70Z080-19-Q-P45C800_-_ACTIVE_-_EMERGENCY_DRYDOCK_-_SPECIFICATION.pdf

USCGC ACTIVE (WMEC 618)

SPECIFICATION FOR UNPLANNED DRYDOCK REPAIRS

FY2019

Developed By: Julius K Toida

(Rev-0, 20 March 2019)

USCGC ACTIVE (WMEC-210A) UNPLANNED AVAILABILITY FY2019

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property ................................................................................. vi Consolidated List of Critical Inspection Items ........................................................................................... vii Principal Characteristics ............................................................................................................................ viii General Requirements WORK ITEM 1: Propulsion Shaft (Starboard); Remove, Inspect, and Reinstall WORK ITEM 2: Propulsion Shaft Seal (Starboard) Assembly, Inspect And Repair Or Renew WORK ITEM 3: Controllable Pitch Propeller (CPP) System, Inspect and Service WORK ITEM 4: Drydock WORK ITEM 5: Temporary Services, Provide - Cutter WORK ITEM 6: Sea Trial Performance, Support, Provide WORK ITEM 7: Starboard Controllable Pitch Propeller Oil Tube, Repair WORK ITEM 8: Propulsion Shaft Coating, Renew iii (Rev-0)

REVISIONS RECORD

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

iv (Rev-0)

CONSOLIDATED LIST OF REFERENCES

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at the time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – from links located on the SFLC website. Commercial sites provide access to their respective documents.

COAST GUARD DRAWINGS

Coast Guard Bill of Materials 618 WMEC 151, Rev D, Shafting, Arr & Det’s (Water Lubricated) Coast Guard Bill of Materials 618 WMEC 65, Rev A, Shaft Oil Tube and Coupling Modifications Coast Guard Drawing 618 WMEC 085-182, Rev D, Docking Plan, (ACTIVE) Coast Guard Drawing 618 WMEC 243-001, Rev E, Arrangement and Details John Crane Type Stern

Tube System Coast Guard Drawing 618 WMEC 243-002, Rev H, Arrangement & Details of Piping & Hydraulics Coast Guard Drawing 618 WMEC 243-003, Rev G, Shaft Oil Tube and Coupling Modifications Coast Guard Drawing 618 WMEC 243-005, Rev C, Piping Mods for Water Lubricated Stern Tube Seal Coast Guard Drawing 618 WMEC 243-007, Rev A, CPP Oil Tubes Fabrication, Details & Assy Coast Guard Drawing 618 WMEC 243-008, Rev A, Shafting Arrangement & Details Coast Guard Drawing 618 WMEC 243-050, Rev-, Hub Oil Tank 10 Gal. Cap.

Coast Guard Drawing 618 WMEC 243-051, Rev -, John Crane Seal Coast Guard Drawing 618 WMEC 244-001, Rev B, Shafting Alignment Coast Guard Drawing 618 WMEC 244-003, Rev G, Shafting Arrangement & Details (Water Lubricated

Bearing) Coast Guard Drawing 618 WMEC 245-052, Rev -, Propeller Hub Double Crank Coast Guard Drawing 618 WMEC 801-008, Rev -, Curves of Form

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Jun 2006, Coatings and Colors

Manual Coast Guard Technical Publication (TP) 3231A, Feb 2012, Manufacturer’s Instruction Book-SWBS

Group(s) 242-245, Chapter 243, Section B, Stern Tube Seal, MX9, US-71736 (S/A 210R-A-021) Coast Guard Technical Publication (TP) 3231A, Sept 2014, Manufacturers Instruction Book - SWBS

Group(s) 242-245 Coast Guard Technical Publication (TP) 3231A, Sept 2014, SWBS 245, Section A, Controllable Pitch

Propeller Double Crank, Liaaen Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and

Allied Processes v (Rev-0)

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2014, Auxiliary Machine Systems

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 8634 (SFLC Std Spec 8634), 2014, Drydocking Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), 2014, Temporary

Services

OTHER REFERENCES

ASTM International (ASTM) D4174, R2015, Standard Practice for Cleaning, Flushing, and Purification of Petroleum Fluid Hydraulic Systems International Standard Organization (ISO) 4406, 2017, Hydraulic Fluid Power – Fluids – Method for

Coding the Level of Contamination by Solid Particles – Third Edition MIL-STD-2199A(SH), July 2010, Covering for Waterborne Main Propulsion Shafting on U.S. Naval

Surface Ships and Submarines The Society for Protective Coatings (SSPC)/NACE International (NACE), 2007, Joint Surface

Preparation Standard SSPC-SP 10/NACE No.2, Near-White Blast Cleaning vi (Rev-0)

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

WORK

ITEM

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

2 N Overhaul kit NSN: 5330-01-527-1036

PN: 210A-JCL001228001B

1 ea. 1,500.00

2 Y **Seal Assy NSN: 2040-01-350-5468

PN: MX9 US-71736

1 ea. 12,000.00

2 N **Seal, Seat Assy NSN: 2010-01-361-7722

PN: H48626A03

1 ea. 600.00

3 Y **Hub Assembly (L/H)

NSN: 2010-01-143-5217 1 ea. 87,439.00

3 N **Hub Seal Kit NSN: 2010-01-602-8461 1 ea. 6,524.50 3 Y **Starboard Propeller

Blades (L/H) NSN: 2010-00-906-6010 1 set 33,090.26

3 N **Propeller Blade Bolts

NSN: 5306-01-201-0438 24 ea. 1,900.02

3 N **Propeller Blade Bolt Washers

NSN: 5306-01-517-0914 24 ea. 278.02

3 N Seal for Prop Blade NSN: 5330-01-043-9659 P/N: 13369-A

4 ea. 1,155.00

3 N **Servo Box seal kit (NOTE: Parts may require machining for proper fit.)

NSN: 5330-01-476-2026 1 ea. 850.00

3 N Shaft Line Seal Kit NSN: 5330-01-172-1829

P/N: 9891-LUP

1 ea. 800.00

3 N Hub Change-out Kit NSN: 2010-01-630-1155 1 ea. 6,500.00 *Government-loaned property, which shall 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 ServiceCenter vii (Rev-0)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.1.4 (Inspection report particulars)):

Work Item Title

1 Propulsion Shaft (Starboard); Remove, Inspect, and Reinstall

2 Propulsion Shaft Seal (Starboard) Assembly, Inspect And Repair Or Renew viii (Rev-0)

PRINCIPAL CHARACTERISTICS

210' WMEC (A-CLASS)

PHYSICAL

Length overall 210' 6" Length between perpendiculars 200' 0" Beam molded 34' 0" Depth molded, main deck amidships 19' 6" Full load displacement 1,170 long tons Draft, full load to baseline amidships *Baseline is 9” below keel amidships

12' 0"

Design drag between perpendiculars 1' 6" Highest projection above baseline *VHF-FM ADF antenna

90' 0"

Shore tie voltage requirements 400A / 440V Frame spacing 1' 0"

MACHINERY

Main propulsion 2 ALCO Model 16-251-CE Diesel Engines, 5,000 BHP total Ship's service generators 2 Caterpillar Model 3406B Diesel-driven SR4, 250 KW each @ 0.8 power factor, 440VAC, 3 phase, 60 cycle

Emergency generator Caterpillar Model 3306B Diesel-driven SR4, 180 KW @ 0.8 power factor, 440VAC, 3 phase 60 cycle

Number of propellers 2 Propeller diameter 7' 6" Number of blades, Each 4 Pitch Controllable Shaft RPM 300 Shaft diameter 8.25" at exit of hull Anchor & chain Two 2,800 lb Navy Stockless Anchors, 7 shots of chain each

TANK CAPACITIES

Diesel fuel total (95%) 47,140 gal.

Fresh water total (100%) 11,135 gal.

JP-5 fuel total (95%) 4,717 gal.

Lube oil total (95%) 2,331 gal.

1 (Rev-0)

00000_0618_FLT

REC_00000_FLT_Commercial Project @ Contractor’ Facility (1212)

General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed at a commercial contractor’s facility for Coast Guard vessels.

1.2 Term interchangeability. The terms 'Contractor', 'CG Yard', 'NAVSTA EVERETT', 'shipyard', 'Base', and 'Coast Guard Industrial' are used interchangeably in this specification. Where the primary service provider is Coast Guard personnel, references to contractor and other noted descriptors within this specification or within drawings, publications, SFLC Standard Specifications or other commercial and military references are deemed the same as prime service provider.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and

Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

2 (Rev-0)

3.2 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

• Provide portable fire extinguishers for Coast Guard fire watch personnel. Coast Guard fire watch is in lieu of contractor personnel during the hours of 0800-1600, Monday through Friday, and limited to two Coast Guard fire watch personnel.

• Provide fire watch personnel and fire extinguishers for the duration of the availability period, during and beyond noted Coast Guard fire watch support.

3.3 Preservation requirements. The Contractor shall accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec 6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

3.3.2 Coating colors and system color schemes. Ensure that all colors and color coat/paint schemes are in accordance with COMDTINST M10360.3, Chapter 6 (Cutter and Boat Colors Exterior and Interior).

NOTE

Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes (provided in Chapter 6 of COMDTINST M10360.3) are strictly prohibited.

3.4 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDE in accordance with SFLC Std Spec 0740.

3.5 Environmental protection requirements. The Contractor shall adhere to the following environmental protection requirements in accordance with the SFLC Stand Spec 0000:

3.5.1 Contractor operated (non USCG) facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix A, Requirements for Environmental Protection at Contractor Operated (Non USCG) Facilities, as applicable, during the performance of this availability. Contractor shall plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor shall comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.2 Test and procedures. The Contractor shall be required to promptly conduct tests and procedures for the purpose of assessing whether operations are in compliance with applicable Environmental Laws. Analytical work shall be done by qualified laboratories; and where required by law, the laboratories shall be certified.

3.5.3 Regulatory notifications. The Contractor shall be responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The Contractor shall submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications shall be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System

3 (Rev-0)

(NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

3.5.4 Environmental manager. The Contractor shall appoint in writing an Environmental Manager for the project, and shall be responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager shall ensure compliance with Hazardous Waste Program requirements, including hazardous waste handling, storage, manifesting, and disposal; implement the Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas;

ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the Environmental Records binder and required documentation, including environmental permits compliance and close-out.

3.5.5 HW disposal. Contractor shall comply with SFLC Std Spec 0000 Appendix A, Requirements For Environmental Protection At Contractor Operated (Non USCG) Facilities for HW disposal.

3.6 Local Policy. None.

3.7 SFLC standard specification approved changes. The Contractor shall be aware that the following are approved changes to published SFLC 2014 Edition Standard Specifications and supersede published content:

3.7.1 Change to SFLC Std Spec 0000, paragraph 1.3. ‘Acronyms and term definitions’, page 5, “PCL (Paint Containing Lead)” definition replaced by, “Any paint or coating containing lead in excess of 0.009 percent by weight (1.0 mg/cm2 or 90 ppm). Lead Based Paint (LBP) is an interchangeable term with PCL.”

3.7.1.1 Change Std Spec 0000 paragraph 3.2.4.2.3(QP 1 inspector or tech rep duties) bullet, “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph 3.1.19 of SFLC Std Spec 6310 (Critical drying time requirements)).” to “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph 3.1.17 of SFLC Std Spec 6310 (Critical drying time requirements)).”

3.7.2 Change to Std Spec 5000, paragraph D2.2.1.1 bullet, "For running rigging, furnish class 6x37, uncoated, independent wire rope core (IWRC), right regular lay (RRL) wire rope or Dyform-18, rotation resistant wire rope," to "For running rigging, furnish class 6x36, uncoated, independent wire rope core (IWRC), right regular lay (RRL) wire rope or Dyform-18, rotation resistant wire rope."

3.7.2.1 Change to Std Spec 5000, page D-2, Table D-1 title from "DYFORM-18, 6X19 AND 6X37 IWRC RRL," to " DYFORM-18, 6X19 AND 6X36 IWRC RRL"

4. NOTES

4.1 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 6310 to be completed and submitted during preservation of “critical-coated surfaces”, are provided at the end of this document.

4 (Rev-0)

5 (Rev-0)

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

VESSEL NAME HULL # WORK ITEM

WORK ITEM TITLE

LOCATION OF WORK (INCL. FRAME #’S) AREA (SQFT)

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

Ensure all coatings are in compliance with SFLC Std Spec 6310, Appendix C.

CHECKPOINT 2 - PAINT STORAGE

Ensure all coatings are kept at a temperature of 65 to 85°F at all times, unless otherwise specified by the coating mfgr.

CHECKPOINT 3 - AMBIENT CONDITIONS

Ensure surface and surrounding temperatures are each between 50 and 90°F for water-containing coatings, and 35 and 95°F for other coatings, unless otherwise specified by the coating manufacturer(s).

Ensure maximum relative humidity (RH) is as follows, from surface preparations through final curing of topcoat: 50% for tanks, voids, and vent plenum; and 85% for all other areas, unless otherwise specified by manufacturer(s).

Ensure surface temperature is at least 5°F above the dew point, unless otherwise specified by the coating mfgr.

CHECKPOINT 4 - PRE-SURFACE PREPARATION

Remove surface contaminants (soluble salts, loose rust, mud, and marine growth) with low pressure fresh water wash down (maximum 5,000 psi). If oil and grease are present, perform solvent cleaning, as per SSPC SP-1.

Verify equipment setup, blast media, and surface preparation methods match designated test coupon.

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure cleanliness of prepared surface is as per specification (i.e.: SSPC SP-11, SP-10, SP WJ-2…).

Verify surface anchor profile using ASTM D4417-Methods B or C against SFLC Std Spec 6310. Conduct profile readings at a minimum of 5 locations for the first 1000-sqft area, and 2 locations for each succeeding 1000-sqft area.

Measure soluble salt conductivity in accordance with SSPC-Guide 15. Conduct 5 measurements per each 1000-sqft area (max. threshold: 70 microsiemens/cm for non-submerged surfaces, 30 microsiemens/cm for submerged surfaces).

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Verify proper mixing and stand-in (induction) times.

Ensure no paint is applied when the temperature is expected to drop to freezing before the paint has dried.

Ensure surfaces are completely dry, unless otherwise allowed by the coating manufacturer(s).

Verify wet film thickness (WFT) at random, to prevent under or over application. Verify final DFT.

Brush out all runs, sags, drips, and puddles.

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

After primer coat (mist coat after inorganic zinc), brush-apply un-thinned coat of same primer paint over edges, weld seams, cut-outs, and areas of complex geometries @ 3-4 mils wet film thickness (WFT).

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

Verify proper mixing and stand-in (induction) times, as applicable.

Verify wet film thickness at random, to prevent under or over application.

Brush out all runs, sags, drips, and puddles.

CHECKPOINT 9 – FINAL INSPECTION

Verify final system dry film thickness. Conduct 5 sets of 3 readings for each of the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area.

Ensure that system cure is in accordance with manufacturer's recommendation for intended service.

Ensure potable water tank exhaust ventilation is maintained continuously from and during coating application through final system cure, to exhaust all solvent to the atmosphere and to prevent solvent entrapment.

For immersion coatings (including tank U/W body), record date and time of the following events:

Final coat application: _____/_____; Return to service or removal from environment controls: _____/_____

CHECKPOINT 10 – RECORD KEEPING

Complete, sign, and submit all provided QA Inspection Forms.

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE / TIME

6 (Rev-0)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

VESSEL NAME HULL # WORK ITEM

# WORK ITEM TITLE

Use one sheet for each activity. Record conditions every four hours from before surface preparation to application of final coating system coat.

DATE

TIME

ACTIVITY (SURFACE

PREPARATION, PRIMER COAT,

BARRIER COAT, TOP COAT,

ETC…)

LOCATION (FRAME &

DECK, RELATION TO

EQUIPMENT, ETC.)

TEMPERATURE % REL.

HUMID-

ITY

DEW

PT.

SURFACE AMBIENT ΔT

| DP -

SURFACE |

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE / TIME

7 (Rev-0)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-C)

VESSEL NAME HULL # WORK ITEM

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area) Brush-blasting (non-metallic substrate)

ABRASIVE MANUFACTURER: ABRASIVE SIEVE SIZE:

PLACE SURFACE PROFILE REPLICA TAPES IN THE SPACES PROVIDED BELOW, TO SERVE AS

PERMANENT QA RECORD. MAINTAIN A SEPARATE LOG FOR EACH LOCATION. WHEN AN AREA IS

DIVIDED INTO SEPARATE SECTIONS, MAINTAIN A SEPARATE LOG FOR EACH SECTION.

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

MEAN MIL READING (IAW ASTM D4417-METHOD C) FOR ABOVE 15 READINGS:

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE /

TIME

8 (Rev-0)

QA-3b - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-B)

VESSEL NAME HULL # WORK ITEM

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area) Brush-blasting (non-metallic substrate)

ABRASIVE MANUFACTURER: ABRASIVE SIEVE SIZE:

RECORD MEASUREMENTS TAKEN IN THE SPACES PROVIDED BELOW, TO SERVE AS PERMANENT QA

RECORD. MAINTAIN SEPARATE LOG FOR EACH LOCATION. WHEN AN AREA IS DIVIDED INTO

SEPARATE SECTIONS, MAINTAIN A SEPARATE LOG FOR EACH SECTION.

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Mean Reading (mils)

Mean Reading (mils) IAW ASTM DD4417).

9 (Rev-0)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

VESSEL NAME HULL # WORK ITEM

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15.

DATE TEST LOCATIONS CONDUCTIVITY (MICROSIEMENS/CM)

10 (Rev-0)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

VESSEL NAME HULL # WORK ITEM

# WORK ITEM TITLE

COATING MFG PRODUCT NAME BATC

H #

INDUCTI

ON TIME

COATING SYSTEM

SEQUENCE

(PRIMER/TOUCHUP/3RD

COAT, ETC.)

DRY FILM THICKNESS (DFT) MEASUREMENTS IAW SSPC-PA 2.

SPOT 1 2 3 4 5 AVERAGE

VALUE

*BASE METAL READING

(BMR) Required, If Magnetic Pull-Off (Type I/Banana) Gauge Is Used.

LOCATION (FRAME REFERENCE):

SPOT 1 2 3 4 5 OVERALL AVG. DFT ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE ADJUSTMENTS AFTER ADJUSTMENTS

AVG.

1 AVG. BMR DEVIATION

1 AVG. BMR DEVIATION

APPLICATION METHOD (AIRLESS,

CONVENTIONAL SPRAY, ROLLED)

AVERAGE DFT

11 (Rev-0)

24310_0617_FLT

REC_24310_FLT_210’ WMEC ‘A’ Class (ALL) (0718)

S19_0010_24310_JKT_0319_618

WORK ITEM 1: Propulsion Shaft (Starboard); Remove, Inspect, and Reinstall

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to disconnect and temporarily relocate the starboard shaft to facilitate CPP hydraulic piping repair.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 618 WMEC 243-008, Rev A, Shafting Arrangement & Details Coast Guard Drawing 618 WMEC 244-001, Rev B, Shafting Alignment

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes Coast Guard Technical Publication (TP) 3231A, Sept 2014, Manufacturers Instruction Book -

SWBS Group(s) 242-245

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

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

• 3.2.1 Initial shaft coupling alignment check

12 (Rev-0)

3.1.2 Tech Rep.

Not Applicable.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

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

• Deck plates.

• Cat walk over the shaft

• Rope guard

• Fairwater

• CPP hub

• OD box

• Oil tubes.

3.2 Work to be accomplished. Using Coast Guard Drawing 618 WMEC 243-008 as guidance, as applicable, the Contractor shall accomplish the following for the stbd shaft:

3.2.1 Initial shaft coupling alignment check. Prior to the vessel’s initial drydocking, perform the bore and face alignment check between the reduction gear output flange and shaft coupling as follows and Submit a CIR:

• Angular (face-to-face) readings in 4 positions at 90° intervals;

• Parallel (coupling OD-to-coupling OD) readings in 12 positions at 30° intervals.

NOTE

The following methods for obtaining coupling/hub alignment measurements are acceptable:

1) Dial indicator to obtain total indicator run-out

2) Straight edge or feeler gage.

3.2.2 Removals.

CAUTION

Be aware historically couplings have been difficult to remove, often requiring added heat to loosen.

Ensure shaft is protected and supported at all bearing journals (minimum), at all times, until reinstallation.

When transporting/moving/lifting, ensure the shaft is supported at all times at a minimum of three locations along the shaft.

Provide proper support to the reduction gear shaft flanges to prevent sagging.

13 (Rev-0)

• Remove the CPP oil tubes from the shaft bore and clean the inside shaft bore free of all grease, oil and dirt.

• Mark existing shaft position, and match-mark shaft coupling bolts to their respective holes, to facilitate reinstallation procedures.

• Disconnect the inboard shaft coupling assembly and slide the shaft and attached components (as applicable) approximately 18 inches aft, and secure.

3.3 Reinstallation. Upon completion of authorized repairs, the Contractor shall reinstall the stbd shaft to its original configuration and accomplish the following, using Coast Guard Drawing 618 WMEC 243- 008, as applicable.

3.3.1 Reassemble the CPP oil tube assembly into the associated shaft with new seals and fasteners in accordance with TP-3231A, SWBS 245.

3.3.2 Reinstall the inboard shaft coupling.

3.4 Final shaft coupling alignment check. The Contractor shall perform the bore and face alignment check between the reduction gear output flange and shaft coupling as follows and submit a CFR:

• Angular (face-to-face) readings in 4 positions at 90° intervals;

• Parallel (coupling OD-to-coupling OD) readings in 12 positions at 30° intervals.

3.5 Operational test, post repairs. After completion of work, the Contractor shall witness an operational test (by Coast Guard personnel) of the shafting system, for a minimum of 4 hours, to prove satisfactory operating condition. Submit a CFR.

4. NOTES

4.1 Definitions.

4.1.1 The propeller shaft consists of two shafts (tail and line/forward) connected by a hydraulic coupling.

The tail shaft is approximately 25' long and weighs about 7,500 pounds.

14 (Rev-0)

24360_0616_210 REC_24360_210_210’ WMEC ‘A’ Class (ALL) (0716)

S19_0010_24360_JKT_0319_618

WORK ITEM 2: Propulsion Shaft Seal (Starboard) Assembly, Inspect And Repair Or Renew

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to remove the stern tube seal assembly for the starboard propulsion shaft to facilitate CPP oil tube repairs. The stern tube seal assembly consists of both mechanical and inflatable components.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

N Overhaul kit NSN: 5330-01-527-1036

PN: 210A-JCL001228001B

1 ea. 1,500.00

Y **Seal Assy NSN: 2040-01-350-5468

PN: MX9 US-71736

1 ea. 12,000.00

N **Seal, Seat Assy NSN: 2010-01-361-7722

PN: H48626A03

1 ea. 600.00

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

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 618 WMEC 243-001, Rev E, Arrangement and Details John Crane Type

Stern Tube System Coast Guard Drawing 618 WMEC 243-002, Rev H, Arrangement & Details of Piping &

Hydraulics Coast Guard Drawing 618 WMEC 243-005, Rev C, Piping Mods for Water Lubricated Stern

Tube Seal Coast Guard Drawing 618 WMEC 243-051, Rev -, John Crane Seal Coast Guard Drawing 618 WMEC 243-008, Rev A, Shafting Arrangement & Details

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3231A, Feb 2012, Manufacturer’s Instruction Book-

SWBS Group(s) 242-245, Chapter 243, Section B, Stern Tube Seal, MX9, US-71736 (S/A 210R-A-021)

15 (Rev-0)

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph:

• 3.2.2 Inspection

3.1.2 Tech Rep. The Contractor shall provide the services of a qualified Tech Rep, who is familiar with the John Crane type MX9 shaft seal system/equipment, to do the following on site:

• Advise on manufacturer's proprietary information pertinent to the system.

• Assist with proper installation and repair methods.

• Ensure compliance with manufacturer's procedures and standards during disassembly, inspection, and reassembly of the system.

• Attend the sea trial and assist with final adjustment.

3.1.2.2 Ensure that the Tech Rep has a resume of demonstrated experience with the system/equipment stated above.

3.1.2.3 Submit a copy of the Tech Rep’s résumé and a list of references to the COR at the Arrival Conference.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

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

• Deck plating and framing

• Shelves/supply storage

• Safety grating

• Propulsion shaft

• Cooling water piping

• Air line.

3.2 Inspection and repair requirements. The Contractor shall accomplish the below-specified tasks for the stbd stern tube seal assembly, in accordance with TP 3231 and all applicable sections therein, and using

16 (Rev-0)

Coast Guard drawings 618 WMEC 243-001, 618 WMEC 243-002, 618 WMEC 243-005, 618 WMEC 243-051 and 618 WMEC 243-008 as guidance:

3.2.1 Disassembly and removal. Disassemble and remove the seal assembly, which consists of following major components, in accordance with TP 3231, Subsection 4.4 (Seal Overhaul):

• Mounting ring

• Inflatable seal

• Bellows assembly

• Face insert and sealing strip

• Seat and O-rings

• Compression adapters, rods, and nuts

• Drive ring

• Splash guard

3.2.2 Inspection. After removal of seal components, clean and visually inspect the shaft sleeve surfaces, and the removed seal components for wear, defects and deterioration. Visually inspect the shaft seal mounting faces (including bulkhead mounting flange) and exposed adjacent surfaces for evidence of corrosion or deterioration. Submit a CIR, including recommended repairs, if any.

3.2.3 Reassembly and reinstallation. Upon completion of all authorized repairs, if any, accomplish the following:

3.2.3.1 Reassemble the seal components, using the Government-furnished seal kit, in accordance with TP 3231, Subsection 8-5 (Site Preparation), 8-6 (Tool and Materials Required), 8-7 (Installation Instructions).

3.2.3.2 Re-machine the seal seats, in accordance with TP 3231, Subsection 6.5.

3.2.3.3 Provide and install new mounting gasket as specified in TP 3231, Section 1.

3.2.3.4 If a Change Request is released and approved by the KO, build-up/repair the shaft seal bulkhead mounting flange using a commercially available metallic polymer (e.g. Belzona or equivalent).

3.2.4 Setting of seal compression. Set the stern tube seal compression during the installation, using TP 3231, Subsection 6.2 (Setting Seal Compression) as a guide.

3.2.5 Alignment of seat. Align each seat to run true with its associated shaft, as shown on TP 3231, Figure 6.2, and as follows:

• Attach a dial indicator so as to indicate either the face of the seat, aft side of the face carrier, or the flat side of the forward main clamp ring near the butt joint.

NOTE

This will indicate relative misalignment of the seat in relation to the stationary face insert as the shaft rotates.

• Engage turning gear to rotate the shaft.

• Adjust the alignment bolts and drive bolts to have a total indicator reading of 0.002" while the shaft is rotating. Take readings for three complete revolutions of the shaft. Submit a CFR.

17 (Rev-0)

• Once alignment is complete, lock the alignment bolts with their locking nuts while the shaft is rotating and the indicator is still installed. Recheck alignment after locking. Submit a CFR.

• Disengage turning gear and install splash guard onto the face carrier.

3.2.6 Inflatable seal air test. Conduct the inflatable seal pressure drop test as follows:

• Operate the inflatable seal and increase pressure to 45 PSI.

• Visually inspect to ensure all pipe joints are tight.

• With seal inflated to 45 PSI, shut off all supply valves, and monitor air leakage. Ensure that pressure does not drop more than 3 PSI in 15 minutes. Correct any discrepancy noted. Submit a CFR.

WARNING

Do not rotate shaft while testing inflatable seal!

3.2.7 Inflatable seal water leakage test. After the vessel is waterborne conduct the inflatable seal water leakage test as follows:

• Operate inflatable shaft at normal pressure in accordance with manufacturer's instructions.

• Slowly open the seal drain valve and drain the seal cavity.

• Once seal cavity is drained, measure the seal leakage; which shall not exceed one pint per minute. Take corrective action if the leakage exceeds one pint per minute. Submit a CFR.

• Align the seal water flush lines for normal operation.

3.3 Stern tube seal change-out. The Contractor shall be aware that the Government reserves the right to furnish a new stern tube seal for installation in-place of the one removed at no additional cost. When the Government exercises this right, the Contractor shall turn over the removed stern tube seal(s) to the Coast Guard Property Administrator as a MTI item.

3.4 Pipe flushing. After all authorized work is completed the Contractor shall accomplish the following:

WARNING

Do not drain any fluids, including fresh water, into any space, bilge, or exterior location.

3.4.1 Flush all new and disturbed piping with clean fresh water until all debris is removed but not longer than five minutes. Ensure flushing fluid is directed to move scale and foreign debris away from installed machinery to prevent possible damage upon operational testing. Submit a CFR documenting date and time of flushing process and level of pipe cleanliness.

3.4.2 Dispose of flushing fluid in accordance with all applicable Federal, state, and local regulations.

3.5 Operational test, post repairs. After completion of work and in the presence of the Coast Guard Inspector, the Contractor shall thoroughly test and prove stern tube seal assemblies to be in satisfactory operating condition. Submit a CFR. Inspect and correct any water leaks, abnormal noise, and any binding caused by stern tube seals in normal shaft operation.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

18 (Rev-0)

4. NOTES

This section is not applicable to this work item.

19 (Rev-0)

24510_0518_210_270 REC_24510_210_270_210’ WMEC ‘A’ Class (ALL) (0518)

WORK ITEM 3: Controllable Pitch Propeller (CPP) System, Inspect and Service

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect and service the starboard Controllable Pitch Propeller (CPP) system.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST

($/UNIT)

Y **Hub Assembly (L/H) NSN: 2010-01-143-5217 1 ea. 87,439.00 N **Hub Seal Kit NSN: 2010-01-602-8461 1 ea. 6,524.50 Y **Starboard Propeller

Blades (L/H) NSN: 2010-00-906-6010 1 set 33,090.26

N **Propeller Blade Bolts NSN: 5306-01-201-0438 24 ea. 1,900.02 N **Propeller Blade Bolt

Washers NSN: 5306-01-517-0914 24 ea. 278.02

N Seal for Prop Blade NSN: 5330-01-043-9659 P/N: 13369-A

4 ea. 1,155.00

N **Servo Box seal kit (NOTE: Parts may require machining for proper fit.)

NSN: 5330-01-476-2026

1 ea. 850.00

N Shaft Line Seal Kit NSN: 5330-01-172-1829

P/N: 9891-LUP

1 ea. 800.00

N Hub Change-out Kit NSN: 2010-01-630-1155 1 ea. 6,500.00 **New or refurbished equipment that the Government may provide for installation in place of existing equipment.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 618 WMEC 243-002, Rev H, Arrangement & Details of Piping &

Hydraulics Coast Guard Drawing 618 WMEC 243-050, Rev-, Hub Oil Tank 10 Gal. Cap.

Coast Guard Drawing 618 WMEC 245-052, Rev -, Propeller Hub Double Crank

20 (Rev-0)

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3231A, Sept 2014, SWBS 245, Section A, Controllable

Pitch Propeller Double Crank, Liaaen Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2014, Auxiliary Machine Systems

OTHER REFERENCES

ASTM International (ASTM) D4174, R2015, Standard Practice for Cleaning, Flushing, and

Purification of Petroleum Fluid Hydraulic Systems International Standard Organization (ISO) 4406, 2017, Hydraulic Fluid Power – Fluids – Method for Coding the Level of Contamination by Solid Particles – Third Edition

3. REQUIREMENTS

3.1 General. The Contractor shall accomplish all work specified herein for the stbd CPP system under the supervision of the Tech Rep, using the Coast Guard drawings referenced in Section 2 (References) and

TP 3231.

NOTE

Work specified in this work item should be coordinated with work item “Starboard Controllable Pitch Propeller Oil Tube, Repair”

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of a certified Tech Rep, who is familiar with the LIAAEN CPP system, to accomplish the following tasks – on site:

• Provide information, software, and tools pertinent to the equipment/system.

• Assist with proper repair methods, 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 that the Tech Rep is a Certified Representative of LIAAEN.

3.1.2.2 Submit the Tech Rep’s name and resume to the COR at the Arrival Conference.

3.1.3 Protective measures, general. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

21 (Rev-0)

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.

NOTE

Be aware that plastic bags may be used only when arrangement or configuration prevents the use of the other sealing methods specified above.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.1.5 Personnel and equipment safety. The Contractor shall ensure that only personnel experienced with the existing CPP system may take part in the removal and reinstallation of the hub, if required.

3.1.6 Hydraulic fluid sampling and testing. Prior to and immediately following the work herein, the Contractor shall sample and test the system hydraulic fluid in accordance with SFLC Std Spec 5000, Appendix C, Paragraph C2.1 (Fluids).

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.1.7 Operational test, initial. Prior to commencement of work, the Contractor shall 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. Submit a CFR.

3.1.8 Pitch checks. Prior to commencement of work, the Contractor shall check pitch of blades against indicated pitch scale in accordance with TP 3231 to ensure synchronization. Check the time for pitch to advance from zero to full pitch ahead and full pitch astern. Submit a CFR.

NOTE

Seals must be water-lubricated during pitch checks.

3.1.9 System fluid drainage and disposal. The Contractor shall drain all hydraulic oil from the stbd CPP system (approximately 200 gallons) into a suitable container; dispose of removed fluids in accordance with all applicable Federal, state and local regulations. Prior to draining, the Contractor shall verify with the Coast Guard Inspector that the oil is to be disposed of, and not reused. If a Change Request is released and approved by the KO to reuse or further test the removed oil, the Contractor shall ensure all hoses and containers used for removal and storage are clean and free from dirt, contaminants and moisture prior to use. Submit a CFR stipulating cleanliness. (See Section 4.)

3.2 Maintenance requirements. The Contractor shall accomplish the following for the complete stbd CPP system.

3.2.1 Propeller hub. The Contractor shall accomplish the following for the stbd propeller hub:

3.2.1.1 Removal. Remove the stbd propeller hub using TP 3231 as guidance.

22 (Rev-0)

3.2.1.2 Hub installation. Following all authorized repairs, re-install the stbd hub assembly, using Government-furnished reinstallation kit.

3.2.1.3 Government’s right for changing out CPP hub. The Contractor shall be aware that the Government reserves the right to furnish a new CPP hub for installation in place of the existing CPP hub.

If the Government exercises this right, the Contractor shall return the removed CPP hub to the Coast Guard PA as an MTI item.

3.2.2 System flushing. After completion of all authorized system work, flush the stbd CPP hydraulic system using the system's operating fluid in accordance with the requirements specified in Section 9 (Flushing Program) of ASTM D4174. Contractor shall provide the COR with a detailed plan for flushing via CFR and notify the COR at least 24 hours prior to beginning flushing operation.

3.2.2.1 Continue flushing until the fluid entering temporary filters reaches the minimum cleanliness standard specified by the system manufacturer.

NOTE

In the absence of manufacturer’s specifications, hydraulic fluid with a particulate count of -/18/15 or better (per ISO 4406) and a water content no greater than 500 ppm (0.05% by volume) is acceptable.

3.2.2.2 Submit a detailed report to the COR within 24 hours. Report shall include:

• Method used to obtain the particulate contamination reading.

• Method used to determine particle size.

• Final contamination level readings.

3.2.2.3 Drain and retain the flushing fluid for reuse (see 3.2.8 (System refilling)).

3.2.2.4 After flushing, remove and dispose of temporary filters and mesh screens. Renew all system hydraulic filters.

WARNING!

Do not operate the system hydraulic pumps, motors and other components while filled with flushing fluid.

3.2.3 System refilling. Refill the stbd controllable pitch propeller system with 200 gallons of the same oil used for the system flushing, filtered through a nonbypass type, 10 micron absolute filter while refilling.

Ensure all hoses and containers used are clean and free from dirt, contaminants and moisture prior to use.

Submit a CFR stipulating cleanliness.

3.2.4 Pressure test. The Contractor shall perform a pressure test of the stbd CPP system per manufacturer instructions. Repair all leaks. Submit CFR.

3.3 Positioning and control adjustments. The Contractor shall make all necessary positioning and control adjustments in accordance with TP 3231. Submit CFR.

Coast Guard personnel will operate all shipboard machinery and equipment.

23 (Rev-0)

3.4 Operational test, post repairs. After completion of work, the Contractor shall thoroughly test, in the presence of the Coast Guard Inspector and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition and then repeat the requirements of paragraph 3.1.9 (Pitch checks) while the vessel is still in drydock. Repair all defects.

Submit a CFR.

3.5 The Contractor shall accomplish the following tests and inspections, and submit a CFR:

3.5.1 Hydraulic filters and strainers. Make a check of differential pressure indicators on the filters and strainers for clogged conditions. When the discharge filter differential pressure gauge reads in excess of 50 psid, clean the filtering element and recheck. When the suction filter telltale indicator enters the red zone, clean the element and recheck. Both filters allow changeover to alternate filtering elements without interrupting system operation.

3.5.2 Hydraulic oil temperature. Check hydraulic oil temperature range during operation of the CPP system; should be between 105°F and 135°F. This reading is taken from the thermometer at the inlet side of the oil cooler.

3.5.3 Oil Sump Tank. Check and record sump tank level.

3.5.4 Air in the system. Check sight gauge on head tank for indication of air. Oil should be clear. If there is air in the system, oil will be clouded and frothy.

3.5.5 Actuating Unit Seal. Check sight glass in connection piping from the actuating unit. Ensure a small oil flow through the unit housing seal to relieve the pressure on the oil retainer ring. High oil flow indicates the pressure on the retainer ring is too high.

3.5.6. Sump Tank Oil Sample. Extract one pint of oil from stbd CPP return line. Test samples for water and other impurities.

3.5.7. Pitch Change Rate. Measure and record time for blades to…