0547_A_HP Crossover to EDG Start Air System.doc

USNS CHARLES DREW

(T-AKE 10)

MACHINERY, AUXILIARY SYSTEMS

RFP NO. N40442-10-R-3012

23 FEBRUARY 2010

ITEM NO. 0547

Van Vleck/N43C//French HP air Crossover to EDG start air system (TRANSALT T-AKE 09-120)

1.0 ABSTRACT

1.1 This item describes installation of a reducing station and cross over piping between the HP Air System and the EDG start air system.

2.0 REFERENCES/ENCLOSURES:

2.1 References:

2.1.1 NAVSEA DWG. 342-7488747 Rev B (NASSCO 471-342-7137) Rev B, Emergency Diesel Generator Services Diagram

2.1.2 NAVSEA DWG. 551-7488862 Rev C (NASSCO 471-342-7173) Rev C, High Pressure Air System Diagram

2.1.3 NAVSEA DWG. 802-7488866 Rev N (NASSCO 471-341-7008) Rev N, GENERAL ARRANGEMENT

2.1.4 MSC Dwg 551-8195625 Rev B EDG Start Air Crossover

2.2 Enclosures:

2.2.1 Enclosure 1; HP Air X-Over to EDG Start Air (guidance)

2.2.2 Enclosure 2; UNREP Station 8 Tie In (guidance)

3.0 ITEM LOCATION AND DESCRIPTION

3.1 Locations/Quantity

3.1.1 Location:

· EDG Room 02-73-1 (03 level mezzanine level)

· Station 8 Motor Control Room 02-74-0

3.1.2 Quantity: 1 each HP air to EDG Start Air Cross Connect Station.

3.2 Bill of Material:

Isolation Valves

· SA-V-114

· SA-V-115

· SA-V-116

¾” CPV O-Seal System 6000 PSi Vale

W/socket weld Union end tail piece.

O-ring to be provided.

3 each

MIL-T-16420 CL 3300 , SML

Approx 75 Lft

Dial face 5” dia minimum 2 each

3.2.1 All components and piping shall be rated for use in the High Pressure Air System with the design characteristics as per drawing ref 2.1.2.

3.2.2 Quantities given in the List of Materials are considered estimates and for reference only. These quantities shall be verified and revised based on actual piping run and equipment location in subject spaces. The Contractor shall provide these quantities and reasonable additional material in order to install a fully functional system that meets the requirements of this specification.

3.2.3 Additional material/components necessary to accomplish work required by this work item, such as hangers, weld material, etc. are not included below in section 4.0, and shall be provided by the Contractor.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIALS/SERVICES:

4.1 Reducing Valve CASHCO 0B5-ks37-13000000B

4.2 Relief Valve Farris Engineering 27EA45-170

5.0 NOTES

5.1 The contractor and subcontractors must consult Military Sealift Command’s General Technical Requirements, (GTR’s), to determine applicability to this work item. The contractor and all subcontractors must comply with all applicable GTR requirements.

5.2 The contractor and subcontractors shall review other work items under this contract, including but not limited to Work Item 021, to determine their effect on the work required by this item. Based on this review the contractor shall plan and schedule work to minimize conflicts between work items.

5.3 The definitions of many terms used in this work item are found in Work Item 001.

5.4 This ship contains High Voltage (HV) electrical systems. The contractor and subcontractors shall obey all posted and verbal instructions regarding safety and exclusion from High Voltage areas. At no time shall a contractor or subcontractor approach, work on, or enter a High Voltage area with out proper authorization.

5.5 THE USNS T-AKE ELECTRICAL COLOR CODING DOES NOT FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK AND WHITE. THE CONTRACTOR SHALL ASSUME ALL ELECTRICAL CABLES ARE HOT UNTIL TESTED OTHERWISE. THE CONTRACTOR SHALL TEST ALL ELECTRICAL CABLES TO ENSURE THEY ARE DEAD PRIOR TO WORKING ON THE ITEM.

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

7.0 STATEMENT OF WORK

7.1 Piping Modifications:

7.1.1 Install piping cross connect between the HP air system and the EDG Start air system as follows:

7.1.1.1 Prior to start, a working drawing shall be developed, and approved by the Port Engineer.

7.1.1.2 New piping and components shall meet requirements of ABS class I piping system.

7.1.1.3 All new piping shall be designed and installed to meet the system design requirements for high pressure air plant piping listed on reference 2.1.2.

7.1.1.4 Tee into UNREP Station 8 high pressure air flask piping. See Enclosure (2) for guidance.

7.1.1.5 Piping shall run from Station 8 Unrep Motor Control Room to the EDG room above. This will require approximately 75’ of piping.

7.1.1.6 Where piping goes through the deck a deck penetration collar shall be installed. 100% welded pipe to collar and collar to deck.

7.1.1.7 Install piping hangers. Assume 25 each ¾” pipe strap hangers will be required.

7.1.1.8 Install reducing station on the 03 level of the EDG room. This station shall be in the vicinity of the EDG start air bottles. See Enclosure (1) for guidance.

7.1.1.9 The reducing station shall have a pressure reducing valve. 3000/435 psi. Cashco Model 345.

7.1.1.10 The reducing station shall have isolation valves on each side of the pressure reducing valve. Valves to be CVP 6000 psi o-ring seal type.

7.1.1.11 The reducing station shall have bypass piping with valve. The valve shall be a CVP 6000 psi o-ring

7.1.1.12 Inlet and outlet gauges shall be installed on the reducing station. Each gage shall have isolation valves. Gauges shall be installed using 3/8” 316 stainless tubing 0.065 wall thk. Gauges shall have minimum 5” Diameter face.

7.2 Preparation of Drawings:

7.2.1 Develop “Working Drawings” based on conceptual design presented by Enclosures (1) and (2).

7.2.2 Prepare and submit “red-lined” markups of references 2.1.1, and 2.1.2, system drawings. Drawings shall include one hard copy with the original hand written red lines. In addition this shall be electronically scanned and a CD with the scanned red line drawing submitted to the COR.

7.2.3 Upon completion of work, submit updated Working Drawings, these shall be called the “As-Built” drawings. They shall be submitted to the COR in AutoCAD format on CD.

7.3 Testing/Inspection:

7.3.1 Preliminary Tests

Contractor shall conduct preliminary tests on all completed work before calling for an official test.

7.3.2 Completion Test

The Contractor shall conduct a completion test that verifies that all aspects of the work item have been completed. A completion test may include a series of functional, operational, and hydrostatic tightness tests.

7.3.3 Welding and Brazing Test

Visually inspect new, modified, or repaired welds or brazed materials in accordance with Regulatory Body requirements.

7.3.4 Tightness Test

Verify that all structural work including any structural attachments, which would affect the tightness of the structure, is complete and ready for service.

7.3.5 Clean and Flush

The Contractor shall clean the entire piping systems after completion of all new piping installation by flushing with fresh water in the presence of the MSC Representative.

7.3.6 Hydrostatic Test

a. The Contractor shall hydrostatically test the new Air piping installation per Regulatory body requirements and based on design conditions indicated in reference 2.1.2.

b. Perform a shop valve seat leak test on new valves. Test at system operating pressure. No leakage allowed.

7.3.7 Painting Test and Inspection

a. The Contractor and MSC Representative shall conduct a joint inspection of areas disturbed by the installations. These areas are to be prepared and primed before final painting begins to ensure that protective measures are implemented.

b. The Contractor shall perform inspections after completion of each stage of surface preparation, each coat, and each stripe coat, to verify surface condition, DFT and space cleanliness, and before requesting final inspection by the MSC representative.

7.3.8 Operational Test

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

· 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 performs its intended purpose.

7.4 Painting

Clean and prepare the disturbed areas and apply a primer and two topcoats of paint to all areas disturbed to match the surrounding areas.

7.5 Markings

Install nameplates, notices, and markings for all new and modified systems. Valve label plates shall read as follows:

7.5.1 For SA-V-114: “SA-V-114 HP X-Connect Reducer Isolation”

7.5.2 For SA-V-115: “SA-V-115 HP X-Connect Bypass”

7.5.3 For SA-V-116: “SA-V-116 HP X-Connect Reducer”

7.5.4 For SA-V-117: “SA-V-117 HP X-Connect Reducer Isolation”

7.6 Manufacturer's Representative: None.

8.0 GENERAL REQUIREMENTS: None additional

547-1

_1328590624.pdf

A

B

7 6 5

C

D

FSCM NO.

4 3 2

SCALE

SIZE DWG NO.

SHEET

REV

ZONE REV

REVISIONS

DESCRIPTION

APPROVED

DATE

PS PT

PT

P

NC

M OIST.

SEP.

CONN @ START AIR MOTOR

20SA01 -051

S

-0

2 0SA01 -051

4 0SA01 -052

4 0SA01 -053

2 0SA01 -057

20SA01 -056

1 5SA01 -060

25SA01 -058

25SA01 -059

EDG START AIR SYSTEM

471 -342-7137

NASSCO DRAWING NUMBER

NAVSEA DRAWING NUMBER

342-7488747

SA-V -1 01

SA-V -1 08

SET @ 30 BAR

0 .2 M 3 0 .2 M 3

SA-V -1 03 SA-V -1 04

SA-V -1 06 SA-V -1 07

SA-V -1 05

SA-V -1 09

SET @ 30 BAR

SA-V -1 02

SA-G A-1 1

RESERVE

START AIR

FLASK

(SEE NOTE S1 1 )

PRIM ARY

START A IR

(SEE NOTE S1 1 )

SKID M OUNTED CONTROLLER

FOR LOCAL START/STOP AND

AUTOM ATIC UNLOADING

SYSTEM OPERATIONS

AUTOM ATIC OPERAT ION

(START/CUT-OUT) V IA

SA-PS -1 0

REM OTE SUM M ARY

FAULT ALARM AND

RUN STATUS AT M CCS

SA-F-51

SA-F-53

LED TO DECK

LED TO DECK

LED TO DK DRAIN

(SEE NOTES S7 & S8)

DRAIN TO OILY WASTE

HOLDING TANK (REF. 19)

20SA01 -057

SA-PT-1 1 RESERVE AIR FLASK PRESS

INDICATION & LOW PRESS ALARM

SET @ 1 5 BAR

EDG START A IR

COM PRESSOR ROOM

EM ERG ENCY DIESEL

G ENERATOR

LED TO DK DRAIN

SA-V -1 1 0

25SA01 -062

PS

SA-G A-1 0

(LOCAL)

SA-PS-1 0 FOR REMOTE COMPRESSOR

CONTROL START @ 28 BAR & STOP

@29.3 BAR (SEE NOTE S10)

LOCATE MOISTURE

SEPARATOR NEAR

STRUCTURE TO

FACILITATE GRADE

A SHOCK MOUNTING

SA-PT-10, REMOTE PRIMARY AIR FLASK

PRESS INDICATION & LOW PRESS ALARM

IN MCCS, SET @ 15 BAR

SA-PS-1 1

SET @ 14 BAR (RISING) TO ACTIVATE START AIR

READY LIGHT AND ALARM ON THE EDG CONTROL

PANEL SET TO ENSURE SUFFICIENT AIR FOR 6

CONSECUTIVE START ATTEMPTS.

LP RELIEF VALVESET AT

9. BAR ATTACHED TO

COMPRESSOR

HP RELIEF VALVE

ATTACHED TO COMPRESSOR

SET @ 31 .5 BAR

TS

VENDOR SUPPLIED

STARTING AIR

COMPRESSOR SKID

EDG SKID

SA-V -1 1 4 SA -V -1 1 6

SA -V -1 1 7

N C

SA-V -1 1 5

From HP A ir -U N REP S ta tion #8

20m m (3 /4 ")

20m m (3 /4 ")

HP CROSSOVER TO EDGE

START AIR---SEE SERVICE ORDER

SO-08-009

HP AIR X-OVER TO EDG START AIR

TAKE-1 VRR 07-1 5

SERVICE ORDER SO-08-009

MODIFIED

ENCLOSURE 1

19FEB08

_1328590650.pdf

FSCM NO.

SCALE

SIZE DWG NO.

SHEET

REV

ZONE REV

REVISIONS

DESCRIPTION

APPROVED

DATE

UNREP STATION 8 TIE IN

TAKE-1 VRR 07-15

SERVICE ORDER SO-08-009

ENCLOSURE 2

NO. 8

RAM TENSIONER

CHARGING PANEL

NO. 8 DETAIL 12-B

40AH01 -038

UNREP STATION

NO. 8

UNREP STATION

NO. 7

SHIP CL

RESERVE

HP AIR FLASK BANK &

CHARGING VALVE PANEL

SEE DETAIL 15-B

40AH01 -038 FROM

AIR FLASK BANK

BELOW

40AH01 -038 DN TO

RT PANEL NO. 8

15AH01 -023 FROM

HP AIR MAIN BLW

STA NO 8

MOT CONT RM

02-74-0

NASSCO DRAWING NUMBER

NAVSEA DRAWING NUMBER

551 -7488862

471 -342-7173

HP AIR

(T Y

1 5 MM FROM HIGH

PRESSURE AIR MAIN

VALVE C

VALVE J

FITTING A

20 PIPE A

40 PIPE A

20 PIPE A

15 PIPE A

15 PIPE A

IP

E

G

20 PIPE F

20 PIPE E

20 PIPE D

20 PIPE C

15 PIPE B

8 PIPE L 8 PIPE K 8 PIPE J 8 PIPE H

8 PIPE H

32/50

DECK

AIR BANK CHARGING STATION ASSEMBLY

(PROVIDE ADEQUATE

SWAY BRACING

FOR SILENCER)

ENTIRE LENGTH OF PIPE A

IS 1 5 DIA FOR RESERVE

AIR BANK ONLY

GAUGE A

(VISIBLE FROM THE

AIR BANK CHARGING

STATION ASSEMBLY)

40 MM PIPE "M"

TO RAM TENSIONER

CHARGING STATION

(NOT REQUIRED FOR

RESERVE AIR BANK)

VALVE N

N.C.

VALVE M

VALVE L

VALVE K

VALVE B

VALVE A

VALVE D

N.O.

VALVE O

SET AT 17,200 kPa

FOR MAIN AIR BANKS

(SET AT 20,700 kPa

FOR RESERVE AIR BANK)

LED TO WEATHER DECK

03 DECK

EDG ROOM 02-73-1 MEZZANINE

20 MM (3/4") PIPE

TO EDG NEW REDUCING STATION

DECK SLEEVE

MODIFIED FROM

UNREP STATION 8

NEW PIPING

NEW PIPING

19FEB08