501Ballast MOV HYdraulic Pump_Valve Repair.docx

USNS Comfort

( TAH 20 )

1. ABSTRACT

1.1. This item describes the requirements for the contractor to refurbish Ballast Valve Remote Operator System Hydraulic Pumps, motors and valves.

2. REFERENCES/ENCLOSURES

2.1. References:

2.1.1. Technical Manual T9529-AF-MMC-010/12190 Operation and Maintenance Manual Ballast & Ballast Valve Control System Console

2.1.2. MSC Drawing 437-5980654 Rev B, Bilge / Ballast Valve POSN IND and CONT SYS ELEM WRG DIAG

2.1.3. MSFSC Standard Item 19 Motor and Ventilation Fan Repairs.

2.2. Enclosures: None

3. ITEM LOCATION/DESCRIPTION

3.1. Location

3.1.1 Location: Auxiliary Machinery Access(1-91-1)

3.2. Item Description/Manufacturer’s Data:

3.2.1. (2 ea.) Hydraulic Pump MFR: Vickers Inc.

378804 D/91/0

PVB29 RS 20

CM 11

3.2.2. (2 ea.) Electric Motor

3.2.3. (1 ea.) Valve Block Assembly Consisting of the following:

MFR: Vickers Inc.

(1 ea.) Relief Valve: Model CG-06-C-40 (2 ea.) Valve: G5G-815 (1 ea.) Valve: G/G-815-S3S

3.3. 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: None

5. 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 including but not limited to GTRs 1-7, 22, 23, 28, and 29.

5.2. 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. Many of the definitions relating to performance of this work item are found in Work Item 0001.

5.3. The Hydraulic Pumps and motor will need to worked one at a time. The first pump and motor will need to be repaired, reinstalled and tested before the second pump and motor is removed for repair.

5.4. Each Hydraulic Pump and motor will be removed from the system, drained and packaged for shipment by the ship’s crew. The government will ship the pump to/from the contractors facility for repair.

5.5. The hydraulic valves will need to be worked onboard the vessel once it returns to Pier One at Naval Base Norfolk VA at a time TBD.

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. Provide all material and special equipment. Make all removals and restorations. Remove and replace all interferences, rig and unrig, stage and unstage, make all disassemblies and subsequent reassemblies, provide and operate equipment, and supply all services and assistance to accomplish the following work. (Material, unless specifically stated as Government Furnished Material (GFM) shall be supplied by the contractor).

7.2. Refurbish the system Hydraulic Pumps:

7.2.1. Provide the services of a repair facility that specializes in the servicing and repair of marine hydraulics to accomplish the following to each hydraulic pump:

7.2.1.1. Disassemble, clean and inspect each hydraulic pump.

7.2.1.2. Submit a condition found report listing the results of the inspection. The report shall include a list recommended repairs and list of repair parts required to restore each pump to original operational condition.

7.2.1.3. Provide up to 80 hours and $5,000.00 material to accomplish repairs identified as directed in writing by the MSCREP. Additional repairs and parts above this threshold will be the subject of a change order.

7.2.1.4. Reassemble each hydraulic pump replacing normal wear parts using new 316 CRES hardware, gaskets and seals.

7.2.1.5. Accomplish a shop test to prove operation of each hydraulic pump in the presence of the MSC and ABS Surveyor for 1 hour.

7.2.1.6. Submit a final report providing an “As Released” status of each hydraulic pump. The report shall list all repairs accomplished and repair parts installed.

7.3. Refurbish the Hydraulic Pump Motors:

7.4 Refurbish the system Hydraulic Block Valves:

7.4.1 Provide the services of a repair facility that specializes in the servicing and repair of marine hydraulics to accomplish the following to each hydraulic block valve:

7.4.2 Disassemble, clean and inspect each hydraulic valve.

7.4.2.1 Submit a condition found report listing the results of the inspection. The report shall include a list recommended repairs and list of repair parts required to restore each valve to original operational condition.

7.4.2.2 Provide up to 20 hours and $2,500.00 material to accomplish repairs identified as directed in writing by the MSCREP. Additional repairs and parts above this threshold will be the subject of a change order.

7.4.2.3 Reassemble each hydraulic valve replacing normal wear parts and using new 316 CRES hardware, gaskets and seals.

7.4.2.4 Accomplish a shop test to prove operation of each hydraulic valve in the presence of the MSC and ABS Surveyor. Cycle each valve 3 times to prove proper operation with no binding.

7.4.2.5 Submit a final report providing an “As Released” status of each hydraulic valve. The report shall list all repairs accomplished and repair parts installed.

7.4.3 Re-install and reconnect each hydraulic valve in its original location.

7.4.3.1 Purge air from the hydraulic system for each hydraulic valve where applicable.

7.4.3.2 Align and adjust each hydraulic valve for proper operation.

7.5 Preparation of Drawings/Documentation:

7.5.1 The following minimum documentation is required:

7.5.1.1 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

7.5.1.2 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.

7.5.2 All documentation shall conform to the following minimum requirements:

7.5.2.1 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.

7.5.2.2 Format:

7.5.2.2.1 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.

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

7.5.2.2.3 Provide three (3) paper copies of all reports, type written.

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

7.5.2.4 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.

7.6 Inspection/Test:

7.6.1 After all repairs to the hydraulic pumps and valves are complete, accomplish a final operational test of the Ballast Valve Control System to the satisfaction of the MSCREP AND ABS/USCG. This is an ABS hit that requires their signature to clear.

7.6.1.1 Cycle each valve operator from fully closed to fully open to fully closed positions (3) times.

7.6.1.2 Ensure that the operator cycles the valve smoothly with no binding in both directions.

7.6.1.3 Verify that the valve position indicators are correct and that the limit switches are properly set at each position during each cycle.

7.7 Painting:

7.7.1 Mechanically clean, prime and paint all new and disturbed surfaces to match surrounding areas using the coating manufacturer’s product data sheets for guidance.

7.8 Marking:

7.8.1 Install nameplates, notices, cable tags, and markings for all new and modified systems.

7.9 Manufacturer’s Representative:

7.9.1 Provide the services of a Repair Facility that Specializes in the Servicing and Repair of Marine Hydraulics to accomplish the requirements of 7.2.4 and 7.3.5. The following is a recognized source for this service:

Global Hydraulics Inc.

629 Acorn Hill Road Sunbury, North Carolina 27979 POC: David Jarrett Phone: (757) 621-7152 E-mail: ghidj64@gmail.com Hyval Corporation 898 Widgeon Road Norfolk, Virginia 23513 POC: Brian Tender Phone: (757) 855-2026 E-mail: briantinder@hyval.com

8. GENERAL REQUIREMENTS: None Additional 0501 - 1