J.1 NOAA Ship Oscar Dyson FSV Midlife Extension Program Work Specification-001.pdf

WORK SPECIFICATION NOAA SHIP

OSCAR DYSON FISHERIES SURVEY

VESSEL (FSV) MIDLIFE EXTENSION

PROGRAM (MEP)

Vessel Particulars

Year Delivered: 2005 Call Sign: WTEP Builder: VT Halter Marine, Inc.

Moss Point, Mississippi

ABS ID: 05113227

IMO Number: 9270335 Construction: Welded Steel Hull/ Aluminum superstructure Propulsion: Diesel-Electric in line dual 1508hp DC motors

Single Propeller, fixed pitch Bow Thruster: AC Induction Azimuthing Elliot 40T3S/940 HP Length Overall: 208.6 Feet Beam: 49.2 Feet Draft: 19.4 ft Full load Centerboard retracted Draft: 29.7 ft Full load Centerboard extended Frame spacing: 600 mm (23.62”) Displacement: 1,840 metric Tons Light Ship

2,479 metric Tons Full Load

Revision 001

NOAA Ship Oscar Dyson FSV Midlife Extension Program Work Specification

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TABLE OF CONTENTS

Attachment J.1

Detailed Work Specifications

Item # Title ................................................................................................................................ Page

Basic – Class 20000 Items

Hull 20101 - Install Diesel Exhaust Fluid (Urea) Tank & Delivery System 20102 - Structural Repairs to Hull and House 20103 - Relocate Net Sonde Winch 20104 - Replace Trawl Gallows 20105 - Replace Mast 20106 - Remove SM200 Sonar and Dome 20107 - Inspect and Service Sliding Water Tight Doors

Propulsion 20201 - Vessel Repowering 20202 - Tail Shaft Removal & Inspections 20203 - Inspect/Service Thrust & Line Shaft Bearings 20204 - Replace Propeller Blades & Hub 20205 - Bow Thruster Inspections & Overhaul

Electrical 20301 - Remove Unused Cabling 20302 - Service ROXTEC Cable Transits 20303 - Overhaul Emergency Generator 20304 - Service & Inspect Transformers 20305 - Control Center Inspections & Maintenance 20306 – Inspections & Maintenance Emergency Switchboard 20307 - Convert Auxiliary Electric Motors to 480V

Mission 20401 - Replace VHF & HF Antennas 20402 - Replace Navigation Lights with LED Lights 20403 - Replace Dynamic Positioning System 20404 - Replace Fire & Alarm Detection System (FAD) 20405 - Replace RAPP Pentagon System 20406 - Replace Furuno S Band Radar 20407 - Replace Furuno X Band Radar

Auxiliaries 20501 - Replace Ship Service Pumps 20502 - Replace Through Hull Piping Penetrations 20503 - Replace Flexible Couplings & Hoses 20504 - Replace Tank & Void Vents 20505 - Replace Ventilation Ducting 20506 - Replace Ventilation Fans 20507 - Replace Air Conditioning (AC) Plants 20508 - Replace Refrigeration Plants 20509 - Fire Main Systems Repairs 20510 - Renew Seawater Piping Systems Valves 20511 - Drain & Gray Water Piping Repairs 20512 - Install Reverse Osmosis (RO) Water Makers 20513 - Rebuild Fuel Oil Purifiers 20514 - Service Oily Water Separator (OWS) Unit 20515 - Service Air Compressors & Replace Storage Receivers

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20516 - Inspect Fixed & Portable Fire Fighting Equipment 20517 - Inspect & Service RAPP Hydraulic Power Unit (HPU) 20518 - Inspect & Service Appleton Hydraulic Power Unit (HPU) 20519 - Inspect & Service Davit Hydraulic Power Units (HPU) 20520 - Replace Hydraulic Hoses 20521 - Inspect, Service, & Relocate the Centerboard Hydraulic Power Unit (HPU) 20522 - Rudder Service & Inspections 20523 - Replace Bow Crane 20524 - Replace Starboard A-Frame 20525 - Upgrade Anchoring System 20526 - Overhaul Work Boat Davit 20527 - Annual Life Raft Inspection 20528 - Trawl System Equipment Servicing 20529 - Service Trawl Blocks 20530 - Overhaul MSD System 20531 - Reconfigure 01 Deck Fan Room 20532 - Flush & Test Auxiliary and Main Salt Water Piping 20533 - Reconfigure After Steering Station 20534 - Overhaul Rescue Boat Davit 20535 - Replace Main Seawater Overboard Discharge Piping

Outfitting/Preservation/Furnishing 20601 - Modify Hull Marking Designations 20602 - Portlight and Window Maintenance 20603 - Preservation Underwater Hull 20604 - Preservation Exterior Decks 20605 - Preservation Freeboard 20606 - Preservation of Deck House, Stack & Mast 20607 - Preservation Deck Machinery 20608 - Preservation Chain Locker 20609 - Preservation Ballast Tanks 20610 - Preservation Miscellaneous Tanks 20611 - Service/Inspect Cathelco Anti-Fouling and Impress Current System 20612 - Hull Anode Replacement 20613 - Refresh Wet Lab 20614 - Modify Berthing 2nd Deck 20615 - Refresh Mess Deck 20616 - Replace Galley Appliances

Engineering/Integration 20801 - Drawing Updates 20802 - Vessel Inclining 20803 - New Equipment Spare Parts & Special Tools 20804 - Technical Publications 20805 - Weight Control 20806 - Crew Training

Support/Services 20901 - Dock Trials 20902 - Sea Trials 20903 - Conduct ABS & USCG 5 Year Special Surveys 20904 - Weight Testing of Cranes, A-Frames, and Davits 20905 - Utilities & Services 20906 - Protective Coverings & Cleaning 20907 - Routine Dry Docking 20908 - Underwater Body Inspections & Repairs

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Optional – Class 40000 Items

40001 - Additional Government Requirements

Optional – Class 60000 Items

Hull 60101 - Miscellaneous Welding and Fabrication 60102 - Trawl & Oceanographic Winch Room Flush Hatch Repairs 60103 - Service Forward Mast 60104 - Fabricate and Install Wood Deck for Trawl Way

Auxiliaries 60501 - Miscellaneous Piping Repairs 60502 - Replace Tank Level Indicators (TLI) 60503 - Miscellaneous Insulation & Lagging Repairs 60504 - Replace Air Circulation Units (ACU) 60505 – Replace Water Heaters 60506 - Replace Cranes 60507 - Replace Hydrographic WINCHES

Outfitting/Preservation/Furnishing 60601 - General Repairs to Railings 60602 - Interior Bulkhead Painting 60603 - Interior Joiner Door Painting 60604 - Void Preservation 60605 - Bilge Preservation 60606 - Deck Covering Replacement 60607 - Install Sheathing 60608 - Sound Proof Stateroom Overheads

Attachment J.1

Detailed Work Specifications

Item No 20101 Title: Install Diesel Exhaust Fluid (Urea) Tank & Delivery System

1. SCOPE

1.1. Background - Work item 20201, Vessel Repowering, will include Tier 4 CAT 3512 SSDG units and required a Diesel Exhaust Fluid (DEF) supply tank, distribution equipment, and systems. To support this effort a new internal storage tank and delivery system for DEF (urea), is required.

1.2. Intent - To construct a new internal DEF tank using part of the existing 4C ballast tank. New stainless-steel plate and stiffening will be installed, piping runs inside the tank will be replaced with corrosion resistant stainless steel (CRSS) materials, along with anti-corrosion coating on the interior of the new tank and voids. Reach rods currently in the 4C ballast tank will be relocated to avoid the new tank. New vent and fill piping will be run, and existing ballast fill and vent piping will need to be removed or blanked. A pump will be installed in the engine room to transfer DEF from the new tank. A new DEF day tank, along with all DEF dispersion equipment and systems will be installed in the lower engine room. The following major systems will be affected:

Vessel Arrangement, Structure & Stability Ballast System Generator Exhaust System Electrical Power/Distribution/Controls

2. REFERENCE DOCUMENTS

2.1. Attachment J.2 Specific Contract Work Definitions and Requirements

2.2. NOAA Standard Specification S0100; Implementation and Conduct of Check Points

2.3. NOAA Standard Item S2906, Arc Welding on Waterborne Vessels

2.4. IEEE Std 45-1983; Recommended Practice for Electric Installations on Shipboard

2.5. NOAA Standard Item S6900; General Requirements for Electrical/Electronic Items

2.6. NOAA Standard Specification - S3900 Insulation/Lagging on Piping/Machinery

2.7. American Bureau of Shipping, Marine Vessel Rules

2.8. Drawing DY-201-01 Revised Machinery Arrangement

2.9. Drawing DY-110-FH03 Hull Midbody Scantlings Rev 4

2.10. Drawing DY-298-001 Diesel Exhaust Fluid Tank Installation

2.11. Drawing DY-529-FP01 Bilge & Ballast System Diagram Rev 4

2.12. Drawing DY-801-FC05 Tank Capacity Curves & Tables

2.13. Work item 20609 Preservation Ballast Tanks

2.14. CAT Guide Marine Air-Assist Aftertreatment A&I - LEBM0023-6

2.15. International Standard, (ISO) 14726-1:1999(E) Ships and Marine Technology Identification Colors for the Content of Piping Systems

3. GOVERNMENT FURNISHED MATERIAL (GFM)

3.1. None

4. REQUIREMENTS

4.1. General Requirements

4.1.1. The new DEF tank shall be identified as Urea 4-44-0 and the two voids, identified as Void 4-39-1 (stb) and Void 4-39-2 (port).

4.1.2. The Contractor shall perform all work in accordance with the requirement documents cited in paragraph 2 above.

4.1.3. All Joints shall be flanged or welded. No tapered pipe thread joints or fittings are allowed.

Where the Contractor must make up to an existing pipe thread fitting, a short spool piece shall be used to transition to an acceptable fitting.

4.1.4. Repaired or replaced piping shall at a minimum be the same as the material schedule of the existing system. Sufficient take down joints shall be provided to allow removal of pipe without cutting it.

4.1.5. DEF tank piping and fittings shall be CRSS 316 schedule 80. New structural and plate steel used for DEF tank fabrication shall be CRSS 316 and sized per reference 2.10.

4.1.6. New DEF piping and tanks shall be labeled indicating Urea and color coded per reference 2.15, color violet (Fed Std 595C 27142). Labeling shall include the direction of flow.

4.1.7. All new metal installed on the ship shall be cleaned in accordance with Steel Structures Painting Council (SPPC)-10 and shall have two coats of primer applied before installation. Primer must be compatible with other paint systems used to meet the requirements of these specifications. Epoxy primer must be used over galvanized metal.

4.1.8. Piping and penetrations through bulkheads, decks, and tank tops are to be made per reference 2.7 which will maintain the same degree of fire, smoke, or watertight integrity.

4.1.9. The DEF tank and voids shall be prepared and coated with ARCOR EE-121 or equal. Provide the services of an authorized ARCOR marine coating specialist to approve surface preparation and application of the coating systems used in this work item.

4.1.10. Tank preservation shall be performed after all hot work in the affected tanks and adjoining spaces is complete, as well as all testing.

4.2. Tank Removals

4.2.1. Structural Removals - per Reference 2.10:

4.2.1.1. Remove port and starboard swash bulkhead within the 4C ballast tank.

4.2.1.2. Remove brackets around Centerline Vertical Keel (CVK).

4.2.1.3. Remove the ladder under the current tank access manhole.

4.2.1.4. Remove sections of the auxiliary machinery room deck in the way of new manholes.

4.2.1.5. Remove sections of vertical stiffeners on the aft bulkhead in the way of the new stainless-steel plate.

4.2.2. Piping and Equipment Removals - per Reference 2.10:

4.2.2.1. Remove through-piping and reach rods in 4C ballast tank that will be inside the new Urea tank.

4.2.2.2. Remove or raise up the forward fuel oil purifier in the AMR that is in the way of the new manhole to access starboard 4C tank void.

4.2.3. Bilge & Ballast System Removals - per reference 2.10:

4.2.3.1. Remove or modify 4C ballast tank vent piping.

4.2.3.2. Remove the 4C ballast tank fill/suction piping.

4.3. Tank Fabrications & Installations

4.3.1. Structural Installations – per reference 2.10

4.3.1.1. Install new stainless-steel bulkhead and stiffeners at Frame 44.

4.3.1.2. Install stainless-steel plate, stiffeners, and brackets over CVK between Frames 44 and 49.

4.3.1.3. On the starboard side of the AMR between frames 45 & 46, replace the manhole with a CRSS unit and install stainless-steel ladder under the manhole for Urea tank access.

4.3.1.4. Install mild steel brackets between vessel and tank stiffeners at Frames 46, 47, 48.

4.3.1.5. Install mild steel brackets between aft bulkhead stiffeners and new tank stiffener at Frame 48.

4.3.1.6. Install a new manhole in the AMR between Frames 39 and 40 with mild steel ladders for new void access. The forward fuel oil purifier will require re-positioning aft or be raised up to provide access.

*****CHECK POINT*****

4.3.2. Piping & Equipment Installation - per reference 2.10:

4.3.2.1. Install 4C ballast tank through-piping replacements inside the new DEF tank.

4.3.2.2. Install DEF discharge piping to terminate at the DEF day-tank. Route to be determined by the Contracting Officer Representative (COR).

4.3.2.3. Per reference 2.14 install piping and required components from the DEF transfer pump to the dosing units, and from the dosing units to the Clean Emission Modules (CEM).

4.3.2.4. Install vent piping from new DEF tank, DEF day tank, and DEF dosing units to main deck. Route to be approved by the COR.

4.3.2.5. Install a sounding tube for the DEF tank.

4.3.2.6. Recalibrate the 4C tank level indicator (TLI) for use in the DEF tank.

4.3.2.7. Install vent piping for the two new voids using the existing 4C vent piping run from the AMR to the weather deck. Install a new vent valve at the current weather deck location and label the piping accordingly.

4.3.2.8. Install a DEF day-tank fill pump per reference 2.8. Pump shall be located in the vicinity of the DEF day tank. Pump shall be 480V and be designed/rated for Urea use. The pump location shall be determined by the COR.

4.3.2.9. Install a DEF transfer pump. Pump shall be 110 or 480V. The pump location shall be determined by the COR.

4.3.2.10. Install DEF Doser units.

4.3.2.11. Purchase & install a sight glass and TLI for the DEF Day Tank. The tank TLI shall be added to the machinery control system.

4.3.2.12. Reinstall Fuel Oil Purifier (FOP) to avoid the new manhole for access to the starboard tank void. Reconfigure FOP skid the by making a section of the platform removable, condensing the platform aft three (3) feet or by raising the skid at its current location. If raised the height of the bottom of the raised skid shall be no higher than 30“. Final location shall be determined by the COR.

4.3.3. Bilge & Ballast System Installations

4.3.3.1. Install bilge suctions in the two new voids and each to the bilge manifold.

4.3.3.2. Install sounding tubes for the new voids.

4.3.3.3. Install high water level alarms in both voids. The alarms shall be added to the machinery control system.

4.3.4. Electrical System Installations per Reference 2.10:

4.3.4.1. Connect DEF transfer pump serving the day tank.

4.3.4.2. Connect DEF transfer pump serving the doser units.

4.3.4.3. Connect DEF doser Units.

4.3.4.4. Connect all sensors/monitors for the Def dosing units.

4.3.4.5. Reconfigure 4C ballast tank TLI for new DEF tank levels.

4.3.4.6. Connect new day tank TLI.

4.3.4.7. Connect new void high water sensors.

4.3.4.8. The shipyard is responsible for developing cable routing and identifying circuits if not already indicated on the new electrical distribution system. All routing shall be approved by the

COR.

4.4. DEF Day Tank - Fabricate & install a DEF day tank per the following requirements:

4.4.1. Tank dimensions shall be 48“wide x 48“long x 60“high, fabricated form CRSS 316, and be fully welded.

4.4.2. Tanks wall thickness must be designed with a factor safety of four on the ultimate strength of the material used with a design head of no less than 4 feet of liquid above the tank. Vertical baffle plates shall be installed at an interval not exceeding 30“. Baffle plates shall be of the same material and not less than the tank walls and must be connected to the tank by welding. Limber holes at the bottom and air holes at the top shall be provided.

4.4.3. Provide bolt on access covers to the tank top. Size should provide access for cleaning/inspection of tank interior.

4.4.4. Provide four (4) lifting staples on the tank top, one at each corner, sized to support the weight of the tank full of DEF.

4.4.5. Provide a sufficient number of legs on the tank bottom to support the tank weight fully loaded.

Tank legs shall provide a minimum of three (3) inches of space between the tank bottom and ship structure attachment points. The legs shall bolt onto the existing ship structure.

4.4.6. Provide the following penetrations in the tank. Tank penetrations shall be threaded and sized as required by the regulatory bodies and DEF system components. Exact locations will be determined by the COR:

4.4.5.1. Fill line with valve. Pipping to discharge at tank bottom.

4.4.5.2. Vent line.

4.4.5.3. One (1) discharge line with valves for the DEF transfer pump. Piping to take suction at tank bottom.

4.4.5.4. Mounting of an electronic Tank Level Indicator

4.4.5.5. Mounting of a visual sight glass (tank side)

4.4.5.6. One (1) unassigned at the top of the tank

4.4.5.7. One (1) for a drain line at the bottom of the tank

*****CHECK POINT*****

4.4.7. DEF Day Tank Painting: Sandblast the tank exterior to Society for Protective Coatings (SSPC) SSPC-6 Commercial Blast cleaning. Apply one (1) coat of a suitable primer compatible with the topcoat, then apply one (1) coat of polyurethane PPG AMERSHEILD, or equal, color violet (Fed Std 595C 27142) to a DFT of 5-6 mils. Tank shall be labeled on all four (4) sides in 4” letters DEF (Urea)

4.4.8. Install the tank in the location identified in reference 2.8. Modify the ship structure as required to attach and support the tank legs. The final location shall be determined by the COR.

4.4.9. As required by the DEF system, install the DEF transfer pump for supplying the dosing cabinets.

The final location shall be determined by the COR.

4.5. Testing & Inspections

4.5.1. New and modified piping systems shall be tested per the American Bureau of Shipping (ABS) requirements by pressurizing the respective system to the design pressure for a duration of no less than 30 consecutive minutes. All joints shall be inspected and if tested with air there shall be no drop in pressure after 30 minutes. If tested with water, there shall be no sign of leakage after 30 minutes.

4.5.2. New tanks and voids shall be pressure tested per the ABS requirements for a duration of no less than 30 consecutive minutes. All joints shall be inspected and if tested with air there shall be no drop in pressure after 30 minutes. If tested with water, there shall be no sign of leakage after 30 minutes.

***** CHECK POINT *****

4.5.3. The Contractor shall operationally test and demonstrate proper operation and performance of the equipment and installations with regards to design functions, features, and capabilities as identified in the equipment instruction books (operating manuals), USCG regulations, ABS rules, and these specifications. Operational testing shall also include all applicable manufacturer specified installation and functional testing. Manufactures testing shall be incorporated in the Contractor developed test memorandums be clearly identified as manufacturer testing requirements, and be approved by the COR.

***** CHECK POINT *****

4.5.4. All welds shall be inspected and tested in accordance with National Oceanic Atmospheric Administration

(NOAA) General Requirements, Ref 2.4. In addition, all pipe welds shall undergo 100% visual inspection plus Ultrasonic testing of 10% of welds. Visual inspection shall be in accordance with Part 2, Chapter 4 of Reference 2.7. Documentation of all weld inspections and testing shall be provided to the COR and ABS inspector describing any deficiencies discovered, and remedial actions taken.

***** CHECK POINT *****

4.5.5. Documentation of all electrical inspections and testing shall be provided to the COR and ABS inspector describing and deficiencies discovered, and remedial actions taken.

4.5.6. Inspections and Approvals - The Contractor shall obtain ABS approval of the installations, equipment, and details described in the section. NOAA General Requirements and Reference 2.5 provide further requirements regarding regulator body inspections and requirements for certificates and other documentation associated with regulatory body certification processes.

4.6. Tank and Void(s) Preservation

4.6.1. Surface Preparation - Perform Near-White Blast Cleaning (SSPC-10) to a 3 to 5 mil profile with chloride free abrasive, to remove the existing coating system, corrosion and foreign matter in the new DEF tank and voids. Grind flat all burrs, weld seams, and radius sharp edges. Fresh blasted ferrous surfaces shall be primed immediately to prevent oxidation of the surface. Inspect tank for coating system removal and correct profile in the presence of the COR and ARCOR representative. No coatings may remain on the bulkheads, overhead, or deck of the tank or in the sump of the tank.

*****CHECKPOINT*****

4.6.2. Test the surfaces for chloride contamination in accordance with standard NV-2 using Chloride Chemical Test Strips in at least 20 random locations. If chloride level is above 7μg/cm², wash prepared areas with low pressure, 1200 PSI water. HoldTight102 Flash Rust Inhibitor/Salt Remover (or equal) shall be used at the manufacturer’s recommended level. Retest the prepared areas in accordance with

NV-2.

*****CHECKPOINT*****

4.6.3. Void Preservation - Apply one coat of ARCOR EE-121 epoxy Novolac coating at a DFT of 60 mils. Measure and record the dry film thickness (DFT) the coating system at 30 locations. Submit a written report to the COR of all DFT readings.

*****CHECKPOINT*****

4.6.4. DEF Tank preservation - Apply two (2) coats of ARCOR EE-121 epoxy Novolac coating at a DFT of 50-60 mils per coat. Measure and record the DFT of the coating system at 30 locations. Map these locations so that final DFT readings are in the same locations. Submit a written report to the COR of all DFT readings.

*****CHECKPOINT*****

4.7. Painting Touch-up - Clean all damaged paint to sound paint or bare metal. Clean all exposed metal free of foreign matter and corrosion. Spot prime all damaged paint or exposed metal. Coat all new and damaged areas with 2 coats of finish paint to match the surrounding area. Epoxy paint must be used over galvanized metal. Rubber parts should not be painted.

4.8. Drawings - Contractor shall provide new as-built drawings of the modification including a bill of materials for each drawing. The Contractor shall develop a drawing for the DEF from the new storage tank to each CEM showing locations of all equipment, components and piping. The As-built drawings may be provided as a revision to the reference drawings provided herein. Drawing Updates - The Contractor shall revise the following drawings to reflect the as built configuration of the tank modifications. Drawings identified with an “S” are structural or system drawings which are directly impacted by these modifications. Drawings identified with an “R” are record drawings or drawings required for Regulatory approval; these drawings will likely require additional updates to incorporate previous modification beyond the changes required for these modifications. The following list is provided as a guide and is not inclusive of all drawings that will require updating for this work item.

Drawing # Drawing Rev Type DY-070-FL01 Major Equipment List 0 S

DY-079-FC12 T & S Booklet 3 R

DY-085-PZ55 DC Diagram Liquid Loading 0 R

DY-085-FA02 General Arrangements 7 R

DY-085-FZ30 Booklet of Gen Drawings 0 R

DY-167-FH62 Structural Doors & Hatches 8 R

DY-201-FA03 Machinery Arrangement 2 R

DY-202-FE25 Alarm & Control Pts List 1 R

DY-202-FE30 PSTP 2 R

DY-259-FP06 Exhaust Sys Diagram 3 S

DY-300-PE01 Power One Line 7 R

DY-505-9020 Valve List 3 S

DY-506-FP02 Vents & Sounding Systems 7 S

DY-542-FP05 DEF System & Transfer System Diagram New New

DY-631-FF04 Paint Schedule 2 S

DY-801-FC05 Tank Capacity Curves & Tables 0 R

DY-985-FA05 Fire Control Plan 7 R

DY-985-FA07 Safety Plan 4 R

5. QUALITY ASSURANCE

5.1. Submit a written report of the results of the testing/checkpoints required by this item. The report must contain the date, time, results, and names of the witnesses.

6. NOTES

6.1. NOTE - The components for the DEF system will be supplied via contract work item 20201 – Vessel Repowering which requires the purchase of the Tier 4 3512 SSDG units and required DEF distribution equipment and systems.

6.2. Contractor shall provide revised drawing listed in 4.12.

6.2.1. Contractor shall provide all test data for all installed systems to prove functionality.

6.2.2. Contractor shall provide one (1) year of spare parts, scheduled maintenance items and similar materials as recommended by the manufacture for the new installed systems.

6.2.3. All deliverables shall be provided in number and formatting as follows:

6.2.3.1. Drawings:

One (1) electronic PDF Copy, One (1) electronic CAD copy in AutoCAD 2015 or later Two (2) paper copies

6.2.3.2. Test Data and All other Deliverables:

One (1) Electronic copy in PDF, MS Word and/or MS EXCEL, as applicable One (1) Hard Copy

6.3 Typical DEF Delivery System Schematic form the Day Tank to the CEM.

(1) DEF Filter: 100µm (recommended)

(2) Transfer Pump Pressure Relief Valve: 500 kPa (72.5 psi)

(3) Pressure Regulator: 34.5-69 kPa (5-10 psi)

(4) Pressure Relief Valve: 69 kPa (10 psi)

(5) Dosing Cabinet Vent

(6) DEF Filter: 40µm, (Cat Option: 491-6779)

(7) Dosing Cabinet Solenoid Refill Valve

Pressure regulators must be installed before each Dosing Cabinet to ensure that the pressure at each Dosing Cabinet is between 34.5–69 kPa (5-10 psi).

Pressure relief valve on the DEF Transfer Pump should be set at its maximum valve of 500 kPa (72.5 psi).

Pressure relief valves should be placed between each pressure regulator and corresponding Dosing Cabinet. These pressure relief valves should be set to 69 kPa (10 psi). They will help purge any trapped pressure in the line between the pressure regulators and Dosing Cabinets back to the bulk tank.

Item No 20102 Title: Structural Repairs to Hull and House

1.1. Intent - This item is to complete structural repairs and/or modifications to the vessel’s hull and house structures, that are discovered during repairs and not addressed in a specification.

1.2. Objective - Provide labor and materials for major steel and aluminum structural repairs.

2.2. NOAA Standard Item S2906, Arc Welding on Waterborne Vessels

2.3. American Bureau of Shipping, Rules for Building and Classing Steel Vessels

2.4. NOAA Standard Specification S0100; Implementation and Conduct of Check Points

4.1.1. The Contractor shall perform all work in accordance with the requirements of the documents cited in paragraph 2 above.

4.1.2. All new metal installed on the ship shall be cleaned in accordance with SSPC-10 and shall have two coats of primer applied before installation. Primer must be compatible with other paint systems used to meet the requirements of these specifications. Epoxy primer must be used over galvanized metal.

4.2. Provide labor and materials for welding and fabrication to the ships structural hull and house structural plating. Submit a unit price per square foot for ferrous and non-ferrous welding. Estimate two-hundred fifty

(250) square feet of area for each size and one-hundred (100) linear ft of welding per each material.

Welders must be ABS certified.

4.2.1. Steel plate and structural components (angles/beams/channels) thickness will range from ⅜ to ½ inch and shall be ABS approved.

4.2.2. Aluminum plate and structural components (angles/beams/channels) thickness shall range from ¼ to 1 inch and shall be 5083/6031 aluminum and ABS approved.

4.3. Painting - Clean all damaged paint to sound paint or bare metal. Clean all exposed metal free of foreign matter and corrosion. Spot prime all damaged paint or exposed metal. Coat all new and damaged areas with 2 coats of finish paint to match the surrounding area. Epoxy paint must be used over galvanized metal. Rubber parts should not be painted.

5. QUALITY ASSURANCE

5.1. None

6. NOTES

6.1. None

Item No 20103 Title: Relocate Net Sonde Winch

1 SCOPE

1.1 Remove and relocate net sonde winch from starboard gallows to 02 Level Deck.

2 REFERENCE DOCUMENTS

2.1 Attachment J.2 Specific Contract Work Definitions and Requirements

2.2 NOAA Standard Specification S0100; Implementation and Conduct of Check Points

2.3 NOAA Standard Item S2906, Arc Welding on Waterborne Vessels

2.4 NOAA Standard Specification S1904-1 Cleanliness Requirements for Hydraulic Piping Systems

2.5 NOAA Standard Specification 1904-2 Hydraulic Piping and System Testing, Flushing and Assembly

Procedures

2.6 American Bureau of Shipping (ABS), Rules for Building and Classing Steel Vessels

2.7 Drawing DY-100-FH12 Aft House Scantlings Rev 4

2.8 Drawing DY-582-FH35 Deck Lifting Equipment Foundations Booklet Rev 4

2.9 Drawing DY-591-FH78 Winch Foundation Booklet Rev 01

2.10 Drawing SH-591-FA17 Mission Equip Layouts and Rigging Arrangements

2.11 Drawing SH-170-FH78 Winch Foundation Booklet

2.12 Drawing FSV6-180-83 Winch Foundation Booklet Rev A

2.13 Drawing DY-631 FF04 Paint Schedule Rev 2

2.14 Technical Manual DY-591-01 Trawling & Scientific Winch System Engineering Manual

2.15 Technical Manual DY-591-02 Trawling & Scientific Winch System Operations Manual

2.16 Work Item 20604 Preservation of Exterior Decks

2.17 Work Item 20521 Replace Hydraulic Hoses

2.18 Work Item 20528 Trawl System Equipment Servicing

2.19 UNOLS Handbook of Winch, Wire, & Cable Technology 2001, 3rd Edition

3 GOVERNMENT FURNISHED MATERIAL (GFM)

3.1 None

REQUIREMENTS

4.1 General Requirements

4.1.1 The Contractor shall perform all work in accordance with the requirements cited in paragraph 2 above.

4.1.2 The vessel is ABS Classed and USCG inspected. ABS/USCG will attend inspections required in this specification. The Contractor is responsible for advising ABS/USCG when the inspections will occur.

4.1.3 The new location for the winch is on the 02 exterior deck which is fabricated from aluminum.

4.1.4 All new metal installed on the ship shall be cleaned in accordance with SPPC-10 and shall have two coats of primer applied before installation. Primer must be compatible with other paint systems used to meet the requirements of these specifications. Epoxy primer must be used over galvanized metal. The overhaul of this winch is performed under reference 2.18. All system component inspections, servicing, repairs, adjustments, testing, winch removal/installation, hydraulic piping modifications, and re-spooling of the wire shall be completed by or under the supervision of an Original Equipment Manufacturer (OEM) MacGregor USA certified Technician:

MacGregor 2260 W. Commodore Way Seattle WA 98199-1259

(206) 406 2311

4.1.5 Ships force shall operate all equipment.

4.2 Net Sonde Winch Removal

4.2.1 Remove all wire from the winch onto a storage reel.

4.2.2 Disconnect all electrical cables and components from the existing control system. Ensure care and protection of all components as they will be reused once the winch is relocated.

4.2.3 Disconnect all hydraulic piping and hoses and cap all corresponding lines on the winch and the gallows. The Contractor is responsible for disposal of hydraulic fluid and hoses, Contractor is responsible for cleaning of any spilled fluids.

4.2.4 Remove any insulation in the way of any electrical and mechanical component removals during this work item. Save the insulation for reinstallation after all work has been completed.

4.2.5 Remove the net sonde winch from its current foundation and remove the net sonde winch from the ship. The boom and block will not be used at the new location. NOTE – Servicing of the net sonde winch is covered under work item 20528 – Trawl System Equipment Servicing.

4.2.6 Winch Relocation Preparation - NOTE: Reference 2.12 is for a sister ship with an electric winch. This reference should be used as a guide as it shows some details not provided in related documents.

4.2.7 Per reference 2.10, 2.11, & 2.12, modify the ship structure on the exterior 02 deck in preparation for the winch foundation. The winch shall be located per reference 2.11 and structural modifications completed per reference 2.12. The exact location shall be approved by the COR. Remove and replace interferences and insulation as required to complete the structural work.

*****CHECK POINT*****

4.2.8 Fabricate and install the winch foundation per reference 2.11 which shall match the structural modification accomplished in 4.3.1. Determine electrical/electronic cable runs and install wiring kick pipes as required. Location of the foundation and kick pipes shall be approved by the COR. Mark and drill mounting holes in the winch foundation.

*****CHECK POINT*****

4.2.9 Install new Hydraulic Piping to accommodate the new winch location and local control. Piping shall be the same size and type as the existing system. Installation shall include all necessary pipe, fittings, valves, hangers/supports, insulation, flexible hose assemblies, structural modifications, and all other items that may be required to complete this work item. The piping run and final locations shall be approved by the COR.

*****CHECK POINT*****

4.3 Net Sonde Winch Installation – Note: The exterior deck area below the winch shall be preserved before installation of the winch.

4.3.1 Install the net sonde winch on the new foundation and secure the net sonde winch in place per the manufacturer installation requirements. Install hard rubber gaskets between the winch steel surfaces and the aluminum foundation. NOTE - Any gaps between the winch mounting pads and foundation must be eliminated with the use of shims or chocking compound. Provide and install M20, grade 8.8 bolts (length to suit), washers and nuts. Torque the bolts per reference 2.14.

4.3.2 Reinstall new hydraulic hoses per reference 2.17.

4.3.3 Reinstall local hydraulic controls at the winch and trawl gallows.

4.3.4 Run new electric and electronic cables as required per reference 2.11 & 2.14.

4.3.5 Reinstall all electrical cables and components to the existing winch control system. Cabling shall be the same as the original.

4.4 Painting - Exterior painting of the winch foundation, structural modifications, and surrounding deck shall be completed before installation.

4.4.1 Exterior Painting - The new foundations, deck under and around the winch foundation, and decking 4ft past the foundation shall be prepared and preserved per the requirements of work item 20604.

4.4.2 Interior Painting - Paint new structure and touch up any disturbed coatings with two coats of Ameron 235 or equal, color white.

4.5 Insulation Repairs - All removed insulation that cannot be reinstalled shall be replaced with new. Insulation shall be the same type as the original. All insulation will be pinned with all seams taped/lagged. Insulation shall be painted to match the surrounding areas.

4.6 Testing - Prior to testing follow the start-up/commissioning guidelines in reference 2.14. Complete all check lists and provide copies to the COR. Perform operational test of the net sonde winch to ensure all electrical components are working properly. Tests shall be done dockside and during sea trials.

Demonstrate winch controls from all electronic and local hydraulic actuators. No leaking of hydraulic fluid allowed.

4.7 Upon successful testing reload the removed wire on the winch.

4.7.1 Prior to Installation perform conductivity checks on the wire and provide a report to the COR.

4.7.2 Prior to Installation the wire will be end for ended.

4.7.3 Install the wire under tension per reference 2.19 with under the direction of the OEM Macgregor USA.

4.7.4 The wire shall be lubricated during installation. The COR will provide equipment and materials for this process.

*****CHECK POINT*****

4.8 Painting Touch-Up - Clean all damaged paint to sound paint or bare metal. Clean all exposed metal free of foreign matter and corrosion. Spot prime all damaged paint or exposed metal. Coat all new and damaged areas with 2 coats of finish paint to match the surrounding area. Epoxy paint must be used over galvanized metal.

5 QUALITY ASSURANCE

5.1 Submit a written report of the results of the testing, inspections and check points required by this item. The report must contain the date, time, results, and names of the witnesses.

6 NOTES

6.1 Winch Drawings & Photographs

6.2 Photos of winch Install on a sister ship:

Hydraulic Piping Runs on a Sister Ship

Item No 20104 Title: Replace Trawl Gallows

1.1. Remove the existing Trawl Gallows and Replace with an updated design.

2.2. NOAA Standard Specification S0100; Implementation and Conduct of Check Points

2.3. NOAA Standard Specification MOC-631-2D – Coating Systems for Steel Surfaces

2.4. NOAA Standard Item S2906, Arc Welding on Waterborne Vessels

2.5. NOAA Standard Specification 1904-2 Hydraulic Piping and System Testing, Flushing and Assembly Procedures

2.6. NOAA Standard Item S6900; General Requirements for Electrical/Electronic Items

2.7. American Bureau of Shipping (ABS), Rules for Building and Classing Steel Vessels

2.8. Steel Structures Painting Council, Surface Preparation Specifications

2.9. Drawing DY-582-FH35 Deck Lifting Equip Foundations Booklet Rev 4

2.10. Drawing DY-100-FH05 Hull Transom Scantlings Rev 3

2.11. Drawing FSV6-589-03 Deck Lifting Equip Foundation Booklet Rev A

2.12. Drawing FSV6-167-01 Structural Doors, hatches, manholes, & Scuttles Rev C

2.13. Drawing DY-170-FH22 Mast, Rigging & Flagstaff Layout & Details

2.14. Work Item 20604 - Preservation of Exterior Decks

2.15. Work Item 20606 - Preservation of Deckhouse and Stack

3. GOVERNMENT FURNISHED MATERIAL (GFM):

3.1. None.

4. REQUIREMENTS:

4.1.1. The Contractor shall perform all work in accordance with the requirements of the documents cited in paragraph 2 above.

4.1.2. The vessel is ABS Classed and USCG inspected. ABS/USCG will attend inspections required in this specification. The Contractor is responsible for advising ABS/USCG when the inspections will occur.

4.1.3. All steel shall be ABS approved Grade A unless otherwise specified and have all appropriate stamps and documentation.

4.1.4. All new metal installed on the ship shall be cleaned in accordance with SSPC-10 and shall have two coats of primer applied before installation. Primer must be compatible with other paint systems used to meet the requirements of these specifications. Epoxy primer must be used over galvanized metal.

4.2. Gallows Component Removals - The net sonde winch is being removed and relocated per work item 20103 Relocate Net Sonde Winch. The trawl blocks are being removed, installed, and serviced per work item 20531 Reconfigure 01 Deck Fan Room. The following system components shall be removed.

Prior to removal inspect all system components with the COR for operation. Provide a report with the results of the inspection.

*****CHECK POINT*****

4.2.1. Electrical Systems - Disconnect all electrical components and wiring from the port and starboard trawl gallows. Ensure care and protection of all components and wiring as they will be re-installed once work is completed.

4.2.2. Hydraulic Systems - Disconnect all hydraulic equipment, fluid lines, and controls. Retain any controls and hydraulic piping for the aft A-Frame, net sound winch, outhaul winch, and trawl gate door as they will be reinstalled once the work is completed. Remove all hydraulic piping that was installed for the operation/support of the net sonde winch. Remove piping through the deck and cap all piping runs in system piping located in the trawl winch room.

4.2.3. Ventilation Systems – The trawl gallows serve as ventilation ducting. Disconnect any equipment/components. Ensure care and protection of all components as they will be reinstalled once work is completed.

4.2.4. Miscellaneous - Remove flag and flag mast from port gallows. Remove CCTV camera and mount sand relayed components. Remove any electronic equipment/sensors. Ensure care and protection of all removed items as they will be retained and reused upon completion of work.

4.3. Gallows Removal – Remove the port and starboard gallows and related fendering/guards and discard.

Retain the fendering/guard materials for possible reuse/reconfiguration on the new gallows. The exact configuration will be determined by the COR once the new gallows are installed.

4.4. New Gallows Fabrication – (see figures 4, 5, & 6). Fabricate replacement gallows in accordance with reference 2.11. The fabrication of the crane rest shall not be per the drawing. Work item 60506 provides a new crane and it is the Contractors responsibility to design a revised rest to accommodate the new crane. The revised crane rest shall be approved by the COR. Provide revised drawings of the new crane rest for incorporation into the revised version of reference 2.9.

4.4.1. Repair any disturbed steel of the deck around and beneath the Port and Starboard gallows.

4.4.2. Both gallows shall have access ladders or rungs at locations determined by the COR. The top of the port side gallows shall have railings.

4.4.3. Both gallows shall have internal lift out scuttles located on the main deck per reference 2.12.

4.4.4. Fabricate and install new foundations for removed electrical, hydraulic, ventilation, and miscellaneous components. Locations shall be as close as possible to the removed gallows. The COR shall approve all final locations. Fabricate and install vent goose necks per figure 5. Goose necks shall have hinged clovers that are gasketed, dogged, and provide a water tight seal when closed/dogged.

Dogs shall be CRSS or bronze.

*****CHECK POINT*****

4.4.5. Fabricate new fendering/guards. New guards will be similar to the removed units and the layout/location will be determined by the COR. Fendering/guards shall be hard faced along impacted surfaces such that the transition will be smooth and rounded.

*****CHECK POINT*****

4.5. Gallows Installation – Install the gallows in the exact location of those removed per references 2.9 and 2.11.

4.5.1. Install all removed components. The locations of removed electrical, hydraulic, ventilation, and miscellaneous components shall be as close as possible to the locations on the original gallows. The COR shall approve final locations.

4.5.2. Per Work Item 20529, reinstall all trawl blocks.

4.6. Painting – Preserve the new gallows as follows:

4.6.1. All interior and exterior surfaces shall be prepared and preserved per the requirements of work item 20604. Exterior/exposed areas posed areas shall be top coated black. Internal area top coat shall be white.

4.7. Insulation Repairs - Replace all removed insulation with new. Insulation shall be the same type as original. All insulation will be pinned with all seams taped/lagged. Insulation shall be painted to match the surrounding areas.

4.8. Testing – Check the movement of the block swivels. Blocks shall move freely with no binding or rubbing.

Check the operation of all restored electrical, hydraulic, ventilation, and miscellaneous components. All components shall be 100% operable. Check the watertight integrity of the gallows. Secure ventilation closures and the flush main deck hatch. Perform a hose test of these areas and the foundations per reference 2.1 and ABS requirements. No leaking allowed.

*****CHECK POINT*****

4.9. Painting Touch-Up - Clean all damaged paint to sound paint or bare metal. Clean all exposed metal free of foreign matter and corrosion. Spot prime all damaged paint or exposed metal. Coat all new and damaged areas with 2 coats of finish paint to match the surrounding area. Epoxy paint must be used over galvanized metal.

4.10. Documentation – Revise the following drawings to reflect the new gallows design:

DY-085-FA02 General Arrangements Rev 7 DY-170-FH22 Mast, Rigging & Flagstaff Layout & Details DY-574-001 Aft Gallows Modifications DY-582-FH35 Deck Lifting Equip Foundations Booklet Rev 4 DY-591-FA17 Mission Equip Layouts & Rigging Arrangements Rev 2

5.1. Submit a written report of the results of the testing, inspections, and check points required by this item. The report must contain the date, time, results, and names of the witnesses.

6. NOTES:

6.1. Figures.

Figure 1 - Starboard Gallows - as built, view aft and Starboard sides with fendering/guards.

Figure 2 - Starboard Gallows - as built, view inboard and aft with fendering/guards and ventilation trunk.

Figure 3 – Port Gallows – as built. Inboard and aft view and with fendering/guards and ventilation trunk.

Figure 4 – Fwd view new trawl gallows port and Starboard as built on a sister ship.

Figure 5 – New Trawl Gallows

Figure 6 – New Trawl Gallows

Item No 20105 Title: Replace Mast

1.1. Objective - This work item is to accomplish the removal of the existing main mast on the Oscar Dyson house top and install a mast identical to that which is currently installed on the Rueben Lasker. The antenna, radar arrangements, associated cabling, and existing structure in the Pilothouse will be affected by this work.

2.1 Attachment J.2 Specific Contract Work Definitions and Requirements

2.2 NOAA Standard Specification S0100 Implementation and Conduct of Check Points

2.3 NOAA Standard Specification S2906 Arc Welding on Waterborne Vessels

2.4 NOAA Standard Specification S6900 General Requirements for Electrical/Electronic Items

2.5 NOAA Standard Specification AMC-631-4 Coating Systems for Aluminum Surfaces

2.6 IEEE Std 45-1983 Recommended Practice for Electrical Installations on Shipboard

2.7 ABS Rules for Building and Classing Marine Vessels

2.8 Drawing DY-100-FH12 Aft House Scantlings 01-03 Lvl, Fr 39-Aft

2.9 Drawing DY-100-FH14 Pilothouse Scantlings 03-04 Level

2.10 Drawing FSV6-170-01 Revised Mast Structural Arrangement and Details 2.11

Drawing FSV6-170-C1 DRL A112 Rev A Mast Structural Calculations

2.12 Drawing DY-170-FH22 Mast Rigging and Flag Staffs Rev P13

2.13 Drawing DY-631-FF04 Paint Schedule

2.14 Drawing DY-405-PE51 Antenna Arrangement

2.15 FSV-405-01 Antenna Arrangement

2.16 Work Item 20401 - Replace VHF & HF Antenna

2.17 Work Item 20402 - Replace Navigation Lights with LED Units

2.18 Work Item 20406 - Replace Furuno S Band Radar

2.19 Work Item 20407 - Replace Furuno X Band Radar

2.20 Work Item 20606 - Preservation of Deckhouse, Stack and Masts.

2.21 Drawing DYSON-170-01 Revised Mast Structural Arrangement and Details

3.1. Equipment as indicated in work items 20401, 20406, & 20407

4.1.1. The Contractor shall perform all work in accordance with the requirements of the documents cited in paragraph 2 above.

4.1.2. All new cables shall be MIL-C-24643 low smoke, halogen free type or IEEE-45 marine cable sized in accordance with the applicable requirements.

4.1.3. Existing wireways and Multiple Cable Transits (MCTs) shall be used to the maximum extent practical. Where adequate space for new cables does not exist, or where existing wireways are removed as a result of structural modifications, new cable supports shall be installed. The Contractor shall consider the cable banking limitations of the wireways as described in the regulatory requirements.

4.1.4. All cable banding shall be stainless steel.

4.1.5. Power cabling shall not share cableways with control or signal cabling. Cable crossings between power and control cabling shall be accomplished as near to 90 degrees as practical with maximum practical separation. When run parallel, power and control cabling shall maintain a minimum separation of 18 “.

4.1.6. In decks, MCTs shall extend above the finished deck no less than 6“.

4.1.7. The Contractor shall provide all materials (cabling/cable penetrations/banding/etc.) in this item minus those provided by the government as listed in Paragraph 3.

4.1.8. All new metal installed on the ship shall be cleaned in accordance with SPPC-10 and shall have two coats of primer applied before installation. Primer must be compatible with other paint systems used to meet the requirements of these specifications. Epoxy primer must be used over galvanized metal.

4.2. Engineering

4.2.1. The Contractor shall be responsible for developing a revision to Reference 2.12 for approval by the COR, using Reference 2.10 as guidance.

4.2.2. The Contractor shall be responsible for developing any foundations and mounting details for all equipment to be installed on the new mast for approval by the COR.

4.2.3. The Contractor shall be responsible for developing a drawing for the relocation of the ship’s whistle to the stack for approval by the COR.

4.3. Main Mast Modifications - Perform the following removals, fabrications, and installations per Reference

2.10 & 2.21.

4.3.1. Removals

4.3.1.1. All cables that are to be retained and reused shall be disconnected from the equipment, pulled off the mast, coiled, and relocated to the Pilothouse for re-routing.

4.3.1.2. Remove approximately 15 antennas from the existing main mast structure. These antennas include approximately five (5) GPS, one (1) INMARSAT C, one (1) Wavetalk, one (1) NAVTEX, four (4) VHF, two (2) cell, and one (1) AM/FM/TV. These antennas will be replaced with new equipment under a separate work item.

4.3.1.3. Remove and dispose of all cabling associated with the above antennas. These cables will be replaced based on the requirements of the new antennas.

4.3.1.4. Disconnect the cabling for the five (5) anemometers and roll back to the Pilothouse for reuse on the new mast.

4.3.1.5. Remove approximately five (5) anemometers from the existing main mast and retain for reinstallation.

4.3.1.6. Remove and dispose of approximately five (5) navigation lights from the existing main mast. These lights include one (1) aircraft warning light, one (1) aft masthead light, and three (3) Not-Under-Command (NUC) lights. These lights will be replaced with new equipment under a separate work item.

4.3.1.7. Remove and dispose of all cabling associated with the above lights. These cables will be replaced based on the requirements of the new antennas.

4.3.1.8. Remove the ship’s whistle from the existing mast. The whistle will be relocated to the stack in a similar location to the Reuben Lasker.

4.3.1.9. Roll back the cabling for the ship’s whistle to the Pilothouse for rerouting to the stack.

4.3.1.10. Remove and dispose of the S-Band and X-Band radars from their masts. These radars will be replaced with new equipment under a separate work item.

4.3.1.11. Remove and dispose of all cabling associated with the S-Band and X-Band radars.

These cables will be replaced based on the requirements of the new radars.

4.3.1.12. Disconnect the cabling from approximately two (2) floodlights and roll back to the Pilothouse for reuse.

4.3.1.13. Remove approximately two (2) floodlights from the existing mast and retain for reuse.

4.3.1.14. Disconnect the cabling from approximately three (3) loudspeakers and roll back to the Pilothouse for reuse.

4.3.1.15. Remove approximately…