SOW VENTUROUS NR2 Boiler Replace.pdf

51700_0225_210WMEC

WORK ITEM 1: Boiler, Renew

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew the ship's port (NR2) service boiler assembly; including shell, tubes, associated valves and burner assembly located in the

Engine Room.

1.2 Location.

USCGC VENTUROUS (WMEC-625)

600 8th Ave. SE

St. Petersburg, FL 33701

1.3 Period of Performance. 23FEB26-18MAR26

1.4 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

N Way-Wolff Boiler Model

No. 5848-14E

NSN: 4410-01-230-8024 1 ea. 43,682.00

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Bill of Materials 618 WMEC 11, Rev J, 3rd Dk, 2nd Dk, Main Dk, 02 Dk & Bridge

Dk Plt g & Supports

Coast Guard Bill of Materials 618 WMEC 61, Rev J, Arr. Stm., Feed & Conds. Sys. Piping

Coast Guard Bill of Materials 627 WMEC 11, Rev C, 3rd Dk, 2nd Dk, Main Dk, 02 Dk & Bridge

Dk Plt’g & Supports

Coast Guard Bill of Materials 627 WMEC 61, Rev H, Arr. Stm. Feed & Cond. Sys. Piping

Coast Guard Drawing 618 WMEC 131-001, Rev M, 2nd & Main Deck Plating & Supports

Coast Guard Drawing 618 WMEC 182-002, Rev W, Foundations in Engine Room

Coast Guard Drawing 618 WMEC 535-001, Rev M, Diagram Steam, Feed & Condensate System

Piping

Coast Guard Drawing 618 WMEC 535-002, Rev K, Arr. Stm., Feed & Condensate System Piping

Coast Guard Drawing 618 WMEC 535-004, Rev-, Split Pipe Drain Duct for Boiler Overboard

Disch

Coast Guard Drawing 618 WMEC 601-001, Rev J, Outboard Profile

Coast Guard Drawing 618 WMEC 601-002, Rev B, Inboard Profile

Coast Guard Drawing 618 WMEC 601-003, Rev K, General Arrangement - Second and Third

Decks

Coast Guard Drawing 618 WMEC 601-004, Rev K, General Arrangement Main & 01 Deck

Coast Guard Drawing 627 WMEC 131-001, Rev D, Second & Main Deck Plating & Supports

Coast Guard Drawing 627 WMEC 182-001, Rev C, Main Engine Foundations

Coast Guard Drawing 627 WMEC 182-002, Rev G, Major Main. Avail Foundations in Engine

Room

Coast Guard Drawing 627 WMEC 201-001, Rev C, Arrangement of Machinery Plans, Sections, & Elevations

Coast Guard Drawing 627 WMEC 517-001, Rev H, Boiler & Feedwater Pump Control Block &

Schematic Wiring Diagram

Coast Guard Drawing 627 WMEC 535-001, Rev J, Diagram Steam, Feed and Condensate System

Piping

Coast Guard Drawing 627 WMEC 535-002, Rev H, Arr. Stm., Feed & Condensate System Piping

Coast Guard Drawing 627 WMEC 535-003, Rev-, Steam Piping Mods Incid to Bos’n Stores and

Workshop Ventilation Mods

Coast Guard Drawing 627 WMEC 535-006, Rev-, Steam, Feed & Condensate Steam Mods to

Incidental to Boiler Life Improvement

Coast Guard Drawing 627 WMEC 601-001, Rev G, Outboard Profile

Coast Guard Drawing 627 WMEC 601-002, Rev B, Inboard Profile

Coast Guard Drawing 627 WMEC 601-003, Rev E, General Arrangement - Second and Third

Decks

Coast Guard Drawing 627 WMEC 601-004, Rev D, General Arrangement Main & 01 Decks

Coast Guard Drawing 627 WMEC 622-001, Rev D, Arrg’t Dets of Ladders, Grating, Floor Plates in Machy Space – Plans

NAVSEA Drawing 804-5959214, Rev-, Piping Insulation - Installation Details

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 8636 (SFLC Std Spec 8636), 2022, Temporary Hull Accesses

Coast Guard Technical Publication (TP) 2188, Dec 2024, Steam Heating Boiler - Model 5848-

14E

OTHER REFERENCES

ASTM International (ASTM) F683, 2014, Standard Practice for Selection and Application of

Thermal Insulation for Piping and Machinery

ASTM International (ASTM) F992, 2017, Standard Specification for Valve Label Plates

3. REQUIREMENTS

3.1 General. The Contractor must renew designated ship's service boiler assembly (including shell, tubes, associated valves (including blow-down valve) and burner assembly (Way-Wolff steam boiler, Model

5848-14E) with a Government-furnished Way-Wolff boiler assembly. Refer to TP 2188 and the applicable Coast Guard drawing(s) listed in Section 2 (References) for guidance.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, (Vessel component, space, and equipment protection).

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, (Interferences). Known interferences include, but are not limited to the following:

• Fuel oil piping

• Steam piping

• Condensate piping

• Insulation

• Metal sheathing

• Handrail

• Stanchions

• Deck frames and grating

• Wiring brackets

• Ducting

• Transformers

• Demineralizer

• System fluids, steam and chemical additives

• Bilge piping

• Bilges

3.1.4.1 Fluid removal. Remove of oily water to facilitate gas-freeing.

3.1.4.2 Bilge cleaning. Clean (e.g. pressure wash, hand wash, wipe down, etc.) all bilge surfaces in the

Engine Room free of all foreign materials, such as dirt, oil, sediment or sludge to facilitate gas-freeing.

Remove all persistent residues, taking care not to damage the coating system or to allow any contamination to enter the machinery. Remove fluids, cleaning media, and residues continuously during the washing process. Remove any residual wash media and wipe up residual moisture with clean, lint-free cloths. Collect, contain, and dispose of all fluids, wash media, residues, and cleaning materials in accordance with all Federal, state, and local regulations.

3.1.4.3 Fluid disposition, disposal. Dispose of all removed fluids in accordance with all applicable

Federal, state, and local regulations. Refer to paragraph 4.1 (Tank content restoration).

3.2 Temporary access openings. With express permission of the KO via submission of a CFR and in accordance with SFLC Std Spec 8636, the Contractor may perform all work required to cut open and close temporary access openings to facilitate accomplishment of the work specified herein.

3.3 Additional structural supports. When ship’s structure is removed as an interference or is otherwise temporarily modified to facilitate repairs, the Contractor must maintain existing structural integrity of the ship by installing temporary supports equivalent to those temporarily modified or removed. These temporary supports must be approved by the COR prior to removing or modifying ship’s structure via

CFR. Pay particular attention to structure supporting the Ship Service generators. Restore to original configuration after completion of work.

3.4 Boiler removal. The Contractor must accomplish the following for the designated boiler assembly(s):

3.4.1 Disconnect all piping, insulation, sheet metal wrap, exhaust ductwork, and accessories in way of boiler removal.

3.4.2 Crop out, remove, and dispose of the existing boiler assembly, including shell, tubes and burners.

3.5 Inspection. The Contractor must visually inspect the associated ship’s service boiler piping, foundations, exhaust ductwork, and electrical wiring for corrosion and deterioration. Submit CFR.

3.6 Foundation surface preservation. The Contractor must prepare and coat the boiler foundation surfaces, including all adjacent structural members, in accordance with SFLC Std Spec 0000 and SFLC Std Spec

6310; using the coating system specified for “Machinery, Interior (Machinery, Steel, Operating

Temperatures Over 200oF Surfaces)” in SFLC Std Spec 6310, Appendix B (Cutters and Boats Interior

Painting Systems). Select finish/top coat color to match existing adjacent surfaces.

3.7 New boiler installation. The Contractor must accomplish the following for the designated boiler assembly:

3.7.1 Rig in the new Government-furnished Way-Wolff boiler assembly through the same route used for removing the old boiler.

3.7.2 Assemble and install the Government-furnished Way-Wolff boiler and accessories to original configuration using TP 2188 as guidance. Weld the new boiler shell onto its foundation in accordance with the requirements of SFLC Std Spec 0740.

3.7.3 Fabricate and install new flanges to suit the existing exhaust duct flange. Minor modifications to the exhaust port may be required to facilitate a proper fit in the machinery space. Submit a CFR.

3.7.4 Prior to shipboard installation and again after installation, hydrostatically test the new boiler and associated piping in accordance with SFLC Std Spec 0740 in the presence of the Coast Guard Inspector.

Plug all external holes on the boiler; hydrostatically test the water side with clean fresh water for 15 minutes. Notify the Coast Guard Inspector 24 hours prior to testing. Be aware that no leakage or permanent deformation of pressure-containing parts is permissible. Repair all leaks and discrepancies found. Submit a CFR for each test.

CAUTION

Historically, it has been necessary for Contractors to provide and weld install three 4-inch to varying size reducer fittings into each boiler to accomplish the hydrostatic test.

-Base the test pressure and relief settings on the designated boiler’s pressure rating for 15 psi steam and 30 psi water. The operating and relief settings for steam service relief valves has been downgraded from 30 PSI to 15 PSI, which will be the case for all newly installed boilers, however some boilers in the fleet are still rated at 30 psi for steam.

NOTE

Boiler burner assembly igniter gaps are not preset from the factory, and must be set and verified in accordance with TP 2188 prior to attempting any operational tests.

Excessive igniter gaps can result in soot damage to the diffuser cone and poor boiler performance.

NOTE

Wiring arrangements may vary between vessels.

3.7.5 Accomplish all piping installation and restoration in accordance with the welding and testing requirements of SFLC Std Spec 0740.

3.7.5.1 Reconnect/reinstall all piping.

3.7.5.2 Renew boiler shell insulation. Install outer sheet metal wrap and exhaust ductwork to their original configuration. Renew all disturbed piping insulation and thermal blankets.

3.7.5.3 Renew all disturbed gaskets and fasteners. Verify that boiler relief valve is set at 2 psi above max operating pressure (per boiler dataplate). Renew the following associated valves for each designated boiler:

• 1 ¼” gate valve

• 1 ¼” solenoid valve

• 1 ¼” check valve.

3.7.5.4 If a Change Request is released and approved by the KO, the Contractor must install new insulation material over the exposed designated steam piping surfaces, including associated pipe hangers, valves, fittings, and flanges, in accordance with details in NAVSEA Drawing 804-5959214; select appropriate insulation materials and thicknesses for the application and temperature ranges specified in

ASTM F683, Tables S1.1, S1.2, and S1.4. Paint the newly installed insulation system, in accordance with

SFLC Std Spec 6310, using the system specified for “Insulation Surfaces, Fiberglass Sheet/Closed Cell

PVC Foam” in Appendix B (Cutter and Boat Interior Paint Systems).

3.8 Touch-up preservation. The Contractor must prepare and coat all new and disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, (Touch-ups and minor coating repairs.)

NOTE

The Contractor must not drain any fluids into the bilges during the performance of this work item. All fluids must be drained and disposed of in accordance with all applicable Federal, state, and local regulations.

Coast Guard personnel will operate all shipboard machinery and equipment.

3.9 Operational test, post repairs. After completion of work and in the presence of the Coast Guard

Inspector, the Contractor must thoroughly test and demonstrate the equipment listed below to be in satisfactory operating condition. Submit a CFR.

• New boiler system including all associated valves

• New burners properly adjusted in accordance with manufacturer's instructions

• All new and disturbed components.

3.10 Label nameplate, installation. The Contractor must furnish and install a nameplate label onto the valves and pressure vessel; and must ensure each nameplate is made of the melamine type material with either engraved black letters on white background or white letters on black background, or metal photo type material with black letters photographically sealed onto an aluminum surface.

4. NOTES

4.1 Ship check. Due to numerous interferences and limited accessibility for the removal and installation of the boilers, all prospective bidders are strongly encouraged to perform a ship check prior to submitting bids.

4.2 Removal access. Historically, this work has been facilitated by cutting accesses through the deck.

4.3 Boiler feedwater. Ship’s Force will verify the water quality (cleanliness and chemistry) of the boiler system prior to resuming boiler operations.