WI 560 Calcium Carbonate Dosing System.docx

USNS Matthew Perry

(T-AKE 9)

Calcium Carbonate Dosing System Installation

1.0 ABSTRACT

This work item describes the addition of a calcium carbonate dosing system to the ship’s potable water system. This modification will provide the ability to treat potable water being delivered from the distilling units and water stored in the cargo/ship’s potable water storage tanks. This treatment will raise the pH level of the water to at least 7. The intent is to minimize or eliminate the incidence of copper leaching from the system piping.

2.0 REFERENCES

2.1 Selected Records Drawing 471-342-7126_C-SRD_002.

2.2 Selected Records Drawing 471-342-7126_C=SRD_004

2.3 Attachment 3 – Aqua-Chem Drawing No. 656-D-9723 Rev. 1 dtd 10/23/09, On-Line and Recirc CaCO3 pH Adjuster Model pH-53 for SPD35-53 – T-AKE

2.4 pH Adjuster location overview photo

2.5 On-line and Recirc cylinder location photo

2.6 On-line and Recirc pH Adjuster manifold locations photos

2.7 Ball valve removal photo.

2.8 Aqua-Chem Drawing No. 506-D-8534 Rev. 2, Pump Assembly Recirc Brominator Pump

2.9 NAVSEA Drawing No. 531-7488738 Rev C T-AKE 1 Class Selected Record Drawing Distilling Plant System Diagram.

2.10 NAVSEA Drawing No. 505-7488988 Rev B T-AKE 1 Class Piping Material Schedule; System Material Schedule No. DU01.

2.11 NAVSEA Drawing No. 201-7488951 Rev L T-AKE 1 Class Selected Record Drawing Machinery Arrangement

2.12 NAVSEA Drawing No. 505-7488748 Rev BT-AKE 1 Class Flushing Procedures.

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Location: Propulsion Motor Room (5-75-0).

3.1.2 Quantity: Two (2) 55 m3/day calcium carbonate pH adjustment dosing system, and associated piping and fittings.

3.2 Item Description/Manufacturer's Data

3.2.1 Material/Components necessary to accomplish the work required by this work item and approximated equipment and pipe locations are identified in References 2.1, 2.2, 2.3, 2.4, 2.5, and 2.6 above.

3.2.2 Estimated quantities and piping lengths can be determined from References 2.1, 2.2, 2.3, 2.4, 2.5, and 2.6. The contractor shall provide the exact quantities and additional material such as 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 System’s Specification, Manufacturer’s Requirements, Ship Specification and Regulatory Bodies, as applicable.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Government Furnished Equipment (GFE): Aqua-Chem Dosing Unit Bill of Materials listed in Reference 2.3

4.2 Government Furnished Material (GFM): None

4.3 Government Furnished Services (GFS): None

4.4 Government Furnished Information (GFI): None

5.0 NOTES

5.1 The contractor shall install the new dosing systems as close as possible to the locations indicated in references 2.4, 2.5, and 2.6. These locations shall permit access to the corresponding valves for easy operation.

5.2 The contractor shall relocate any equipment and piping that is necessary (i.e. small piping, pipe hangers, etc.) to allow installation of new piping and valves indicated in this work item. No piping or equipment shall be modified without MSC approval.

5.3 The contractor shall provide and install, if required, valve reach roads to allow easy access and operation of the valves.

5.4 The contractor and all subcontractors, regardless of tier, must consult the Military Sealift Command General Technical Requirements (GTRs) to determine applicability to this Work Item. In performance of this Work Item, the contractor and all subcontractors, regardless of tier, shall comply with the requirements of GTR’s 1-7, 23-25, and 29.

5.5 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.

6.0 QUALITY ASSURANCE REQUIREMENTS

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

7.0 STATEMENT OF WORK REQUIRED

7.1 Arrangements/Outfitting: None Additional

7.2 Structural

7.2.1 Installations

a. Install pipe hangar/supports for new piping, hoses, tanks, valves, and manifolds as required.

b. Install/route deck coaming to contain the dosing system calcium carbonate tanks (See Ref 2.5).

7.3 Mechanical/Fluids

7.3.1 Removals: The contractor shall relocate any equipment and piping that is necessary (i.e. small piping, pipe hangers, etc.) to allow installation of new piping and valves indicated in this work item. No piping or equipment shall be modified without MSC approval.

7.3.2 Installations

a. Install one 55 gpm (14” dia x 54” H) capacity calcium carbonate dosing tank for the treatment of water leaving the distilling plants. The tank shall be properly secured both to the deck and supporting structure. The installation shall ensure that any moisture generated by the dosing unit will be collected within the coaming surrounding the brominator panels. Tentative location for this tank is depicted in ref 2.5 under “On-Line Cylinder Location.” The proposed area is indicated by a white square on the deck.

b. Install one pH adjuster manifold, including all valves, piping, hoses, and other fittings necessary for proper installation. This manifold will be part of the in line dosing system. The manifold shall be mounted in the location depicted in ref 2.6, labeled “On-line pH Adjuster Manifold Location.” Means shall be provided to ensure that any moisture or leakoff generated from the manifold will be collected in the coaming surrounding the brominator panels.

c. Install, route, and connect with existing piping new on-line dosing unit, manifold, piping, and hose connections. The location of the connections are depicted in ref. 2.1. The connections should be upstream of the in line brominator and downstream of the distilled water tank fill branch connection.

d. Install one 55 gpm capacity (14” dia x 54” H) calcium carbonate dosing tank for the treatment of water being stored in the ship’s cargo and potable water tanks. The tank shall be properly secured both to the deck and supporting structure. The installation shall ensure that the drain plug is accessible and that any moisture generated by the dosing unit will be collected within the coaming surrounding the brominator panels. The deck coaming shall be modified as necessary to contain any dosing unit moisture. Tentative location for this tank is depicted in ref 2.5 under “Recirc Cylinder Location.” The proposed area is indicated by a white square on the deck.

e. Install one pH adjuster manifold, including all valves, piping, hoses, and other fittings necessary for proper installation. This manifold will be part of the recirc cylinder dosing system. The manifold shall be mounted in the location depicted in ref 2.6, labeled “Recirc pH Adjuster Manifold Location.” Means shall be provided to ensure that any moisture or leakoff generated from the manifold will be collected in the coaming surrounding the brominator panels.

f. Install, route, and connect with existing piping new recirc dosing unit, manifold, piping, and hose connections. The location of the connections are depicted in ref. 2.2. The connections shall be downstream of the recirc pump discharge tee and at the flanged hose connection. Existing 1” nps ball valve to be removed (see ref’s 2.7 and 2.8).

7.4 Electrical/Control

7.4.1 Removals: None

7.4.2 Installation/Modification

a. None

7.5 Electronics: None

7.6 Preparation of Drawings

Prepare “red-lined” markups of the system drawings, References 2.9 and 2.11 showing all modifications to the system necessary during the installation to accomplish this work item. Drawings as a minimum shall include three hard copies and one electronically scanned copy.

7.7 Inspection/Test

7.7.1 Preliminary Tests

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

7.7.2 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.

7.7.3 Welding and Brazing Test

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

7.7.4 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.

7.7.5 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.

7.7.6 Hydrostatic Test

a. The Contractor shall hydrostatically test the new distilled water piping at 38 psi (2.6 bar) and the recirc brominator piping to 77 psi (5.31 bar).

7.7.7 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.

7.7.8 Operational Test

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

All work has been 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. This includes verifying that the on-line dosing unit can raise the distilled water pH level to between 6.5 and 7.0 by adjusting the bypass valve.

7.8 Painting

Paint all new and disturbed surfaces to match surrounding surfaces.

7.9 Markings

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

7.10 Manufacturer Representative: Provide the services of an Aqua-Chem technical representative for three days to assist in the groom and test the system.

Aqua-Chem Inc.

Jim Collins Military Business Development Naval Forces

865.549.5448 Direct

865.705.3107 Mobile

865.546.4330 Fax

8.0 GENERAL REQUIREMENTS: The contractor shall provide the technical documentation required for proper operation and maintenance of the installed systems, including technical manuals and diagrams. This includes updating the existing engineers operating manual to reflect operational changes related to the dosing system.

560-1