502_A_(REV C) SLEP- TLI SENSOR INSTALLATION PHASE 2 (T-ALT 14009).doc

USNS Comfort

( TAH 20 )

1. ABSTRACT

1.1. This item describes the work to install Tank Level Indicating (TLI) sensors in 20 tanks, 6 additional Flat Panels, and replace / install additional UPS units in accordance with Phase 2 of the installation.

2. REFERENCES/ENCLOSURES

2.1. References:

2.1.1. COMSC INSTRUCTION 4700.16, MSC General Technical Requirements.

2.1.2. MSC Drawing No. 803-7080703, Preparation of Computer Aided Design (CAD) Drawings

2.1.3. MSC EPI No. N712-006.00, “Paint Approval Procedures and Approved Products”

2.1.4. NAG-SK-0053C_REV-A_DFM, TLI Installation DFM Tanks

2.1.5. NAG-SK-0054C_REV-D, TLI Bwd & Elem & Pwr Rqmts & Removal & Installation Mods

2.1.6. NAG-SK-0058 REV-_OIP, 19” Flat Panel Display Outline Drawing

2.1.7. NAG-SK-0059_REV-_4-22-15, TLI Installation JP-5 Tanks

2.1.8. NAG-SK-0060C_REV-A_Tank Level Indicator (Wire) Installation Ballast Tanks

2.1.9. MSC Drawing No. 801-5980694, Tank Capacity Tables

2.2. Enclosures: None

3. ITEM LOCATION/DESCRIPTION

3.1. Location/Quantity

3.1.1. Location:

3.1.1.1. Tank Locations: This work item pertains only to the tanks listed below using references 2.1.4 thru 2.1.8 as guidance. Note that there are more tanks listed in the drawings than listed below. Only those listed below and their associated items are applicable to this work item:

DELETED

DELETED

DELETED

DELETED

DELETED

3.1.1.2. Equipment Locations:

(6-95-0)

REPLACE EXISTING APC UPS

(1-52-1)

REPLACE EXISTING APC UPS

(5-84-2)

REPLACE EXISTING APC UPS

(03-36-1)

NEW

(1-91-1)

NEW

(6-51-0)

NEW

(03-91-0)

NEW

(1-91-1)

NEW (ETHERNET NIC)

(6-51-0)

NEW (ETHERNET NIC)

(3-42-1)

NEW (ETHERNET NIC)

(03-33-2)

NEW (FIBER OPTIC NIC)

(04-34-0)

NEW (FIBER OPTIC NIC)

(03-91-0)

NEW (ETHERNET NIC)

3.1.2. Quantity:

3.1.2.1. Equipment Quantities:

Note: 4 of the flat panel monitors require Ethernet network interface cards and 2 require a fiber optic network interface card as noted in References 2.1.4 thru 2.1.8.

3.2. Item Description/Manufacturer’s Data:

3.2.1. Quantities where stated are considered estimates. The contractor shall provide the exact quantities and additional material such as miscellaneous fittings, elbows, caps, valves, pipe hangers, weld material, cable hangers, cable tags, bus-work, etc., which are not included in the Bill of Materials, in order to install a fully functional system which meets the requirements of this specification.

4. GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1. Government Furnished Equipment (GFE): None

4.2. Government Furnished Material (GFM): None

4.3. Government Furnished Services (GFS): None

4.4. Government Furnished Information (GFI): None

5. NOTES

5.1. The ship’s force will provide access to any required spaces.

5.2. The contractor and all subcontractors, regardless of tier, must consult the General Technical Requirements (GTR), Reference 2.1.1, to determine applicability to this work item. In performance of this 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, 3, 4, 5, 6, 7, 28 and 29.

5.3. The contractor 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.

6. QUALITY ASSURANCE REQUIREMENTS

6.1.

In addition to the contractor’s duties under 29CFR1910.147 or similar local safety regulation, the contractor shall comply with all requirements of equipment lock-out/tag-out (LOTO) program as established by MSC SMS procedure 2.1-004-ALL Lock-out/Tag-out. The Chief Engineer shall administer the program. Prior to the start of work, the contractor shall contact the MSCREP and / or the Chief Engineer to coordinate the implementation of the LOTO program for the entire performance period of this item. The prime contractor shall be responsible for compliance by both prime and subcontractor personnel.

7. STATEMENT OF WORK

7.1. Arrangements/Outfitting:

7.1.1. Remove, reinstall, and modify (with approval by MSC REP) interferences as required to complete this WI.

7.2. Structural: None

7.3. Mechanical/Fluids:

7.3.1. Removals:

7.3.1.1. Existing GEM sensors and level switches along with associated equipment and supports shall be removed in their entirety using References 2.1.4 thru 2.1.8 as guidance.

7.3.2. Installations:

7.3.2.1. Design and install foundations for new flat panel repeater display screens. Exact locations and design to be approved by the MSC REP prior to installation.

7.3.2.2. Install foundations for any new junction boxes using references 2.1.4 thru 2.1.8 as guidance. Exact location of the new junction boxes is subject to MSC REP review and approval.

7.3.2.3. Design and install foundations for new UPS units and if possible modify reuse existing UPS foundations for those being replaced. Exact locations and design to be approved by the MSC REP prior to installation.

7.3.2.4. Install the supporting structure for the new TLIs using references 2.1.4 thru 2.1.8 for guidance.

7.4. Electrical:

7.4.1. Removals:

7.4.1.1. If existing GEM sensors or level switches exist for the tanks identified in section 3.1.1.1 then those sensors and signal cables shall be removed using References 2.1.4 thru 2.1.8 as guidance.

7.4.1.2. Remove existing UPS units and power cables identified in reference 2.1.5.

7.4.1.3. Remove cabling and equipment for the JP-5 Storage, Service, and Sludge Tanks using references 2.1.4 thru 2.1.8 as guidance.

7.4.2. Installations:

7.4.2.1. Install new UPS units and power cables for those that were removed in section 7.4.1.2 using references 2.1.5 as guidance.

7.4.2.2. Install new TLIs in locations shown on references 2.1.4 thru 2.1.8. Installation shall be completed using references 2.1.4 thru 2.1.8 as guidance.

7.4.2.3. Run new cables and connect wiring from new TLIs to existing system. Use references 2.1.4 thru 2.1.8 for guidance. The integration of new TLI’s includes a combination of connecting to existing connection boxes, as well as direct connections to input boards on existing programmable logic controllers. All connections shall be made by a NAG representative.

7.4.2.4. A NAG representative shall be present to calibrate the new TLIs using references 2.1.4 thru 2.1.8 as guidance.

7.4.2.5. Install four new flat panel repeater display screens as specified in table 3.1.2.1 and using references 2.1.4 thru 2.1.8 as guidance.

7.4.2.6. Install six new UPS units as specified in table 3.1.2.1 and using references 2.1.4 thru 2.1.8 as guidance.

7.4.2.7. The contractor shall be responsible for integrating the new TLIs into the existing system. This shall include updating the existing displays to show the TLIs installed under this item.

7.4.2.8. Where practical, run new cables in existing cableways, hangers, collars, and penetrations. Pack existing cable penetrations with appropriate material to match. Where they are full, contractor to provide labor and material for new cableways, hangers, and penetrations to include all kickpipes, packing glands, MCT’s, MCT blocks, fire sealant as required and install in accordance with ABS and USCG requirements. All penetrations shall be inspected by ABS, USCG, and MSC REP during a call out.

7.4.2.9. The contractor shall program the system for the following:

7.4.2.9.1. To provide a continuous alarm at all display stations until it is silenced by the Master Panel. Individual station can only silence the audible alarm at that local panel only but the visual alarm should still continue to flash on both the HMI and the alarm list until it is silenced at the Master Panel. Once acknowledged at the Master Panel, the HMI and the alarm list will stop flashing and stay red while still in the alarm condition on all panels.

7.4.2.9.2. The Master Panel, located in the EOS shall be the only panel that acknowledging the alarm for the entire system is allowed.

7.4.2.9.3. Access to time delays and high low level alarms shall be provided to the ships crew and only available at the Master Panel for all TLI’s, including those already installed.

7.5. Electronics: None

7.6. Preparation of Drawings/Documentation:

7.6.1. The following minimum documentation is required:

7.6.1.1. Provide as-built drawings for references 2.1.4-2.1.8 for the complete installations including Phase 1-3 using Reference 2.1.2 for guidance. These drawings shall be delivered in both AutoCAD and electronic PDF format. Update Reference 2.1.9 to include the updated NAG tables. In addition provide a copy of the updated tank tables in both electronic PDF and Excel Spreadsheet format to the MSCREP. Drawings and tables are to be reviewed and approved by local MSCREP.

7.6.1.2. Submit reports detailing “as found” conditions as soon as inspections are complete, measurements are taken and condition observed along with recommended repairs. Additional repair if found to be required shall be the subject of a change order

7.6.1.3. Submit reports detailing “as released” conditions when all work is complete. Report shall summarize repairs accomplished, final dimensional readings, pictures, test data, reports by others, and list parts replaced.

7.6.2. All documentation shall conform to the following minimum requirements:

7.6.2.1. Timeliness: Provide all check sheets, inventories, “as found” and “as released” condition reports, and certificates with in two (2) days of the discovery or completion of the work.

7.6.2.2. Format:

7.6.2.2.1. Provide electronic copies of all reports, type written. Scanned copies of hand written documents may also be included but do not substitute for the type written file.

7.6.2.2.2. No electronic file shall be more than 3 MB in size.

7.6.2.3. Delivery: Hard copies shall be hand delivered to MSCREP and Contracting Officer, with a signed transfer form documenting them as a condition found report.

7.6.2.4. Signatures: All reports and checklists shall be completed and signed by the person who carried out the test, inspection and maintenance work and countersigned by the Company's representative.

7.7. Inspection/Test:

7.7.1. The contractor shall call out the MSCREP to inspect the installation once complete. A walkthrough of all routed cables shall be conducted to verify compliance with reference 2.1.1 and regulatory body requirements. The contractor shall note and correct all deficiencies as identified by the MSC REP.

7.7.2. All penetrations shall be tested for water and smoke tightness and shall be tested in the presence of the MSC, ABS, and USCG REP.

7.7.3. The contractor shall develop a procedure to prove the functionality of the TLI system. This procedure shall include either filling or emptying the tanks and checking the volume against manual soundings every 10%. In addition this procedure shall check all alarm set points as specified by the NAG Marine and MSC REP. The procedure is to be submitted to the MSC REP, USCG, and ABS for review and approval. This procedure shall be demonstrated by a member of NAG Marine in the presence of the MSC REP, ABS, and USCG.

7.7.4. The contractor shall develop a Design Verification Test Procedure for the entire NAG TLI System using input from the NAG representative. This procedure shall meet Coast Guard CFR Requirements and ABS SVR. This procedure is to be delivered to the MSC REP and then forwarded to the USCG and ABS for review and approval prior to testing. The contractor shall demonstrate this procedure in the presence of the USCG, ABS, and MSC REP.

7.8. Painting:

7.8.1. Prime and paint with new primer and paint new foundations, containment, and disturbed surfaces to match surrounding surfaces using GTR No 7, Reference 2.1.1

7.8.2. The contractor shall repair or replace any damaged lagging or insulation using Reference 2.1.1 as guidance.

7.9. Marking:

7.9.1. The contractor shall make and install label plates and cable tags using GTR no. 29, Reference 2.1.1, as guidance.

7.9.2. New nameplates shall be installed using reference 2.1.5 as guidance.

7.10. Manufacturer’s Representative: The existing system was installed and integrated by NAG Marine. A NAG marine representative shall perform final testing. Tom Barbour, 757 965-8723, tbarbour@nagmarine.com, is a contact point.

8. GENERAL REQUIREMENTS

8.1. This item shall be completed within the first 90 days of the shipyard availability. All tank work shall be coordinated and completed prior to closing tanks required by WI 021.

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