WI 0561 Senitec OWS Sys Installation.doc

USNS MATTHEW PERRY

(T-AKE 9)

AUXILIARY SYSTEMS MACHINERY

RFP No.: N40442-10-R-3012

23 February 2010

ITEM NO: 561

Category “A” MSC N752/TNG/French Senitec Oily Water Separator System Installation

1.0 ABSTRACT

1.1 This work item describes the installation of a flocculent type Oily Water Separator (OWS) system. This work item shall install the new OWS for testing and evaluation. The existing OWS shall remain in place as a backup to the new unit.

2.0 REFERENCES:

2.1 MSC Drawing 800-8390078, Rev -, Contract Guidance Drawing, T-AKE 8, Senitec Oily Water Separator Installation

2.2 MSC Drawing 529-7488725 Rev E, Selected Record Drawing, T-AKE Class, Bilge and Oily Waste Transfer System in Machinery Rooms

2.3 MSC Drawing 529-7488762 Rev D, Selected Record Drawing, T-AKE Class, Cargo Hold and Miscellaneous Bilge and Oily Waste Transfer System Diagram

2.4 MSC Drawing 531-7488736 Rev D, Selected Record Drawing, T-AKE Class, Distilled Water Transfer System Diagram

2.5 MSC Drawing 551-7488733 REV D, Selected Record Drawing, T-AKE Class, Ship Service and Control Air System Diagram

2.6 No. 9197402200E, SENITEC M1000 Assembling Instructions

2.7 NAVSEA Drawing No. 505-7488748 T-AKE 1 Class Flushing Procedures

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity

3.1.1 Location: Auxiliary Machinery Room 5-58-01

3.1.2 Quantity: One (1) – Senitec OWS system. The Senitec OWS system consists of three components.

a. The main unit is the M1000 that is delivered in three modules that bolt together to form the basic OWS unit. The internal wiring and piping connecting the three modules that make up the base M1000 unit are provided.

b. A separate drip pan is provided with the M1000 unit.

c. The ONSYS influent pumping and sensing unit is delivered on a stand alone skid to be mounted separately from the M1000.

d. A SOLIDPAC unit that collects solid waste byproduct is a single cabinet type unit that shall also be mounted separately.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE): Senitec OWS as described in 3.1.2.

4.2 Government Furnished Material (GFM): None

4.3 Government Furnished Services (GFS): See 7.13

4.4 Government Furnished Information (GFI): References 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, and 2.7

5.0 NOTES

5.1 The Contractor shall provide all labor, materials, equipment, special tooling, rigging, staging, shop facilities, crane services, and transportation services, as necessary to accomplish all requirements of this work item.

5.2 The Contractor and 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 GTR’s including but not limited to GTR’s 1-7, 22, 23, 24, 25, 28 and 29.

5.3 The Contractor and subcontractors, regardless of tier, shall review other work items under this contract to determine their effect on the work required under this work item. All materials listed in this section are to be Contractor Furnished Material. Material/Components necessary to accomplish the work required by this work item are identified in Reference 2.1.

5.3.1 Material per reference 2.1 to include:

· Structural steel to fabricate equipment foundations.

· Piping, valves and fittings to install a fully functional Senitec OWS.

· Electrical wiring, power panels, junction boxes, etc. to install a fully functional Senitec OWS.

· Gear boxes, hand wheels, reach rods, etc. for actuation of new valves.

· Hardware for installation of piping, valves, wiring, etc.

· Deck grating, hand rails, and supports.

5.3.2 Estimated wiring lengths, fitting quantities, and piping lengths can be determined from References 2.1 through 2.5. The Contractor shall provide the exact quantities and additional material such as wiring, cable connectors, fittings, welding material, pipe hangers, etc., which are not specifically included in the References, in order to install a fully functional system to meet the requirements of the Work Item, System’s Specification, Manufacturer’s Requirements, Ship Specification and Regulatory Bodies, as applicable.

5.4 The Contractor shall install the new equipment and valves as close as possible to the locations indicated in Reference 2.1. These locations shall permit access to the corresponding valves and equipment for easy operation.

5.5 The use of lap joint (Vanstone) flanges is prohibited.

5.6 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.

5.7 THE T-AKE CLASS ELECTRICAL COLOR CODING DOES NOT FOLLOW A CONSISTENT COLOR SCHEME. THE SHIPS ARE KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK AND WHITE. THE CONTRACTOR SHALL PRESUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED OTHERWISE. THE CONTRACTOR SHALL TEST ALL ELECTRICAL CABLES TO ENSURE THEY ARE DE-ENERGIZED PRIOR TO WORKING ON THE ITEM.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 All work and testing shall be in accordance with the latest SOLAS regulations, ABS Rules for Building and Classing Steel Vessels, and to the satisfaction of and in the presence of the ABS Surveyor (if required), Manufacturer’s Representatives (as necessary), and MSC Representative (MSCREP).

6.2 All welding requirements shall be accomplished by certified welders. All welders shall be certified to perform the type of welding required and documentation of such shall be current. Fire watches shall be posted by the Contractor during hot work.

6.3 Clean and gas free affected enclosed spaces per local procedure as approved by the ship and/or MSCREP. Special attention shall be given to ensure proper cleaning and gas free of Fuel Tank (6-58-0) below OWS in preparation for OWS foundation installation hot work.

7.0 STATEMENT OF WORK REQUIRED

7.1 Arrangements/Outfitting:

7.1.1 The Contractor shall design and make all necessary arrangements (temporary accesses, install padeyes and lifting gear, rigging path, etc) to safely install the new OWS System components using Reference 2.1 as guidance.

7.1.2 After installation of Senitec OWS system, the Contractor shall install deck grating at the 2.621m ABL level around newly installed equipment using Reference 2.1 as guidance. Grating design and material shall match existing machinery space grating as is practicable. Grating shall be removable to access piping and equipment as needed. Hinged accesses shall be installed to allow access to operate valves and equipment as required. Safety rails and gates shall be installed to prevent personnel injury.

7.2 Structural

7.2.1 Installations

a. Install new M1000 module OWS foundation in accordance with Reference 2.1.

b. Install new ONSYS unit module foundation in accordance with Reference 2.1.

c. Install new SOLIDPAC module foundation in accordance with Reference 2.1.

7.2.2 Install pipe hangers/supports for new piping installation as required by Reference 2.1.

7.2.3 Install electrical equipment supports for new wiring, power panel, and junction boxes as required by Reference 2.1.

7.3 Assembly:

7.3.1 Assemble the two M1000 drain pan pieces as described in the Senitec Assembly Instructions, Reference 2.6. Plug drain ports internal to drain pan. Mount the M1000 drain pan on foundation provided by 7.2.1a.

7.3.2 Assemble the three M1000 modules on the drain pan as described in the Senitec Assembly Instructions, Reference 2.6 and as directed by the Wartsila Original Equipment Manufacturer (OEM) representative. All interconnecting wiring and piping for the M1000 assembly shall be provided with the unit.

7.3.3 Mount ONSYS on foundation provided by 7.2.1b.

7.3.4 Mount SOLIDPAC on foundation provided by 7.2.1c.

7.4 Mechanical/Fluids

7.4.1 Drain, isolate and tag out the sections of piping being worked using approved tag out procedures.

7.4.2 Removals:

a. Remove piping as required to perform this work item.

7.4.3 Modifications:

a. Tee into existing piping as required by Reference 2.1 to provide a fully functioning system.

b. Install check valves in the existing residual oil discharge and water overboard piping as indicated by the piping diagram in Reference 2.1.

7.4.4 Installations:

a. The Contractor shall design and make all necessary arrangements (temporary accesses, install padeyes and lifting gear, rigging path, etc) to safely install the new OWS System piping and valves using Reference 2.1 as guidance.

b. Install new flanges, valves, gasketing, and hardware per the Reference 2.1 contract guidance drawing and as required to perform this work item. The new piping and fitting material, size, type, and specifications shall be in accordance with Piping Material Schedule OW01 of Reference 2.2 for material not specified in Reference 2.1.

c. Install new 2 inch NPS OWS suction piping from existing piping as indicated in Reference 2.1.

d. Install new 1 1/2 inch NPS OWS water overboard and OWS recirculation piping, connecting to existing piping, as indicated in Reference 2.1.

e. Install new 1 inch NPS OWS residual oil discharge piping, connecting to existing piping, as indicated in Reference 2.1.

f. Install new 1 inch NPS OWS distilled water supply from existing piping as indicated in Reference 2.1.

g. Install new 1/2 inch NPS OWS ship service air supply and pressure reducing station from existing piping as indicated in Reference 2.1.

h. Install new drain piping connecting the three Senitec system components as indicated in Reference 2.1.

i. Install new valves as indicated Reference 2.1. The valves shall be as described in Reference 2.1.

j. Install new pipe hangers per Reference 2.1.

k. Fabricate and install handwheel extensions and /or reach rods allowing operation of the new valves from new or established decking, as required.

7.5 Electrical/Control

7.5.1 De-energize and tag out the sections of the electrical system being worked using approved local tag out procedures.

7.5.2 Removals: None

7.5.3 Installation/Modification:

a. Install new power panels, wiring, junction boxes, and hardware per the Reference 2.1 contract guidance drawing and as required to perform this work item.

7.6 Electronics: None

7.7 Cleanliness

7.7.1 Clean and gas free Fuel Tank (6-58-0) below OWS in preparation for OWS foundation installation hot work. Note that this may be in progress for other work items. See Note 5.3.

7.7.2 Flush piping after installation in accordance with Reference 2.7. The Contractor shall clean the affected piping systems after completion of all new piping installation in the presence of the MSCREP.

7.7.3 Piping relocated as a result of this work item shall be cleaned in accordance with Reference 2.7 and the respective system diagram instructions.

7.8 Painting

7.8.1 Clean, prime, and paint all new and modified surfaces to match surrounding surfaces.

7.9 Marking

7.9.1 Install name plates, notices, and markings for all new and modified systems.

7.10 Inspection

7.10.1 Inspections shall be in accordance with GTR 3 and Reference 2.1 and to the satisfaction of the MSCREP.

7.10.2 Welding and Brazing Inspection

a. The Contractor and MSCREP shall visually inspect new, modified, or repaired welds or brazed materials in accordance with ABS requirements.

b. The Contractor and MSCREP shall inspect all hot work prior to applying paint.

7.10.3 Painting Test and Inspection

a. The Contractor and MSCREP 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 MSCREP.

c. All painted areas shall be inspected prior to covering or insulating.

7.10.4 Other Inspections

a. The Contractor shall perform a preliminary inspection prior to calling out a formal inspection.

b. MSCREP shall inspect the flushing strainers (if applicable) for cleanliness prior to placing the affected systems in service.

c. MSCREP shall inspect the paint and general condition of all affected systems, structures, arrangements, surrounding areas, etc.

7.11 Test

7.11.1 Tests shall be in accordance with GTR 3 and Reference 2.1 and to the satisfaction of the MSCREP.

7.11.2 Preliminary Tests:

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

7.11.3 Tightness Test:

a. The Contractor shall verify that all structural work, including any structural attachments or penetrations which would affect the tightness of the structure, is complete and ready for service.

7.11.4 Hydrostatic Test

a. The Contractor shall perform a hydrostatic pressure test of the affected piping systems. Hydrostatic test on all new and modified systems shall be per Reference 2.1 and GTR 3. Machinery shall be isolated from tested piping, preferably by use of blank flanges.

7.11.5 Operational Test:

a. The Contractor shall perform an operational test of all new and modified systems and equipment. Operational test on all new and modified systems shall be per reference 2.1 and GTR 3. Operation of the new systems and equipment shall be performed to the satisfaction of the MSCREP.

7.11.6 Completion Test:

a. The Contractor shall perform a completion test and provide documentation proving that all aspects of the work item have been completed. A completion test may include a series of functional, operational, and hydrostatic tightness tests. The Contractor shall demonstrate that the installation is USCG and ABS compliant and that the equipment installations are complete and ready for service.

7.12 Preparation of Drawings/Documentation

7.12.1 The Contractor shall prepare working drawings to accomplish the work required by this item. Drawings at a minimum shall include the Piping System Installation Arrangement and Details working drawing.

7.12.2 The Contractor shall prepare as-built drawings to document the work accomplished by this item. Drawings at a minimum shall include a red line mark-up of the Senitec Oily Water Separator Installation Contract Guidance Drawing, Reference 2.1, and the Oily Waste Transfer System in Machinery Rooms Selected Record Drawing, Reference 2.2.

7.12.3 The Contractor shall prepare working and as-built drawings in CAD format in accordance with GTR 5.

7.12.4 Drawings at a minimum shall include one CAD master, three full size hard copies, and one PDF format copy.

7.13 Manufacturer’s Representatives

7.13.1 OEM contract with MSC includes 4 days of commissioning engineer support. Two of those days are to commission the unit and the other two are for ship’s crew training. This is at no charge to the Contractor.

7.13.2 If needed, the Contractor shall provide the additional services of an authorized OEM representative to support the installation set up of the Senitec OWS. Refer to GTR 24.

8.0 GENERAL REQUIREMENTS:

8.1 All areas involved in work or traversed by workmen or equipment shall be left clean and in good order. All waste matter resulting from this work item shall be collected in suitable containers provided by the Contractor and shall be disposed of by the Contractor in strict compliance with current U.S. Government, state and local antipollution and public health regulations.

8.2 All required tests and inspections shall be performed to the satisfaction of the USCG, ABS, and MSCREP as applicable.

8.3 After performing all other items in this work instruction; reinstall all insulation, flange spray shields, lagging, and ancillary equipment as required and to the satisfaction of the MSCREP.

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