 2.2.1 for guidance using ABS, IMO and manufacturer requirements as guidance:

2.1.4 Temporarily remove valves from the vessel to the shop for repair, inspection and testing. Tag and match mark each sea valve to its original location.

2.1.5 Where sea valves have been removed, temporarily install bolted hard blanks on all openings through the sea chests and any open piping systems. Contractor is responsible for any flooding or contamination of interior areas or systems resulting from contractor failure to install blanks. Any/all damages resulting shall be addressed, repaired, and/or corrected, at contractor’s expense.

2.1.6 Replace the valves listed in paragraph 4.2.1 with new valves, utilizing Reference 2.1 as guidance.

2.1.7 Clean the removed 24-inch and 30-inch valves and perform a Seat Leak test in the presence of the MSCREP and ABS. Valves that pass the inspection shall be properly protected, crated, and returned to ship for spare.

2.1.8 Temporarily remove motor operators and actuators from the valves. Protect and secure them in an out of the way location. Do not electrically disconnect the motor operators and actuators. Do not allow the motor operators and actuators to hang from their electrical cables and ensure they are protected from damage.

2.1.9 In lieu of overhaul, replace all 2-½ inch or smaller valves (except GFM provided) with new equivalent valves, new gaskets and stainless steel fasteners.

Disassemble the valves, bonnet, packing gland, and internals. Matchmark and clean all parts. Layout all parts and components for inspection by the MSCREP and ABS Surveyor.

Retain hardware and fasteners for re-use. Damaged or missing hardware or fasteners shall be renewed. For bidding purposes assume that 10% of flange fasteners will require replacement.

Chase and tap all threaded areas. Dress and true gasket mating surfaces. Clean and prepare the valve body interior for painting.

Straighten valve stems to within 0.002 inch total indicator run-out. Polish stems to a 32 finish (RMS). Remove any raised edges and foreign matter.

Machine, grind and lap valve seats and discs. Spot in the gate or disc to its seat obtaining a 360 degree contact. Verify contact using the bluing method in the presence of the MSCREP and the ABS Surveyor and USCG inspector.

For gate valves, the transfer line shall be of uniform width within the center of disc seating surface;

For globe valves, transfer line shall be of uniform width covering one third of the seating surface within the center fifty percent of disc seating surface and at the bottom edge of the conical seat;

For plug and ball valves, vertical misalignment of parts with the plug or ball fully seated is not to not exceed 1/16 inch;

For butterfly valves, provide and renew bushings, O-rings, valve boot (butyl seat), washers, pins, fasteners, packing and seals.

2.1.10 For valves with steel bodies, coat valve body interiors with two (2) coats of Apexior No. 3.

2.1.11 Replace all bonnet gaskets, flange gaskets and valve stem packing with new material.

2.1.12 All fasteners shall be coated with "Anti-Seize" compound prior to installation.

2.1.13 Upon satisfactory inspection of all valve components and seat contact checks by the MSCREP and ABS Surveyor reassemble the valves leaving them in a ready for service condition.

2.2 Coordinate and conduct tests of the sea chests, sea connections, sea suction and overboard valves and their attachments listed in Enclosure 2.2.1 in the presence of the MSCREP and ABS Surveyor:

2.2.1 For valves new and repaired in the shop, conduct;

a. Liquid penetrant inspections of the seats, disc, and body inlay areas for cracks.

b. Hydrostatic tests on each valve to 5 bar (5.1 kgf/cm2, 72.5 psi. Test shall be applied to each side of valve seat and disc. Demonstrate that the valves are leak free in the presence of the MSCREP and ABS Surveyor and USCG inspector. Hydrostatic pressure test shall be performed and demonstrated in direction from sea.

c. After successful testing, convey valves back to ship and install using new gaskets and monel hardware.

2.2.2 With ship’s force assistance, remove tags and operationally test all motor operated valves (MOV) and reach rod operated valves to ensure they are installed and function correctly.

2.2.3 Visually examine the sea chests, sea connections and sea valves during undocking of ship. No leakage is allowed at valve stems or disturbed joints.

2.2.4 Operationally test all the sea chests, sea connections and sea valves during undocking of ship to the satisfaction of MSCREP and Chief Engineer. Verify they operate correctly and are leak free.

2.3 Reports

2.3.1 When examination, servicing and testing reveal any deficiency a condition report is to be submitted to the MSCREP with recommended repair and parts required. Submit three (3) typewritten copies and one (1) electronic copy in Portable Document Format (PDF).

2.3.2 Sea Valves Status Spreadsheet:

7.5.2.1 Provide Sea Valve Status Spreadsheet and updated status with weekly progress report. Sea Valve Status Spreadsheet shall include but not be limited to the following information:

a. Valve designation/type/size/location

b. Removed

c. Hydrostatic Pressure Test (initial)

d. Pass/Fail

e. Disassembled/Cleaned

f. Overhauled

g. Hydrostatic Pressure Test (Final)

h. Pass/Fail

i. Painted

j. Installed / Not installed

2.3.3 Submit three (3) typewritten copies of the sea valve hydrostatic test results and one (1) electronic copy in Portable Document Format (PDF) to the MSCREP and one (1) electronic copy in Portable Document Format (PDF) to the ABS Surveyor.

2.4 Painting/Lagging

2.4.1 Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces.

2.4.2 Restore all disturbed lagging.

2.5 Manufacturer’s Representative: None additional.

2.6 Preparation of Drawings: None

3.0 GENERAL REQUIREMENTS: None additional.

USS MOUNT WHITNEY

(LCC 20)

OVERHAULING SEA VALVES (5YR)

USNS LEWIS AND CLARK

(T-AKE 1)

OVERHAULING SEA VALVES (5YR)

956-6

Enclosure 2.2.1 SEA VALVE LIST –

956-9