POLAR STAR BOILER VALVES

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Work Item 1: BOILER Feed Water and Blowdown Valve, Replace
GFM: None
REFERENCES:
Naval Ship's Technical Manual (NSTM) Chapter 221, Dec 2000, Boilers
COAST GUARD DRAWINGS:
 400 WAGB 0103-14 Rev Q, Booklet Of General Plans
 400-WAGB 5101-5, Rev F; DIAG Of Steam Boiler Blow & Escape
 400-WAGB 5101-3, Rev AC; ARR STM, Boiler Blow, Escape, And Feed Piping
 Coast Guard Drawing 400-WAGB 5101-6, Rev N, Arrgt & Dets Boil Feedwtr Tank
 Coast Guard Drawing 400-WAGB 5101-7, Rev 1, Marine Aux Boiler-Bare Boiler Design Arrgts
COAST GUARD PUBLICATIONS
 COMDTINST M10360.3C, Coatings and Colors Manual
 Coast Guard Technical Publication (TP) 2035, Manufacturer's Instruction Book - SWBS Group(s) 516-521
Scope:
The intent of this item is to remove, replace, test and reinstall the boiler feed and blow down valves for No.1 and No.2 Boilers.
The boilers are “D” Type boilers, Seattle Boiler Model SDW 350M. Information on the boiler design may be found in CG Dwg 400 WAGB 5101-7, CG Dwg 400 WAGB 5101-1, and CG Tech Pub 2035.
3 REQUIREMENTS
The Contractor shall provide all labor and material to accomplish the following in accordance with the General Requirements:
3.2 In the presence of the Coast Guard Inspector inspect all affected equipment and systems (including those subject to interference/removal) to document original condition. Submit a Condition Found Report for each affected space noting any discrepancies in equipment and system operation.
3.3 Interferences – The Contractor shall remove, modify, or protect all interferences to the work. All interferences that are removed shall be tagged to facilitate proper reinstallation. Ensure that all removed equipment is kept in a clean, dry, protected location. Obtain
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verification from the Coast Guard Inspector for the protective measures taken for equipment not removed.
3.4 GAS FREE - Gas free and certify affected compartments in accordance with the General Requirements. The affected compartments must be certified “Safe for Personnel – Safe for Hotwork” for the duration of work performed under this item. (Sound Testing)
3.4.1 Gas Free Certificates indicating the current status of each compartment shall be posted on the Quarterdeck and at each open access to the compartments. Provide one copy to the Coast Guard Inspector.
3.5 Remove the valves listed below and install temporary blank flanges with gaskets over pipe openings while valves are removed from system. Securing blank flanges with fasteners in all of the flange bolt holes.
3.5.1 Remove the 2 bottom blow valves from each boiler located in the boiler space, the first valve is a 2-inch flanged quick opening lever operated valve; the second valve is a 2-inch flanged angle globe valve.
3.5.2 Remove the 2-inch flanged gate valve located in the Gas Turbine Room (5-113-0-E) Lower Level, near the overboard connection.
3.5.3 Overhaul the socket welded 2-inch Globe Stop Check valve in place; the valve is adjacent to gate valve in 3.5.2.
3.5.4 Remove both boiler feed valves.
3.8 “SHOP HYDROSTATIC TEST”
3.8.1 In the presence of the Coast Guard Inspector test for seat tightness using clean fresh water each valve removed from system with the valve in the closed position with opposite side open for inspection. Apply the maximum handwheel force to seat valve in accordance with Table 505-11-2 of NSTM Chapter 505. Test shall continue for three minutes, if there is no evidence of leakage or, in the event of visible leakage, until accurate determination of leakage can be made. Seat tightness test pressure shall be 225 psig. Maximum allowable leakage rates for metal to metal seated valves: 10 cubic centimeters (CC) per hour, per inch of nominal pipe size.
3.8.2 Install each replacement valve conforming to MIL-STD-777, Schedule of Piping, Valves, Fittings, and Associated Piping Components for Naval Surface Ships.
3.8.3 Weld 2EA 2" SOCKET WELD FLANGES/ 1EA 2" 90 DEGREE ELBOW AND 1 FOOT OF 2" PIPING FOR BLR'S 1 AND 2
3.8.4 WELD IN 6EA NEW 3/4" GATE VALVES, ASSOCIATED 3/4" PIPING(4 FEET PER BOILER) AND INSULATION REMOVAL AND REPLACEMENT
3.9 OPERATIONAL TESTING
3.9.1 Coast Guard personnel will operate the Cutter's equipment for the operational test.
3.9.2 Accomplish operational testing for each newly installed Valve to prove satisfactory operation, unobstructed flow and tightness of the disturbed flanged joints. Allowable Leaks: None.
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3.9.3 In the presence of the Coast Guard Inspector, test each valve for ease of operation by cycling each valve from the fully open to the fully closed position.
3.10 Coat each overhauled valve with high heat aluminum paint.
3.11 Accomplish the requirements of SSPC-SP 1 and SSPC-SP 3 for the new and disturbed surfaces, prime and paint the new and disturbed surfaces to match the surrounding area. Provide the Coast Guard Inspector with the MSDS sheet to document the paint used.
3.12 Submit a final closure report (CFR) for this Work Item when complete.
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(RR)