SFLC-Std-Spec-5000-(2022).pdf

SFLC STANDARD SPECIFICATION 5000

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AUXILIARY MACHINE SYSTEMS

1. SCOPE

1.1 Intent. This standard specification describes the requirements for the Contractor to inspect, repair, and test auxiliary machinery systems and their components onboard Coast Guard vessels.

1.2 Appendices.

PROCESS STANDARD APPENDIX

General Inspection Requirements A

General Testing Requirements B

Hydraulic Systems C

Deck Machinery Systems D

1.3 Terms and definitions. The terms used in multiple sections of this standard specification are defined below.

Assembly: A group of two or more interrelated components integral to a system that serve a distinct function. Typically, renewal of components within assemblies can be economically justified where renewal of entire assemblies as one unit cannot be economically justified.

Cleanliness Grade A: An uncoated surface is cleanliness Grade A when all visible or touchable areas of an accessible surface are free of grease, oil, flux, scale, dirt, loose particles or loose corrosion products, and all other contamination foreign to the base material of the surface. Light superficial rust on a carbon steel surface, caused by short time exposure to the atmosphere, is permitted. Potable water residues are permitted.

Component: A group of one or more interrelated parts that are integral to a system that serves a distinct function. A part is a special case of a component. Components can generally be renewed as a unit.

Deck machinery system: A deck machinery system contains the union of all associated mechanical load bearing components, all mechanical power transmission component associated with a prime mover, and each component integral to the operation both of those sets of components and assemblies, up to and including their machinery foundations. If the prime mover is an electric motor then all components prime mover side of the connection point to ship’s service power are part of the system.

Dynamic load test: A weight test used to verify that all mechanical power transmission components in a system are properly assembled, properly installed, properly adjusted, and are capable of producing enough force (i.e., pressure, torque, etc.) to hoist or haul the dynamic load. The weight specified for this test is typically just beneath the weight that the system is capable of hoisting or hauling when all mechanical power transmission components are properly assembled, properly installed, and properly adjusted. Systems installed on vessels and barges are designed to hoist or haul loads greater than their published rating in order to compensate for the increased line tensions experienced while operating in a sea state

(dynamic loading).

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Fine surfaces: The term fine surfaces denotes the union of each of the following definitions:

o Each uncoated surface of a component whose finish is critical to the operation of the component.

o Each uncoated surface of a component that mates with or runs against a machined surface, a plated surface, or software.

o Plated surfaces.

Haul: To pull a mechanical load in the horizontal plane.

Hoist: To raise a mechanical load in the vertical plane.

Mechanical load: The term mechanical load denotes each of the following definitions:

o A weight or mass not integral to a hoisting machine but suspended from a hoisting machine.

o A weight or mass not integral to a hauling machine but being hauled by a hauling machine.

Mechanical load bearing components: Each component in a machine that is subjected to stress while supporting or moving a mechanical load.

Machinery foundation: Structural members welded to or integral to the ship's structure designed to provide an interface for fastening one or more parts of the machine to the ship.

Mechanical power transmission component: Each part in a machine, including those parts integral to the prime mover that is subjected to stress generated by a prime mover.

Nondestructive examination (NDE): The act of determining the suitability of some material or component for its intended purpose using techniques that do not affect its serviceability.

Part: A component that can be disassembled no further.

Pin assembly: The union of all components attached to (e.g., by key, spline, stake, press fit, etc.) and mate with or run against a pin including all sleeves, bushings, and rolling contact bearings that support the pin. For example, when tasked to Disassemble and Inspect a Sheave

Pin Assembly, all components that mate with the pin (e.g., a sheave, at least one rolling contact bearing assembly or bushing) must be disassembled.

Prime mover: The initial source of mechanical energy integral to a deck machinery system in the form of either an internal combustion engine or an electric motor driven directly by current from the ship’s service generator.

Rated load test: A weight test used to verify that all mechanical power transmission components in a system are properly assembled, properly installed, properly adjusted, and are capable of operating through a complete duty cycle without developing unusual or substandard performance characteristics (e.g., noise, binding, overheating, slow operation, etc.). The weight specified for this test is typically the published Working Load Limit (WLL) of the system.

Self-locking fastener: A fastener assembly with a design feature (e.g., a soft insert, pre-deformed threads, etc.) for the purpose of adding friction to the threaded connection.

Shaft assembly: The union of all components attached to (e.g., by key, spline, stake, press fit, etc.) and mate with or run against a shaft including all sleeves, bushings, and rolling contact bearings that support the shaft. For example, when tasked to Disassemble and Inspect a Winch Drum Shaft Assembly, all components attached to the shaft (e.g., winch drum, at least two rolling contact bearing assemblies, a gear on gearbox end of the shaft, and all associated keys, seal, backing rings, etc.) must be disassembled. The associated gear box would be disassembled only to the extent required to access the specified shaft assembly.

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Software: The term software includes seals, gaskets, o-rings, backing rings for o-rings, lip seals, v-ring packing, flax packing, and mechanical packing seals as part of a component union.

Brake/Modified static load test: A weight test used to verify that a winch brake, a brake valve, or a counterbalance valve is properly assembled, properly installed, properly adjusted, and is capable of stopping and holding the dynamic load. The weight specified for this test is typically just beneath the weight that will cause a properly assembled, properly adjusted, and properly installed winch brake, brake valve, or counterbalance valve to slip/relieve. The test also verifies, to a lesser extent, the integrity of all other mechanical load bearing components in the system.

System specifications: All requirements, configuration data, and process descriptions applicable to the work specified that are contained within system drawings, system technical publications, or other documents referenced by a work item or referenced by the standard.

Where specifications provided by the system manufacturer disagree with specifications provided by a manufacturer of a component within that system, the specifications provided by the system manufacturer must take precedent, unless otherwise specified.

Task description: When the work item contains a table similar to the table shown in paragraph 4.1 (Work item interpretation), a task description is a unit of work described by six separate associated cells across one row of a table in a work item that references this standard. Otherwise, it is a sentence or paragraph in a work item that contains a Task Type.

Task type: One or more words, typically verbs, that denotes a general description of work that can be performed on a component or assembly. Examples of standard task types are listed in paragraphs 4.1 (Work item interpretation) and Error! Reference source not found.(Standard task types).

Vital fastener assembly: A fastener assembly that is either a mechanical load bearing component or a mechanical power transmission component.

Wearing components: The term wearing components denotes the union of the following sets of components:

o Software.

o Rolling contact bearings excluding turntable or turret bearings.

o Bushings used in a machine to constrain rotating shafts or mechanical load bearing pins.

o Springs.

o Friction discs in disc brakes and liners in band brakes.

Wear pads and wear strips: defined as relatively soft parts that slide against one or more relatively hard parts within a machine, the soft part being designed to wear at a much faster rate than the hard part.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Fleet Drawing FL-1702-11, Rev -, Inspection of Sheaves

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Latest

Edition, General Requirements

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Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Latest

Edition, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), Latest

Edition, Preserve Ship Structures

OTHER REFERENCES

American Petroleum Institute (API) Specification 9A, Oct 2012, Specification for Wire Rope

American National Standard Institute/American Water Works Association ANSI/AWWA C217, 2017, Petrolatum and Petroleum Wax Tape Coatings for the Exterior of Connections and

Fittings for Steel Water Pipeline

ASTM International (ASTM) A1023, 2019, Standard Specification for Stranded Carbon Steel

Wire Ropes for General Purposes

ASTM International (ASTM) D4174, 2017, Standard Practice for Cleaning, Flushing, and

Purification of Petroleum Fluid Hydraulic Systems

ASTM International (ASTM) E2261, 2017, Standard Practice for Examination of Welds Using the Alternating Current Field Measurement Technique

Commercial Item Description (CID), A-A-50433, Aug 1989, Grease, Sea Water Wash Resistant

Federal Specification (Fed Spec) RR-W-410, Dec 2015, Wire Rope and Strand

International Standard Organization (ISO) 3448, 1992, Industrial Liquid Lubricants - ISO

Viscosity Classification

International Standard Organization (ISO) 4406, 2018, Hydraulic Fluid Power – Fluids – Method for Coding the Level of Contamination by Solid Particles

Manufacturers Standardization Society of the Valve and Fittings Industry, Inc. (MSS), SP-58, 2018, Pipe Hangers and Supports – Materials, Design, Manufacture, Selection, Application, and Installation

MIL-PRF-18458, May 2007, Grease, Wire Rope-Exposed Gear

MIL-A-22262, Mar 1996, Abrasive Blasting Media Ship Hull Blast Cleaning

Society of Automotive Engineers (SAE) J1942-1, 2019, Qualified Hoses for Marine Applications.

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2015, Solvent Cleaning

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.11 (SSPC-SP

11), 2012, Power Tool Cleaning to Bare Metal

3. REQUIREMENTS

3.1 General requirements. The Contractor must adhere to the following general requirements:

3.1.1 Extent of system disassembly and interference removal. When disassembly or interference removal is required to perform specified work, disassemble the system or remove interferences or both only to the extent necessary to perform the work specified.

3.1.2 Protection of fine surfaces. Protect all fine surfaces exposed while a component, assembly, or system is disassembled for repair. Install protective coverings that will prevent damage and corrosion.

Remove and dispose of all protective coverings prior to reassembly.

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3.1.3 Hydraulic system contamination protection. Maintain existing hydraulic system cleanliness. Take all necessary precautions to prevent the introduction of contaminants. Whenever disconnecting or removing components from a hydraulic system, immediately and completely seal all openings to the component and the rest of the system. Use either caps for externally threaded connection points, bolt-on blanks, or taped-on discs and covers of durable plastic or sheet-metal no less than 1/16-inch thick. Plastic bags may be used only when arrangement or configuration prevents the use of the other sealing methods specified above. Filling openings with rags or other articles is prohibited.

3.1.4 Mandatory renewals. If during disassembly of any component software or self-locking fasteners are disturbed, renew them. If during the performance of work hydraulic fluid or lube oil is lost, renew it.

Submit a CFR.

3.1.5 Cleaning of hydraulic system components at reassembly. Prior to installing a new or disturbed hydraulic component into a system, clean all exposed internal surfaces of that component that will come in contact with working system fluid to cleanliness Grade A (see Cleanliness Grade A).

3.1.6 Shaft coupling alignment. Align all new and disturbed shaft coupling assemblies. Unless otherwise specified in the task description or in the system specifications, verify that each hub is round to within 0.002 inches total indicator run-out, and then align both hubs to within 0.005 inches total indicator run-out radial and peripheral per inch of shaft radius.

3.1.7 Pad eye and tie down weld repairs. Pull test all pad eyes and tie downs that have been weld-repaired. Perform testing specified in paragraph 3.2.7 (Pull test), after performing nondestructive examination (NDE) of the weld-repair in accordance with SFLC Std Spec 0740, Appendix C.

3.1.8 Mandatory testing requirements. An operational and weight test must be accomplished for a deck machinery system whenever an associated mechanical load bearing or mechanical power transmission component is disturbed (i.e., disassembled, repaired, renewed, removed and replaced as an interference, etc).

3.2 Task types. The Contractor must be aware that the following task types denote specifications for work. As defined within the requiring work item, submit a CIR or CFR for all completed tests, inspections and flushing.

3.2.1 Operate and inspect: When Operate and Inspect is specified in a task description, perform the following:

Perform a no-load operational test on the system. While the Coast Guard Inspector cycles all actuators, controls, shafting, and linkages associated with the system, note all unusual noise, vibration, overheating, binding, misalignment, maladjusted controls, and malfunctioning controls or read-outs found in the system. Ensure any of these conditions are reported in a

CFR.

An operational test using test weights is not required. However, to supplement the no-load test specified and required above, the Contractor may request to have test weights handled.

The test weights must be handled only after the COR determines that the system is safe to handle weights and has approved the request. All test weights and all necessary rigging equipment must be furnished by the Contractor. The rated load of the system must not be exceeded. Furnishing and handling test weights for the purpose of troubleshooting must result no additional cost to the Government.

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At the conclusion of all operations, perform a visual inspection of the system. Open or remove all inspection covers in the system, as applicable, to facilitate visual inspections. Do not disassemble or disturb mechanical load bearing components or mechanical power transmission components prior to or during the inspection. Inspect all accessible surfaces of each component in the system as specified in Appendix A (General Inspection

Requirements).

Inspect sheave assemblies, as applicable, using Coast Guard Drawing FL-1702-11 as a guide.

3.2.2 Service and inspect: When Service and Inspect or Service, Inspect is specified in a task description, perform the following in conjunction with all other work specified:

Remove inspection plates, cover plates, and other non-mechanical load bearing components, as applicable, to gain access to hidden surfaces of the component or assembly. Do not disturb mechanical load bearing components or mechanical power transmission components prior to or during the inspection.

Clean all accessible uncoated surfaces of the component or assembly to cleanliness Grade A, unless otherwise directed by applicable appendix or in the task description.

Inspect all accessible surfaces in accordance with Appendix A (General Inspection

Requirements).

If a Change Request has been authorized and released by the KO, perform all work resulting from modifications or amendments to the task description as specified.

Lubricate uncoated surfaces of the component or assembly as specified in the system specifications, the task description, or referenced appendix. When a lubricant is not specified in the task description, system specifications, or appendix of this standard use a lubricant conforming to CID A-A-50433.

Prior to reinstalling removed covers, plates, and non-mechanical load bearing components perform all other work specified or invoked by the task description.

Reinstall all removed parts and return the component to normal operating condition.

3.2.3 Disassemble and inspect: When Disassemble and Inspect or Disassemble, Inspect is specified in a task description, perform the following in conjunction with all other work specified:

Completely disassemble the specified component or assembly.

Determine which sub-components are wearing components. Inspect all exposed uncoated surfaces of all non-wearing sub-components in accordance with Appendix A (General

Inspection Requirements).

Clean all accessible uncoated surfaces of the component or assembly to cleanliness Grade A unless otherwise directed by applicable appendix, or in the task description.

Renew each sub-component that corresponds to a component furnished as GFP for the task description.

If a Change Request (CR) has been authorized and released, renew each component determined to be a wearing component and perform all work resulting from modifications or amendments to the task description as specified in the CR.

Lubricate uncoated surfaces of the component or assembly as specified in the system specifications, the task description, or referenced appendix. When a lubricant is not specified in the task description, system specifications, or appendix of this standard, use a lubricant conforming to CID A-A-50433.

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Perform all other work specified or invoked by the task description that can only be performed prior to reassembling the component or assembly.

Reassemble the component or assembly and return it to normal operating condition within the system.

3.2.4 Preservation. Perform the following when Partially Preserve and Preserve tasks are specified in work items for all previously coated surfaces of the specified equipment or components:

NOTE

Deck machinery equipment is considered critical-coated surfaces, as defined in SFLC Std Spec 6310.

3.2.4.1 Fresh water wash. Low-pressure (less than 5,000 psi) fresh water wash all affected equipment/component surfaces, to remove soluble chlorides and other surface contaminants.

NOTE

Freshwater wash is applicable only to in-service equipment.

3.2.4.1.1 Ensure that the water utilized for the low-pressure wash is of sufficient purity and quality that it does not prevent the surface being preserved from achieving the required degree of surface cleanliness or nonvisible contamination criteria.

3.2.4.1.2 Capture, contain, and dispose of wash water for proper disposal in accordance with all Federal, state and local regulations.

3.2.4.2 Disassembly and protective measures.

3.2.4.2.1 For equipment or components not specified to be disassembled in the work item, ensure that equipment or components are disassembled to the extent necessary (e.g.: uncoupling of gear box, hydraulic motor, DCV block, sheaves, etc.) to facilitate surface preparation and coating of inaccessible surfaces. Some examples of surfaces requiring disassembly for access include, but are not limited to the following:

Crevices around sheaves.

Protective boxes around hose manifolds.

Deck grates and platforms.

Faying surfaces.

3.2.4.2.2 Ensure that all surfaces not designed to be coated (e.g.: sensitive hydraulics and oil seals, non-ferrous surfaces, etc.) are protected from contaminants.

3.2.4.3 Surface preparation. Accomplish surface preparation/coating removal, using one or a combination of the following cleaning methods:

Waterjet to a SSPC-SP WJ-2 (M)/NACE WJ-2 (M) standard.

Abrasive-blast to SSPC-SP10/NACE No. 2, using grit conforming to MIL-A-22262 (1.5 to

2.5 mil anchor profile).

Power tool clean to a SSPC-SP 11 (1.0 mil anchor profile).

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NOTE

Working surfaces of winches and capstan drums require abrasive-blasting to

SSPC-SP10/NACE No. 2.

3.2.4.3.1 When Preserve is specified in a task description, prepare 100% of all surfaces designed to be coated.

3.2.4.3.2 When Partially-Preserve is specified in a task description, do the following:

Remove coatings only in areas in which mechanical damage extends into the substrate, or where there is evidence of corrosion (see 3.2.4.3 (Surface preparation)).

Roughen/abrade all surfaces of the entire assembly where existing top-coating is intact with

100-grit paper, to provide a suitable surface profile.

Feather edges of topcoating into adjacent bare areas, to create a smooth transition.

3.2.4.3.3 When Establish profile is specified in a task description, ensure that designated/specified equipment or component is abrasive-blasted, to SSPC-SP10/NACE No. 2, to achieve an anchor tooth profile of 1.5 to 2.5 mils on all previously coated surfaces.

NOTE

Typically establish profile will be specified in the task description when a component or area is known to have a corrosion problem that can be attributed to previous improper surface preparation.

3.2.4.4 Post-surface preparation cleaning. Perform solvent cleaning of all prepared surfaces, in accordance with SSPC-SP 1, prior to coating application.

3.2.4.5 Surface coating.

3.2.4.5.1 Partially-preserve task. For the Partially-preserve task, do the following:

Spot coat/prime all bare areas with an Epoxy Primer/Mid-Coat - Polysiloxane System coating as defined in SFLC Std Spec 6310, Appendix C, to a thickness matching that of existing adjacent undercoating (approximately 10-12 mils DFT). Ensure that the primer coating extends over the feathered edges of the sound/intact coating to minimize edge lifting and provide a better appearance.

Top-coat all primed and abraded surfaces, with a Polysiloxane Sys coating as defined in

SFLC Std Spec 6310, Appendix C, to ensure a uniform thickness throughout. Select Spar

(10371), unless specified otherwise in the work item.

3.2.4.5.2 Preserve task. For the Preserve task, do the following:

Prime and coat all prepared surfaces in accordance with SFLC Std Spec 6310, using the coatings specified for Machinery, Deck in Appendix A (Cutter and Boat Exterior Paint

Systems).

Select Spar (10371) as the top/finish coat color, unless specified otherwise in the work item.

3.2.4.5.3 Coat the working surfaces of machinery and the surfaces of winch and capstan drums that contact line with an Inorganic Zinc (3.0-4.0 mils) in accordance with SFLC Std Spec 6310, Appendix A, Note 12.

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NOTE

Authorized coatings are listed in SFLC Std Spec 6310 Appendix C

(Authorized Coatings For Use On Cutters and Boats).

3.2.4.6 When Inspect and Preserve is specified in the task description, inspect the area specified. If a

Change Request has been authorized, prepare and coat the surface as specified in the Change Request.

3.2.4.7 When preserving or partially-preserving an equipment foundation, ensure that all previously coated surfaces of the foundation, including deck and bulkhead areas enclosed within a perimeter two inches out from the foundation’s footprint are also included.

CAUTIONS

Unless a containment system is used to contain surface preparation dust, debris, and coating application overspray during pier side/dockside preservation, the following must be adhered to:

1. All surface preparation tools/equipment must be vacuum-shrouded.

2. Coatings must be applied by brushing or rolling, which may require additional coats to obtain required dry film thickness.

3.2.5 NDE. When NDE is specified in a task description, perform nondestructive examination of the specified component(s) and/or weld(s) in accordance with SFLC Std Spec 0740, Appendix C.

3.2.6 Groom and lubricate. When Groom and Lubricate is specified in the task description, prepare the system for testing by performing the following, as applicable, in conjunction with all other work specified in the task description while the Coast Guard inspector operates the system in a no-load condition:

Visually inspect all components in the system. Verify that all reservoirs and gear cases are filled to the level required in the system specifications.

WARNING

Verify that all installed system isolation valves (e.g., return line valves, case drain line valves, etc.) are properly aligned prior to energizing and operating equipment, as applicable.

Verify proper alignment of all installed system isolation valves, as applicable. Cycle all actuators. Verify that all associated control valves, electrical and mechanical controls, and actuators are operating properly.

Remove air from the hydraulic system. Break mechanical joints at high points while cycling actuators, if required, to bleed air from the hydraulic system.

Make adjustments, as required, to all components (e.g., sensors, controls, readouts, pressure control valves, flow control valves, limit switches, proximity switches, etc.) to achieve proper operation, as specified in the task description or in the system specifications.

Verify there are no lube oil or hydraulic fluid leaks.

Identify all lubrication points in the system. Lubricate these points as specified in the task description or in the system specifications.

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3.2.7 Pull test. When Pull Test is specified in the task description, do the following:

Determine the required force for the pull test on the specified deck fitting as specified below:

For periodic testing of a deck fitting the force of pull on the fitting must be 1.5 times the deck fitting’s rated load.

For testing subsequent to a weld-repair of a deck fitting (i.e., renewal or repair of a fitting) the force of pull on the deck fitting must be 2 times the deck fitting’s rated load.

Determine the proper direction to pull against the specified deck fitting. The proper direction must be the direction in which the deck fitting and surrounding deck or bulkhead displays its greatest resistance to damage and deformation.

NOTE

General purpose fittings are typically strongest when pulled perpendicular to the deck or bulkhead where they are attached. Special purpose fittings may be stronger in a direction specific to their intended use that may differ from perpendicular to the deck or bulkhead.

Pull the specified deck fitting to the force and in the direction determined above and hold for one minute.

Release the load and verify no permanent deformation or damage to the fitting or the surrounding deck or bulkhead, as applicable.

3.2.8 Operational and weight testing: When Op Test or Weight Test or Op and Weight Test is specified in the task description, do the following:

Furnish all necessary temporary rigging gear (e.g., temporary wire ropes and pendants, external lifting devices such as a crane, strong-backs, test weights, tag lines, dynamometers, come-alongs, steamboat ratchets, shackles, dunnage, bumpers, etc.) required to perform the testing procedures invoked by the task description. Place dunnage under test weights to protect the vessel’s deck and pier, as applicable. Place bumpers or other protective measures between the hull and pier when test procedures involve warping the vessel.

Furnish all necessary rigging services (e.g., riggers, external crane operators, etc.) required to perform the referenced testing procedures invoked by the task description.

Conduct a briefing for cognizant shipboard personnel at least 24 hours prior to the specified test procedure.

Allow the CG Inspector to inspect and approve all temporary rigging gear, prior to being utilized.

NOTE

An external lifting device may not be required if using a water bag to conduct

Static Load tests if it can be gradually filled to prevent shock loading of the equipment.

3.2.8.1 When weight testing is specified, determine the vessel’s load status and verify that the vessel’s stability is adequate and safe for performing the test procedure. Conduct weight testing only when the vessel is waterborne and only after at least one of the following three conditions have been met:

The vessel is in a full liquid load condition.

A full liquid load condition has been simulated through the use of equivalent weights that have been arranged shipboard to achieve the same metacentric height (GM) as a full liquid load condition.

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The vessel’s DCA or EO or EPO has determined that the vessel’s stability meets or exceeds the minimum stability required to safely perform the test procedure.

3.2.8.1.1 Avoid conditions that will cause sudden application of test loads.

3.2.8.1.2 Keep test weights as close to the deck as possible while performing the test procedure to minimize damage to the vessel if control of the test weight is lost.

3.2.8.1.3 Do not allow immersion of a deck edge or a list of over 15 degrees while performing the test procedure.

3.2.9 All other task types. Refer to the Additional Requirements columns of the task description for all other requirements.

4. NOTES

4.1 Work item interpretation. Work items that reference this standard may contain a table similar to the sample table listed below.

SAMPLE TABLE

ADDITION REQUIREMENTS

# TASK

TYPE

QTY

COMPONENT

OR ASSEMBLY

APPENDIX AND

PARA. FROM

SFLC STD SPEC

OTHER

1 Operate and

Inspect

2 Mechanical Chain

Stopper Assembly

3.2.1 (Operate and

Inspect)

Submit a CIR

2 Disassemble, Inspect, and

Preserve

2 Mechanical Chain

Stopper Assembly

3.2.3 (Disassembly and inspect)

3.2.4

(Preservation)

Submit a CIR.

Reassemble chain stoppers with repair listed GFP

3 NDE 2 Mechanical Chain

Stopper Assembly

3.2.5 (NDE) NDE task is limited to Chain stopper welds.

4 Preserve 2 Mechanical Chain

Stopper Assembly and foundation

3.2.4

(Preservation)

Select the following top coating colors:

- Black (17038) for the chain stopper surfaces.

- Gray (16099) for the foundation surfaces.

5 Groom and

Lubricate

2 Mechanical Chain

Stopper Assembly

3.2.6 (Groom and lubricate)

6 Weight Test 2 Mechanical Chain

Stopper

Assemblies

B2.1(Mechanical

Chain Stoppers)

Static Load Test Weight: 24,750#

Dynamic Load Test Weight: N/A

Rated Load Test Weight: N/A

7 Fabricate and

Install

2 Label plate B2.9 (Label plates)

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APPENDIX A

GENERAL INSPECTION REQUIREMENTS

A1. SCOPE

A1.1 Intent. This appendix describes the particular requirements for the Contractor to perform all inspections on Coast Guard deck auxiliary machinery systems, as applicable.

A2. REQUIREMENTS

A2.1 Joint inspections. The Contractor must inspect, either visually or physically by touch, all accessible mechanical joints for hydraulic fluid or air leaks, as applicable.

A2.2 Pressure containing component inspections. The Contractor must inspect, either visually or physically by touch, all accessible internal and external surfaces of the component that are used to contain pressurized gas or fluid for: impacts, deformation, warping, bending, yielding, excessive corrosion, loss of base material, cracks, and all other wear or damage that will affect the strength of the pressure-containing boundary or the proper, trouble-free, safe operation of the component. Examples of these components are pump cases, motor cases, valve bodies, cylinder bodies, cylinder tie rods, accumulator and flask bodies, hose assemblies, and heat exchanger tubing and shells.

A2.3 Mechanical load bearing and mechanical power transmission component inspections. The

Contractor must inspect, either visually or physically by touch, all accessible surfaces of all components that transmit power for: impacts, deformation, warping, bending, yielding, mushrooming, excessive corrosion, excessive wear, unusual wear patterns, loss of base material, cracks, and all other wear or damage that will affect the strength of the component or the proper, trouble-free, safe operation of the component. Examples of these components are shafts, mechanical pins, keys, keyways, splines, set-screws, stakes, gear teeth, cams, cam-followers, couplings, cylinder rods, clevises, and trunnions.

A2.4 Fine surface inspections. The Contractor must inspect, either visually or physically by touch, all uncoated, fine surfaces of components for raised metal, nicks, burrs, scratches, scoring, heat checks, galling, pitting, gouges, corrosion, damage, yielding or stretching, excessive wear, and all other unusual discontinuities with surrounding surfaces that will affect sealing, flow rates and pressures, or the proper, trouble-free, safe operation of the component. Examples of these surfaces are cylinder bores, pistons, piston rods, all surfaces that mate with o-rings or seals, valve spools and spool bores, valve seats, and screw threads.

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APPENDIX B

GENERAL TESTING REQUIREMENTS

B1. SCOPE

B1.1 Intent. This appendix describes the particular requirements for the Contractor to perform testing of

Coast Guard deck machinery systems. Tests must be conducted in the order listed.

B1.2 System test requirements. The following paragraphs specify requirements for the associated system or task:

TITLE PARAGRAPH

Mechanical chain stoppers B2.1

Hydraulic chain stoppers B2.2

Winches B2.3

Booms and cranes B2.4

Anchor Windlass B2.5

Capstans B2.6

Davits B2.7

Small Boats B2.8

Label plates B2.9

B2. REQUIREMENTS

B2.1 Mechanical chain stoppers.

B2.1.1 No-load operational test. While the Coast Guard Inspector releases and resets the chain stopper a minimum of three cycles in a no-load condition, the Contractor must:

Verify that the reset spring does not bottom out (fully compress) when the stopper is fully extended.

Verify that the spring fully resets the stopper.

B2.1.2 Operational test. The Contractor must:

Suspend the operational load test weight specified in the work item from the stopper and hold for a minimum of 10 minutes using an external lifting device and an appropriately sized chain.

Release the operational load test weight using the chain stopper's release mechanism.

Verify that the stopper has no permanent deformation or damage.

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NOTE

Static load weight testing mechanical chain stoppers is only required after weld-repairs have been performed on the chain stopper or its supporting structure.

B2.1.3 Static load test. The Contractor must:

Suspend the static load test weight specified in the work item from the stopper and hold for a minimum of 10 minutes using an external lifting device and an appropriately sized chain.

Remove the test weight.

Verify that the stopper has no permanent deformation or damage.

Return the chain stopper to its normal operating condition.

B2.2 Hydraulic chain stoppers. The Contractor must test hydraulic chain stoppers in conjunction with testing of the associated buoy chain winch.

B2.2.1 No-load operational test. While the Coast Guard Inspector extends and retracts all actuators a minimum of three cycles, the Contractor must verify proper operation and no unusual vibration, noise or binding.

B2.2.2 Operational load test.

B2.2.2.1 The Contractor must suspend the operational load test weight specified in the work item from a chain that attaches to the buoy chain winch and passes through the chain stopper assembly.

B2.2.2.2 While the Coast Guard Inspector demonstrates normal operational use of the stopper using the operational load test weight specified in the work item and the buoy chain winch to raise and lower the test load a minimum of three cycles, the Contractor must verify that the rising sheave freely turns when the loaded chain is pulled through the sheave groove.

NOTE

The Coast Guard Inspector will set the chain in the stopper, slack the chain between the buoy chain winch and the stopper, re-tension the chain between the winch and the stopper, and lift the chain from the stopper with the rising sheave.

B2.2.2.3 After the Coast Guard Inspector retrieves the operational load test weight using the buoy chain winch, the Contractor must:

Verify that the chain loaded with the test weight is properly released from the stopper with no unusual noise, vibration, or binding.

Remove the test weight and verify that the stopper has no permanent deformation or damage.

Return the chain stopper to its normal operating condition.

NOTE

Static load weight testing hydraulic chain stoppers is only required after weld-repairs have been performed on the chain stopper or its supporting structure.

2022 B3 5000

B2.2.2.4 Static load test. After the Coast Guard Inspector has fully retracted the sheave, the Contractor must:

Suspend the static load test weight specified in the work item from the stopper and hold for a minimum of 10 minutes using an external lifting device and an appropriately sized chain.

Remove the test weight.

Verify that the stopper has no permanent deformation or damage.

Return the chain stopper to its normal operating condition.

B2.3 Winches.

B2.3.1 Functional / no-load test. While the Coast Guard Inspector operates the winch in both directions a minimum of 2 minutes, the Contractor must verify that:

All controls and sensors are operating properly.

No unusual vibration or noise is emitted from the winch and there is no binding or misalignment.

Proper setting and release of the winch brake.

B2.3.2 No-load test for level wind arm assemblies. The Contractor must perform the following on winches that have a level wind arm assembly installed. While the Coast Guard Inspector fully extends and retracts level wind arm hydraulic cylinder in a no-load condition do the following:

Verify proper operation of all controls.

Verify no unusual vibration, noise, or binding.

NOTE

1. During no-load operations ensure sufficient tension is kept on wire ropes to prevent improper wrapping on hoist drum.

2. Strongbacks, external cranes, or other Contractor-furnished rigging devices may be needed to perform weight testing on winches not equipped with boom/sheave assemblies (i.e., cross deck winches, mooring winches, etc.)

B2.3.3 Static load test. The Contractor must:

Using an external lifting device, suspend the static load test weight specified in the work item from the winch structure and hold for a minimum of 10 minutes.

Remove the test weight.

Verify no permanent deformation or damage to any components.

B2.3.4 Static load test for level wind arm assemblies. The Contractor must perform the following on winches that have a level wind arm assembly installed. While performing static load test, do the following:

Verify that the level wind arm hydraulic cylinder does not drift.

Verify no permanent deformation or damage to any components.

B2.3.5 Winch Brake / Modified static load test. The Contractor must:

Using an external lifting device, suspend the static load test weight specified in the work item for each hoist from the applicable wire rope assembly and hold for a minimum of 10 minutes.

Verify the winch brake holds without slipping.

2022 B4 5000

Remove the test weight.

Verify no permanent deformation or damage to any components.

B2.3.6 Dynamic Overload test. While the Coast Guard inspector raises and lowers each dynamic load specified in the work item a minimum of three complete cycles and through as wide a range as practicable; stopping the winch at least twice in each direction every cycle, the Contractor must verify the following as applicable:

The winch lifts the dynamic load.

The winch brake stops and holds the dynamic load without slipping.

No permanent deformation, damage to, or overheating of any components.

Proper operation of all controls and sensors.

No unusual vibration or noise is emitted from any component (e.g., winch, actuator, shaft assembly, pin assembly, etc.) and there is no binding or misalignment.

Verify no leakage from hydraulic components.

NOTE

Relief valve and pressure compensator settings must not require adjustment in order to conduct this test.

B2.3.7 Rated load test. While the Coast Guard Inspector operates the winch, raising and lowering the rated load specified in the work item a minimum range of 5 feet a minimum of 10 complete cycles, starting and stopping the winch at least twice in each direction, the Contractor must verify the following:

The winch lifts the rated load at rated speed.

The brake stops and holds the rated load without slipping.

No permanent deformation or damage to any components.

Proper operation of all controls and sensors.

No unusual vibration, noise, or binding.

B2.4 Booms and cranes.

B2.4.1 Functional / No-load test. While the Coast Guard Inspector operates each actuator associated with the boom or crane in both directions a minimum of 2 minutes by topping the boom, rotating the boom, and operating each associated winch, the Contractor must verify that:

All controls, sensors and alarms are operating properly.

No unusual vibration or noise is emitted from any component (e.g., winch, actuator, shaft assembly, pin assembly, etc.) and there is no binding or misalignment.

Proper setting and release of each brake.

NOTE

During no-load operations ensure sufficient tension is kept on wire ropes to prevent improper wrapping on hoist drum.

2022 B5 5000

B2.4.2 Static load test. The Contractor must:

Using an external lifting device, suspend the static load test weight specified in the work item from the boom or crane structure and hold for a minimum of 10 minutes.

Remove the test weight.

Verify no permanent deformation or damage to any components.

B2.4.3 Winch Brake / Modified static load test. The Contractor must:

Using an external lifting device, suspend the static load test weight specified in the work item for each hoist from the applicable wire rope assembly and hold for a minimum of 10 minutes.

Verify that each hoist brake holds without slipping.

Remove the test weight.

Verify no permanent deformation or damage to any components.

B2.4.4 Dynamic Overload test. While the Coast Guard inspector raises and lowers each dynamic load specified in the work item from the applicable hoist a minimum of three complete cycles and through as wide a range as practicable; rotates each dynamic load through as wide a range as practicable a minimum of three complete cycles; and tops each dynamic load through as wide a range as practicable; or as specified in the task description, a minimum of three complete cycles starting and stopping each actuator at least twice in each direction every cycle, the Contractor must verify the following as applicable:

Each actuator lifts or rotates the dynamic load.

Each brake stops and holds the dynamic load without slipping.

No permanent deformation, damage to, or overheating of any components.

Proper operation of all controls and sensors.

No unusual vibration or noise is emitted from any component (e.g., winch, actuator, shaft assembly, pin assembly, etc.) and there is no binding or misalignment.

Verify no leakage from hydraulic components.

NOTE

Relief valve and pressure compensator settings must not require adjustment in order to conduct this test.

B2.4.5 Rated load test. While the Coast Guard inspector raises and lowers each rated test load specified in the work item from the applicable hoist a minimum of 10 complete cycles and through as wide a range as practicable; rotates each rated load through as wide a range as practicable a minimum of 10 complete cycles; and tops each rated load through as wide a range as practicable; or as specified in the task description, a minimum of 10 complete cycles, starting and stopping each actuator at least twice in each direction every cycle, the Contractor must verify the following as applicable:

Each actuator lifts or rotates the rated load at rated speed.

Each brake stops and holds the rated load without slipping.

No permanent deformation, damage to, or overheating of any components.

Proper operation of all controls and sensors.

No unusual vibration or noise is emitted from any component (e.g., winch, actuator, shaft assembly, pin assembly, etc.) and there is no binding or misalignment

Verify no leakage from hydraulic components.

2022 B6 5000

B2.5 Anchor windlass.

B2.5.1 Capstan operational test. The Contractor must test each capstan associated with the anchor windlass system as specified below.

B2.5.2 Wildcat operational test. With the vessel waterborne, and while the Coast Guard Inspector raises and lowers each anchor individually from the hawse pipe to the channel floor a total of three complete cycles, stopping each anchor in the middle of travel at least once each cycle; operates each pawl and pelican hook; and cycles each mechanical band brake twice as applicable, the Contractor must:

Verify that no unusual vibration or noise is emitted from any component (e.g., winch, actuator, each shaft assembly, each pin assembly, etc.) and there is no binding or misalignment.

Verify that wildcat lifts the rated load at rated speed.

Verify that the load is held and controlled by each hydraulic disc brake and each operates satisfactorily.

Verify the load is held and controlled by each mechanical band brake and each operates satisfactorily.

Verify no leakage from hydraulic components.

B2.6 Capstans. With the vessel waterborne and while the Coast Guard Inspector warps the vessel forward a minimum of 30 feet, then aft a minimum of 30 feet three complete cycles, the Contractor must:

Verify that the capstan will warp the vessel.

Verify proper operation of all controls and sensors.

Verify the brake sets and releases properly.

Verify no permanent deformation, damage to, or overheating of any components.

B2.7 Davits.

B2.7.1 Single point davits.

B2.7.1.1 No-load operational test. While the Coast Guard Inspector operates each actuator associated with the davit in both directions a minimum of two minutes by topping the boom (if applicable), rotating the boom, and operating the hoist, the Contractor must verify:

All controls and sensors are operating properly.

No unusual vibration or noise is emitted from any component (e.g., winch, actuator, shaft assembly, pin assembly, etc.) and there is no binding or misalignment.

Proper setting and release of each brake.

NOTE

During no-load operations ensure sufficient tension is kept on wire ropes to prevent improper wrapping on hoist drum.

B2.7.1.2 Static load test. The Contractor must:

Using an external lifting device, suspend the static load test weight specified in the work item from the davit wire rope assembly and hold for a minimum of 10 minutes.

Verify that the davit hoist brake holds without slipping.

2022 B7 5000

Remove the test weight from the davit wire rope assembly.

Verify no permanent deformation or damage to any components.

Verify no leakage from hydraulic components.

B2.7.1.3 Winch Brake / Modified static load test. The Contractor must:

Using an external lifting device, suspend the static load test weight specified in the work item from the davit wire rope assembly and hold for a minimum of 10 minutes.

Verify that the davit hoist brake holds without slipping.

Remove the test weight from the davit wire rope assembly.

Verify no permanent deformation or damage to any components.

Verify no leakage from hydraulic components.

B2.7.1.4 Dynamic Overload test. While the Coast Guard inspector raises, lowers, and rotates the dynamic load specified in the work item a minimum of three complete cycles and through as wide a range as practicable, and if applicable, tops the dynamic load through as wide a range as practicable a minimum of 3 complete cycles starting and stopping each actuator at least twice in each direction every cycle, the

Contractor must verify the following as applicable:

Each actuator lifts or rotates the dynamic load.

Each brake stops and holds the dynamic load without slipping.

No permanent deformation, damage to, or overheating of any components.

Proper operation of all controls and sensors.

No unusual vibration or noise is emitted from any component (e.g., winch, actuator, shaft assembly, pin assembly, etc.) and there is no binding or misalignment.

Verify no leakage from hydraulic components.

B2.7.1.5 Rated load test. While the Coast Guard inspector raises, lowers, rotates, and if applicable tops the rated load specified in the work item a minimum of 10 complete cycles and through as wide a range as practicable, starting and stopping each actuator at least twice in each direction every cycle, the Contractor must verify the following as applicable:

Each actuator lifts or rotates the rated load at rated speed.

Each brake stops and holds the rated load without slipping.

No permanent deformation, damage to, or overheating of any components.

Proper operation of all controls and sensors.

No unusual vibration or noise is emitted from any component (e.g., winch, actuator, shaft assembly, pin assembly, etc.) and there is no binding or misalignment.

Verify no leakage from hydraulic components.

B2.7.2 Dual point davits. Contractor must not use a USCG small boat for operational, dynamic or static load tests of davits.

B2.7.2.1 No-load operational test. While the Coast Guard Inspector operates each actuator associated with the davit in both directions a minimum of 2 minutes by extending and retracting the davit arms and operating the hoist(s), the Contractor must verify:

All controls and sensors are operating properly.

No unusual vibration or noise is emitted from any component (e.g., winch, actuator, shaft

2022 B8 5000 assembly, pin assembly, etc.) and there is no binding or misalignment.

Proper setting and release of each brake.

NOTE

During no-load operations ensure sufficient tension is kept on wire ropes to prevent improper wrapping on hoist drum.

B2.7.2.2 Static load test. The Contractor must:

Using an external lifting device, suspend the static load test weights specified in the work item from each wire rope assembly and hold for a minimum of 10 minutes.

Verify that the hoist brake holds without slipping.

Remove the test weight.

Verify no permanent deformation or damage to any components.

Verify no leakage from hydraulic components.

B2.7.2.3…