58416 TAB 0721 754 Trnsm Door Repair.doc

58416_TAB_0721_754

WORK ITEM 1: Transom Doors, Inspect And Repair

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect and repair the transom doors. The scope of this work item includes the following:

· Force and time to operate measurement

· Transom door guides preservation

1.2 Government-furnished property.

($/UNIT)

Notes

Item # 24, 25, 26, 27, 28, 29

*Government-loaned property, which must be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center.

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing 418A-WMSL-167-001, Rev A, Fabrication & Installation Transom Doors Coast Guard Drawing 750-WMSL-556-006, Rev F, Stern Gate Hydraulic System Diagram (ASC556004) Coast Guard Publications

Coast Guard Technical Publication (TP) 7794, SWBS 584, Oct 2015, Sliding Double Transom Door – Model H-WK-868-29

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2020, Auxiliary Machine Systems

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures

Other References

Code of Federal Regulations (CFR) Title 29, Part 1915, Subpart E, Sep 2015, Scaffolds, Ladders and Other Working Surfaces

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor must submit a CIR for the inspections listed in the following paragraph(s):

None.

3.1.2 Tech Rep. The Contractor must provide the services of an OEM authorized/ licensed Tech Rep for the Transom Door (i.e Walz & Krenzer) and Hydraulic Power Unit (i.e. C. S. Controls) to accomplish the following on site:

· Provide manufacturer's proprietary system/ equipment information, software, and tools.

· Assist with and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé.

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

3.1.3.1 Protective measures, hydraulic system(s). Maintain existing hydraulic system cleanliness and take all necessary precautions to prevent the introduction of contaminants into the hydraulic system. Immediately after disconnecting or removing components from the hydraulic system, seal all openings to the rest of the system using caps for externally threaded connection points, bolt-on blanks, or taped-on discs/covers made of durable plastic or sheet-metal that is no less than 1/16-inch thick.

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following:

· Barge required for work on the exterior side of the transom doors.

· Electrical wiring (open-close cylinders and locking cylinders proximity sensors, heat tracer cables)

· Hydraulic cylinder removal/reinstallation may require crane/barge

· Hydraulic piping and hoses

· Locking cylinders

· Mooring Lines

· Removal of stern door(s) will require crane

· Work on lower rail requires Cutter to ballast forward in order to raise rail out of the water Note

General arrangement and details of transom door described in this work item are shown in CG Drawing 418A-WMSL-167-001 and Coast Guard TP 7794.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.1.5 Background. While opening doors, crew reports that the operation of Starboard side stern gate slows down and stops about 18” before fully open.

3.1.6 Force required to operate test plan. The force and time to cycle the doors (2) to open and to close must be measured after cylinders have been removed/disconnected from door. Measurements must be taken before and after rails have been cleaned, preserved and plastic guides renewed/reinstalled. The Contractor must submit a test plan to measure the force required to operate the doors at arrival conference. Plan must include diagram showing nature and arrangement of loads, weights, pulleys and measuring device.

3.1.7 Rigging. Contractor is responsible for all rigging operations. Provide rigging plan for lifting transom doors at arrival conference.

3.1.8 Staging. The Contractor must, in accordance with 29 CFR 1915, Subpart E (Scaffolds, Ladders, and Other Working Surfaces), erect suitable staging or scaffolding as necessary to facilitate the required work. Disassemble and remove the staging upon completion of work or when designated by the CG Inspector.

CAUTION

Utilize any mechanical device, such as jigs, to ensure that the port and starboard transom doors are secured in place to prevent any movement or shifting of the doors when the open/close and locking cylinders are removed/installed. Failure to heed this caution could result to damage to equipment or cause injury.

Note

General arrangement and details of transom door described in this work item are shown in CG Drawing 418A-WMSL-167-001 and Coast Guard TP 7794.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.2 Operational test, initial. Prior to commencement of work, the Contractor must witness Coast Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Observe and record hydraulic pressure readings and time to complete cycle for each side. In the current condition, the starboard side door may not open fully. If door becomes stuck and will not fully open, the Contractor must measure the distance remaining to fully open and time until the door stopped moving. Submit CFR to asset manager (Jordan.K.Ford@uscg.mil) 510-460-8189.

3.2.1 The Contractor must check the transom doors for proper hydraulic/electrical operation and that the indicator lights at the Control Station and Bridge Station show the correct status. Both station console indicator lights must function as described Coast Guard TP 7794. Check flow divider assembly & valves for leaks and proper operation. Submit CFR to asset manager (Jordan.K.Ford@uscg.mil) 510-460-8189.

3.3 Alignment verification. The Contractor must disconnect the starboard side hydraulic cylinder from the mounting bracket on the door. Verify alignment between mounting bracket and the Open-Close (O-C) Hydraulic cylinder.

Note

The body of the O-C hydraulic cylinder is hard mounted to hull in two places The cylinder’s clevis is hard mounted to the door. Incorrect alignment will interfere with operation of mechanism.

3.3.1 Temporarily secure the cylinder clevis to the bracket. Attach a suitable short heavy chain or steel cable to permit some relative movement but also to allow the O-C cylinder to pull door open and close. Observe relative position between bracket and end of cylinder as the door is cycled from opened and closed. Report any damage and relative movement between clevis end and bracket as the door is operated. Submit CFR indicating alignment/damage and suggested repairs to asset manager (Jordan.K.Ford@uscg.mil) 510-460-8189.

Warning

Ensure that method/materials for temporary attaching the clevis to the bracket have the necessary strength

3.4 Hydraulic cylinder removal. The Contractor must remove the open-close and locking cylinders. For bidding purposes the Contractor must assume that the open close Cylinder’s mounting bracket on starboard side transom door must be renewed.

3.4.1 After all repairs to transom door rails are completed, the starboard cylinder must be renewed using the Government-furnished cylinder. Take extra precaution not to damage the shipping crate. The Contractor must pack the old cylinder and turn them over to the EO. If this cylinder was not provided on day 1, the contractor must refurbish the old cylinder and reinstall.

· Coat the threads of all fasteners with Loctite #242, or equivalent before assembly.

· The cylinders must be bench tested at 2,700 psi at the contractor’s facility to ensure zero-leakage and operationally tested onboard the cutter after installation to ensure proper operation. Submit CFRs certifying bench test and onboard test are satisfactory to asset manager (Jordan.K.Ford@uscg.mil) 510-460-8189.

3.5 Initial condition measurement of force required to operate. After removal of cylinders, the Contractor must measure the time and force required to open and to close each transom door. Follow load test plan as provided per para 3.1.6 above. Submit CFR to asset manager (Jordan.K.Ford@uscg.mil) 510-460-8189.

Note

1. Work on lower guide requires Cutter to be ballasted forward to expose the rail guides.

2. The transom doors normal open-close travel limit does not allow access to all mounting hardware. In order to remove upper guide rail UHMW mounting hardware, the open-close cylinders are removed and the doors manually/emergency opened past the open limits to gain access to all the hardware. However, if the UHMW plastic guides need to be renewed also, it is recommended to have the doors removed from the cutter to facilitate the hardware and plastic guides renewal.

3. Weather seals and plastic guides are provided as GFE in anticipation that they might need to be replaced.

3.6 Remove the transom doors. The Contractor must use a suitable crane to remove both transom doors. Save for reinstallation.

3.7 Inspection and repair. The Contractor must inspect the sliding components of the transom door. Include: metal channels, weather seals, plastic door guides. Report excessive/abnormal wear, misalignment, corrosion. Submit CFR to asset manager (Jordan.K.Ford@uscg.mil) 510-460-8189.

3.8 Surface preservation, 100% exterior. The Contractor must perform 100% preservation in accordance with SFLC Std Spec 6310, Appendix A (Cutter and Boat Exterior Painting Systems) on the following exterior surfaces:

· Interior and exterior surfaces of upper and lower rail guides

3.8.1 Preparation method. The Contractor must prepare exterior surfaces using power tool cleaning to “bare metal” (SSPC-SP 11) with a minimum 1.0 mil anchor profile as the method of surface preparation. Attach a suitable vacuum to power tool equipment to capture and contain all dust and paint debris.

3.8.2 Coating method. The Contractor must apply finish/top coat color to exterior surfaces to match existing adjacent surfaces.

LEVEL

NOTE

Ramp/Deck, Bulkheads, and Frames (Bottom to 2nd Deck)

Door Interiors and Bulkheads in Stern Ramp Bay (2nd to Main Deck excl. Recess Decks) Bulkheads

Foundation

Outfits

Fittings

3.8.3 In-process quality control. The Contractor must abide by all the safety, preservation, and quality control requirements specified in SFLC Std Spec 0000.

Note Perform preservation work on rails prior to reinstallation/renewal of plastic guides and weather seals

3.9 Transom door panels weather seals. Replace existing weather seals (center, upper, and lower) with OEM gasket material per Coast Guard TP 7794 Table 7.1 Items 6, 12, 13, 14, 15 (Silicone Rubber Extrusion, Class 2B, Grade 40).

FIGURE 1 – TRANSOM DOOR weather seals

3.10 Plastic door guides. The Contractor must renew the port and starboard upper, middle, and lower guide rail plastic strips. Guide rail replacement parts are shown in Table 7.1 and Figure 1 of Coast Guard TP 7794. Guide rail plastic material specs: UHMW Polyethylene, Hardness: Shore D61-D77, Tensile: 2470-7740; Coefficient of friction: 0.12 - 0.25.

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

3.12 Reinstall transom doors.

3.13 Final condition measurement of force required to operate. With the OC hydraulic cylinders disconnected from the doors, the Contractor must measure the time and force required to open and to close each transom door. Follow load test plan as provided per para 3.1.6 above. Submit CFR.

3.14 Reassemble the system. Reconnect wiring, switches and hydraulic cylinders.

3.15 Operational test, post repairs. After completion of work and in the presence of the Coast Guard Inspector, the Contractor must thoroughly test and demonstrate the equipment listed below to be in satisfactory operating condition. Submit a CFR including time to open/close doors, hydraulic pressure readings.

· Cycle the transom doors from close to open positions and vice versa and check for proper operation and correct indicator lights status at the local operating console at the fantail and status console at the bridge. All control station indicator lights must function as described in Coast Guard TP 7794. Ensure flow divider assembly & hydraulic valves properly operating.

· Operate the system at normal operating pressure and ensure zero visible leakage from mechanical parts by repairing all leaks and discrepancies.

3.16 Touch-up preservation. The Contractor must prepare and coat all new and disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.)

4. NOTES

This section is not applicable to this work item.

4.1 FLETC Base Security. The Contractor shall contact the Asset Manager upon contract award to obtain FLETC Security Base Access requirements. The Contractor shall note that it can take a minimum of two weeks for FLETC Security to process documentation related to Base Access, and even longer for special cases such as foreign nationals. It is the responsibility of the Contractor to comply with FLETC Base Security measures and the Coast Guard will not be liable for delays or terminations of FLETC Base Access.

4.1.1 Gaining Access to FLETC Charleston:

· Contractors that are U.S. Citizens and seeking access to the FLETC/Federal Complex are required to be issued a FLETC ID Badge. Contractors shall submit completed DHS Form 11000-25 and OF-306 (or updated versions of the aforementioned forms if distributed following the award of the contract) to the Asset Manager a minimum of 14 days prior to the start date. If the Contractor is expected to be onsite for 5 days or less, a FLETC Form 121-00-02 may be utilized. This form cannot replace the normal application process if the Contractor will be returning to base multiple times within the same contract period. A single FLETC Form 121-00-02 is authorized per Contractor per contract period. All Contractors will be subject to fingerprinting and background check.

· Contractors that are either foreign born or are a foreign national seeking access to the FLETC/ Federal Complex, regardless of time frame, must be issued a FLETC ID Badge. Contractors shall submit completed DHS Foreign National Screening Form 11000-25 and OF-306 and shall provide a copy of their U.S. Passport, Visa, and/or Naturalization Certificate. This shall be submitted to the Asset Manager a minimum of 30 days prior to the start date. All Contractors born outside the U.S. but are U.S. Citizens will be required to submit DHS Foreign National Screening Form 11000-25 and OF-306 and shall provide proof of U.S. Citizenship in the form of a U.S. Passport or Naturalization Certificate. Contractors that are either foreign born or are a foreign national shall complete fingerprinting regardless of their duration on the cutter.

· The Asset Manager will distribute the most recent revision of the access forms, as applicable, via email to the Contractor as soon as possible following the award of the contract. Contractors are strongly encouraged to type out and hand sign the forms, as hand written forms may be illegible and slow the review process down. The Contractor is strongly encouraged to complete all required fingerprinting prior to the work start date to allow for immediate and uninterrupted access to FLETC and Cutter.

· It is imperative that the “Work Start Date” on the FLETC access form is as accurate as possible for that individual. This date should be the day the person will be onsite and need access to the base, not necessarily the first day of the contract. This will allow for an adequate amount of time for the Contractor’s fingerprints to be adjudicated. An inaccurate “Work Start Date” may cause temporary loss of FLETC access while the contractor’s fingerprints are being processed. Contractor are strongly recommended to extend the “Work Stop Date” 15 to 30 days past the scheduled work completion date to ensure uninterrupted contractor access to FLETC if a contract extension were to occur.

· Contractors shall be advised that the Department of Homeland Security (DHS) completes background checks on all FLETC applicants and reserves the right to deny access to those with criminal history, those who have not registered for Selective Service, and/or other various conditions. If any disqualifying information is discovered during the background check process, FLETC may require the individual to vacate FLETC property immediately. DHS may not be required to supply a reason for denial of entry or removal from the FLETC facility. Contractors shall abide by the policies and regulations established for the daily operations of FLETC, including but not limited to wearing the FLETC-issued ID badges at all times, adhering to posted speed limit signs, posted restricted area signs, traffic directional signs, and law enforcement directions given by FLETC Security Forces. The Contractor shall be advised that FLETC Badges may be terminated due to violation of FLETC policies and regulations.

4.1.2 Arriving at FLETC Charleston:

· Contractors are required to check in at the visitor’s center prior to entering the main gate and 1) Pick up a visitor’s badge, and 2) Complete a parking pass application prior to gaining access to FLETC. The parking pass shall be completed on-site and requires the contractor to provide a valid license, vehicle registration and proof of insurance. All vehicles are subject to search and FLETC/Federal Complex utilizes 100% ID Checks. Parking for HAMILTON and JAMES is located at the foot of PIER PAPA. THE CONTRACTOR SHALL NOT PARK ON THE PIER.

· Contractors shall proceed to 1050 Register St to meet with the Base Charleston Command Security Officer immediately after the visitor center to be fingerprinted. Hours of operation for the Base Charleston Command Security Officer is Monday thru Friday, 0830-1100. To ensure the Command Security Officer is available, Contractors shall call 843-740-3168 before arrival. Fingerprinting outside hours of operation shall be scheduled in advance with the Base Charleston Command Security Officer. Upon completion of fingerprinting, the Project Manager shall provide the Asset Manager with names of Contractors to be added to the Cutter Access List.

4.1.3 Gaining Access to CGC HAMILTON and CGC JAMES:

· The Contractor must complete required fingerprinting before being placed on the Cutter Access List and permitted on board the Cutter. The Project Manager shall notify the Asset Manager of Contractors who have completed fingerprinting to be added to the Cutter Access List. The Cutter Access List will be kept at the quarterdeck of the vessel, enabling Cutter watch standers to maintain visitor accountability. Contractors shall sign in and out at the quarterdeck each day and abide by 100% ID checks. Contractors who are not on the Cutter Access List will not be permitted onboard the cutter.

4.1.4 Gaining Access to Secure Spaces on the Cutters:

· Certain spaces on board the cutter contain classified information and will require proof of security clearance before access is granted. These spaces are CIC, COMM/MEES, the LAN Room and SCIF. Personnel requiring to work in these areas must have their clearance via OPNAV 5521/17 form at least two weeks prior to arrival in addition completing fingerprinting.

4.1.5 Submitting Access Requests:

· All of the required base access forms contain Personally Identifiable Information (PII). Encryption or password protection of emails is HIGHLY ENCOURAGED.

· Please submit all required forms, completed and signed, via email to the Port Engineer/ Asset Manager listed below. Submit all required forms in a single email, not to exceed 10MB. The designated Port Engineer/ Asset Manager will ensure that the forms are secured, reviewed, and forwarded to the proper personnel. You will be notified of any discrepancies with the paperwork.

· Please do not hesitate to contact any of the personnel on the email list below with questions.