SOW-Hot_oil_flush.pdf

Statement of Work Comprehensive Monitored Flush CCMFl Work Components Perform Hot Oil Flush to Emergency Diesel Generator (EDG) Set: Diesel Lube Oil (DLO) Cooler (in place); DLO External Piping; EDG Set/DLO Internal Piping, Combined Internal/External Final Flush, and Sump Cleaning for the USS TOPEKA (SSN 754) EDG Set at Portsmouth Naval Shipyard (PNS) Kittery, Maine.

1.0 BACKGROUND

1.1 This Statement of Work (SOW) describes tasks to be performed by the contractor in support of USS TOPEKA (SSN 754) repair of the EDG Set at PNS. The contractor will provide the equipment and work required to generate the deliverables outlined below.

1.2 The DLO flush requires contractor expertise and support for the CMF of the EDG Set and DLO system on USS TOPEKA (SSN 754). The Engineering and Planning Department (EPD) of PNS has determined that to meet the Department of Navy and Department of Defense commitments in support of the USS TOPEKA (SSN 754) , it is in the Government's best interest to have the equipment and service be provided by Clarus Fluid Intelligence, LLC (contractor).

1.3 Control Specifications/References:

(a) Diesel Engine Maintenance Standard S9233-DM-HBK-010-005; Flush SSN 688

Class Fa irbanks Morse 38ND 8 1/8 Diesel Generator Engine Lubricating Oil System and Engine

2.0 OBJECTIVE AND SCOPE

2.1 Overall Objective: The contractor shall provide and set up the EDG Set and DLO system oil flushing rig/unit and necessary oil storage tanks consisting of a pier side flush rig pump, filters and in-line monitoring equipment. The EDG Set and DLO system flush shall be in accordance with reference (a). Flushing oil shall be commercial grade (non-synthetic) SAE lOW High Detergent oil, with an API rating of SC or better to be provided by contractor. The contractor will flush the EDG Set and DLO system by fully circulating the flushing oil through the EDG Set and DLO systems at or above the minimum specified flushing flow rates, filtering the oil continuously until NAVSEA directed cleanliness criteria are met, and blow down the system after f lushing.

2.2 Scope: The contractor will be required to support the initial loop flushes scheduled on or about August 2014. Specific start date is dependent on completion of EDG Set repairs. Earlier set up may be required. Flushes will continue through the end of August and into September 2014 as necessary to complete the DLO system flush .

These dates are projected dates and are subject to change. The flush sequence, per reference (a) is : 1) DLO Cooler; 2) DLO External Piping; 3) EDG Set/DLO Internal Piping; and, 4) Combined Internal/External Flush. Additionally, the contractor may be expected to support additional curtailments/stops that may arise due to unplanned work stoppages.

3.0 PERFORMANCE OBJECTIVES

3.1 The required Tooling and Equipment is listed in paragraph 3 of reference (a). The performance specifications for the Tools and Equipment are provided in paragraph 4 of reference (a) and summarized below:

• Positive Displacement Pump capable of 260 GPM @ 120 PSI, with 3" connections, driven by 20 HP (min) 440 V 3-phase motor with Electronic Variable speed control system with local and remote (at engine) start/stop capability and capable of controlling speed between 5 - 2000 RPM.

• Digital flow meter with current calibration and capable of measuring 260 to 300

GPM.

• Optional 2000 Gal Steel Storage tank with connections specified in reference (a) to support inlet/outlet, heater and venting.

• Air Operated Diaphragm Pumps for heating loop and fill & transfer.

• Portable Pore blockage Particle counter with current calibration and capable of measuring NAS output.

• Quadraplex Bag Filter System that allows continuous operation during filer change out and containing QTY 4 Size 2 (25) Micron filter bags.

• Cartridge filter System consisting of 5 (min) 36" tall filters in parallel flow with isolation valves, filtering to 3 Microns with beta ratio of 200 with max 5 PSID while operating. Be fitted with gages and valves to monitor and protect the system.

• Magnetic Filter System with 3 full flow magnetic filters with 1 PSID (max) press drop.

• Process heating system with controllers to maintain 170 to 196 Deg F outlet temp, controls to prevent overheating.

• Oil spill containment

• Hose Assemblies to Mii-H-24135, tested to 1.5 times working pressure, 3" to/from engine connection with aluminum cam-lock self locking fittings per A-A- 59326B.

• Valve Manifold Assembly with 3" valves with locking cam-lock style fittings and each manifold numbered and tagged.

• Various flanges including Blank flanges, Cam-Lock flanges, Pancake Blank flanges and gages.

• Flushing Oil to be provided by contractor.

• Consumable hardware such as rags, labels, soft mallets, pails and tubing .

3.2 The entire temporary system and ship's piping within the flushing boundary must be pneumatically tested for tightness to 75 psig (dockside air) or system operational pressure (if lower than 75 psig) prior to use.

3.3 Contractor personnel assigned to operate the flushing unit shall be provided pre-work briefs by PNS prior to flushing. These briefs will cover all procedures, safety precautions, and technical requirements of the flushing procedure.

3.4 Contractor personnel will participate in pre-shift briefings as directed by PNS.

3.5 Contractor operating procedures are subject to review at any and all times by PNS Occupational Safety and Health Office.

3.6 The flushing unit/rig must be capable of providing flushing loop flow rates that meet or exceed the minimum target flow rates specified by NAVSEA flushing documents (reference (a)).

3. 7 The contractor flushing unit/rig will be installed, operated, and maintained by contractor employees.

3.8 The contractor will provide periodic samples to PNS for verification to ensure the flushing rig monitoring unit is functioning properly. The details of this sampling will be determined by NAVSEA, PNS and/or the Diesel Engine Inspector (DEI) prior to start of flushing.

3.9 It is of special interest to NAVSEA, PNS and the DEI of the material found in the system during the flush. Provide all filter bags and debris to PNS and/or DEI for review prior to discarding.

3.10 Contractor will also provide technical recommendations on flushing techniques, use of diagnostic equipment/monitors to track flushing progress and improve flushing efficiency while meeting the requirements of reference (a).

3.11 Contractor will provide a completed copy of reference (a) to PNS at the conclusion of the DLO flush providing objective quality evidence during performance of the flush.

4.0 QUALITY ASSURANCE

4.1 Final verification and acceptance of flushing oil and system cleanliness will be based upon satisfactory oil analysis by NAVSEA and/or PNS.

4.2 Daily verification of contractor rig flushing oil and rig self-monitoring unit by sample comparison may be used at the sole discretion of PNS.

5.0 GOVERNMENT FURNISHED PROPERTY AND SERVICES

5.1 GENERAL: The government will provide the following:

5.1.1 Electrical power connection and disconnection for DLO flushing unit/rig.

5.1.2 Removal and disposal of waste resulting from DLO flushing.

5.1.3 Location of DLO flushing unit/rig whenever service/trouble calls are requested at flushing unit/rig.

5.1.4 Any new replacement or replenishment oil required.

5.1.5 Additional gasket materials, for example upper engine cover gaskets, air box cover gaskets, lube oil filter housing o-ring, lube oil strainer o-rings, and dry sump cover gaskets are not provided by Clarus.

6.0 POINTS OF CONTACT

6.1 Contracting Officer Representative: XXX

6.2 Technical POC: Mr. Martin Sewell, Code 260.7, Waterfront Mechanical Branch Head, desk 207.438.3384/cell 207.703.3127.

Flush Specifications Hot Oil Flush of EDG Set (Fairbanks Morse Engine 8 Cylinder 0-P) using procedures outlined in MS S9233-DM-HBK-010-005.

IMPORTANT NOTE: Gaskets included in the restoration of system components include all piping flange gaskets removed for flushing purposes, plug-cock valve o ring (as applicable), and wet sump gasket (as applicable) only. (Provided by Clarus)

Additional gasket materials, for example upper engine cover gaskets, air box cover gaskets, lube oil filter housing o-ring, lube oil strainer o-rings, and dry sump cover gaskets are not included in this quote, and require specific direction from the contracting authority for Clarus to provide. (Provided by PNSIShips Force (SF))

1. Flush Component: CMF Operation 1.1.Description of major components of work order provided in this section

2. Flush Component: Setup and Restoration (Performed by Clarus project team member)

2.1. Installation and removal of piping and flex hoses, disconnects, blanks, spool pieces, jumper lines, flushing adapters, and flushing hookups as needed.

2.2. Lock wiring of fasteners as needed during flush.

2.3. Contractor will provide a completed copy of reference (a) to PNS at the conclusion of the DLO flush providing objective quality evidence during performance of the flush.

3. Work component: Material Requirements (Provided by Clarus)

3.1. 600 gallons of 2104 (Or 9259 40Wt.) flushing fluid per DLO system.

4. Work component: Material Requirements (Provided by PNS)

4.1. New 9250 (MIL-PRF-9000) replacement oil per DLO system.

5. Work Component: Assistance Required From PNS I SF I Others, supporting a 2417 work schedule

5.1. Availability of crane and forklift with operators to accommodate placement of two

20 foot ConEx boxes, processing tank, and other supplies such as oil drums on and off pier next to boat, as needed (Provide by PNS).

5.2. Footprint requirements of 30' x 30' on pier close to access to Forward Compartment (FC)/Auxiliary Machine Room (AMR)/Forward Escape Trunk (FET).

(Provide by PNS).

5.3. Placement of Flushing Rigs must be approved by the Clarus Project Manager to ensure safety and proper length of the flushing hose runs.

5.4. If surface blasting operations are being performed in the area of the flushing operations an enclosure shall be provided to prevent contaminants from entering the Flushing Systems.

5.5. Provide lighting for the pier to Submarine flushing hoses for over the water pumping operations 24/7 (Provide by PNS).

5.6. Rigging of pumps manifolds and other equipment as needed to and from the Forward Compartment (FC)/AMR as needed (Provide by PNS).

5.7. Removal, cleaning, and reinstallation of DLO strainers, filters and strainer/filter vessels before/after the flush. New DLO system filters to be provided and installed (Provide by PNSISF).

5.8. Four (4) 55 gallon closed top storage drums for liquid waste disposal (Provide by PNS).

5.9. Four ( 4) 55 gallon open top storage drums for solid waste disposal (Provide by

PNS).

5.10. Electrical Service for equipment as follows: One (1) 440v, 400amp 3-Phase electrical service to pier work area (Provide by PNS).

5.11. Electrician to connect and disconnect electrical services as required (Provide by

PNS).

5.12. Low Pressure Air within 100 feet of all work areas (Provide by PNS).

5.13. Disposal and pump-out of all fluids, sludge, filters, zorbs, rags, etc., generated from flush operations (Provide by PNS/SF).

5.14. If ships lube oil piping is different than expected - reimbursement costs to modify adapters as needed for the flushing operations.

5.15. Mechanical cleaning of all accessible engine areas during engine maintenance such as upper galleries, dry sump, etc (Provide by SF).

5.16. Removal and reinstallation of Diesel Sea Water (DSW), Diesel Fresh Water

(DFW), Generator Bearing, DLO, and DLO priming pumps and piping from the EDG Set for flushing operations as needed (Provide by PNS).

5.17. Removal and reinstallation of hangers to support removal and reinstallation of DSW, DFW, and DLO pumps to the engine (Provide by PNS). May require cutting/welding and inert of the 02 header.

5.18. Removal, cleaning, and reinstallation of DLO sump suction strainer (Provide by

PNS).

5.19. Removal and reinstallation of lockers above EDG set (Provide by PNS).

5.20. Removal and reinstallation of coffin cover (Provide by PNS/SF).

5.21. Removal and reinstallation of lube oil pumps (Provide by PNS).

5.22. Removal and reinstallation of jumper lines as needed for flushing operations

(Provide by PNS).

5.23. Removal and reinstallation of soft patch in AMR/FET (Provide by PNS).

5.24. Removal and reinstallation of piping spray shields as necessary (Provide by

PNS/SF).

5.25. Maintain bilge in dry condition, as necessary. Bilge cleaning service to be provided when and as needed during/after flush (Provide by SF).

5.26. Any new replacement or replenishment oil required (9250, MIL-PRF-9000)

(Provide by PNS).

5.27. Provide Security Escorts as required to perform contracted obligations (Provide by PNS/SF).

EXCEPTIONS

CMF quotation will not include the following:

1. Electrical services.

2. Rigging equipment and supplies on and off Ship.

3. Any valve calibration or lubrication system component calibration.

4. Hydrostatic testing.

5. Bilge cleaning.

6. Any required new replacement or replenishment lube oil.

7. Installation of new spray shields.