Statement_of_Work_-_USCGC_ISAAC_MAYO_FY19_DOCKSIDE_DRY_DOCK_-_70Z080-19-Q-P45E3100.pdf

USCGC ISAAC MAYO (WPC 1112)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2019

Developed By: Kent W Ross

(Rev-0, 8 April 2019)

USCGC ISAAC MAYO (WPC-1112) DOCKSIDE 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 .......................................................................................... viii Principal Characteristics ............................................................................................................................... ix General Requirements WORK ITEM 1: Propulsion Shafting System, Inspect and Repair (DD1) WORK ITEM 2: Rudder Assemblies, Inspect and Repair WORK ITEM 3: Stabilizing Fins, Inspect and Repair WORK ITEM 4: Bow Thruster Propeller and Tunnel, Inspect and Repair WORK ITEM 5: Impressed Current Cathodic Protection (ICCP) and Anti-Fouling System, Inspect and

Maintain

[Type here] 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 Drawing 154 WPC 161-301, Rev B, Skegs and Stern Tubes Support Structures

Coast Guard Drawing 154 WPC 243-201, Rev A, Main Propulsion Shafting A&D

Coast Guard Drawing 154 WPC 204-301, Rev E, Equipment Removal Plan

Coast Guard Drawing 154 WPC 245-304, Rev -, Propeller Plans and Data Six Blade Propeller

Coast Guard Drawing 154 WPC 561-202, Rev -, Steering Arrangement & Details

Coast Guard Drawing 154 WPC 562-201, Rev A, Rudder Details

Coast Guard Drawing 154 WPC 562-202, Rev B, Rudder Arrangement & Details

Coast Guard Drawing 154 WPC 556-202, Rev C, Fin Stabilizer Hydraulic System A&D

Coast Guard Drawing 154 WPC 556-302, Rev -, Fin Stabilizer Hydraulic System Diagram

Coast Guard Drawing 154 WPC 565-201, Rev -, Fin Stabilizer System A&D

Coast Guard Drawing 154 WPC 565-301, Rev -, Fin Stabilizer Control System

Coast Guard Drawing 154 WPC 565-302, Rev B, Fin Stabilizer Control System COED

Coast Guard Drawing 154 WPC 568-201, Rev A, Bow Thruster System A&D

Coast Guard Drawing 154 WPC 633-301, Rev B, Cathodic Protection System

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 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

Coast Guard Technical Publications (TP) 6632, Reduction Gear – Model ZF 280-1

Coast Guard Technical Publications (TP) 8081, Stern Tube Seal with Emergency Packing Gland – Type

PSE, Model H76214 with Emergency Packing Glad Model 78479

Coast Guard Technical Publication (TP) 8913, Sep 2014, Technical Repair Standard For Propellers v (Rev-0)

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

Requirements

Coast Guard Technical Publication (TP) 8153, Type EL + IS Rudderstock seal Model H 78525-01, Installation, Operation and Maintenance Manual

Coast Guard Technical Publication (TP) 8010, 16 JUL 2010, Fin Stabilizer System HPU20 Hydraulic

Power Unit Quantum QC-1500 Operational and Maintenance Manual

Coast Guard Technical Publication (TP) 8911A, 30 APR 2016, Technical Repair Standard, Depot Level, For Use On Fast Response Cutter (FRC-B), Sentinel Class, Fin Stabilizer System Quantum Model

QC-1500 Overhaul Repair Procedures, Vol 1 & 2

Coast Guard Technical Publication (TP) 8096, SWBS 568, Sep 2011, Seawater Service Pump Bow

Thruster Schottel Transverse Thruster 60 LK and Racci Operator Panel and Motor Drive Installation, Service, and Opertation Manual

Coast Guard Technical Publication (TP) 8001, Sep 2018, Cathodic Protection System

OTHER REFERENCES

American Bureau of Shipbuilding (ABS) Rules for Survey After Construction, Part 7

ASTM International (ASTM) D5363, 2008; Standard Specification for Anaerobic Single-Component

Adhesives (An)

MIL-PRF-16173, Sep 2006, Corrosion Prevention Compound, Solvent Cut-Back, Cold-Application

MIL-S-45180, 1998; Sealing Compound, Gasket, Hydrocarbon Fluid and Water Resistant

MIL-C-16173, Jan 1993, Corrosive Preventative Compound, Solvent Cutback, Cold Application 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)

1 Y **Propeller Shaft NSN: 2010-01-605-7516 2 103,000

Y **LH Propeller NSN: 2010-01-628-0276

PN: 531915

1 190,000

Y **RH Propeller NSN: 2010-01-627-9761

531914

1 190,000

N **Stave Kit

(each kit contains 8 reg.

Romor staves, 2 rubber locking staves, 2 Romor staves w/keeper slot)

NSN: 3120-01-605-7400

P/N: 80920203000003

4 2430

N **FWD Bearing Split

External Retaining Ring

Kit

(each kit contains 1ea retaining ring, 10ea socket head cap screws)

NSN: 3120-01-605-7345

P/N: 80920203000004

2 1970

N **AFT Bearing Split

External Retaining Ring

Kit

(each kit contains 1ea retaining ring, 10ea socket head cap screws)

NSN: 3120-01-605-7510

P/N: 80920203000005

2 2575

N **Kit, Installation Part-

Replacement

(see note 4.1 for kit contents)

NSN: 2010-01-629-4693

P/N: 950700 2 1900

Y *Kit, Propeller –

Removal/Installation

Tools and Equipment

(see note 4.2 for kit contents)

NSN: 2010-01-632-2198/

P/N: 999120

1 22,970

N Shaft Seal Overhaul Kit

(see table 7-5 of TP-8081, pg 7-9, “Service Kit C”)

NSN: 5330-01-618-5276

P/N: H76214-8

2 4896

2 Y **Rudder NSN: 2040-01-618-2412 2 19,350

N Shaft Seal Overhaul Kit

(Service Kit A from TP-

8153, pg 7-5, Table 7-2)

NSN: 5330-01-595-4647

PN: H785252-01-6

2 9722

N Shaft Seal Overhaul Kit

(Service Kit B from TP-

8153, pg 7-5, Table 7-3)

NSN: 5330- 01-596-7760

PN: H78525-01-7

2 6,170

N Locknut

PC5 154WPC 562-002

NSN: 5310-33-201-6431

PN: KM32

4 100.00

N Lock Washer

PC6 154WPC 562-002

NSN: 5310-33-201-5247

PN: MB 32

2 150.00

N Upper Roller Bearing NSN: 3110-01-597-3537 2 502.11 vii (Rev-0)

PC7 154WPC 562-002 PN: 23032 CC/C2W33

N Oil Seal

PC8 154WPC 562-002

NSN: 5330-01-618-5091

PN: CR70028 CRWH1R

2 60.00

N Lower Bearing

PC9 154WPC 562-002

NSN: 3120-01-631-4104 2 $1,162

3 Y **Fin Blade NSN: 2040-01-598-8181

PN: 601-15-020S02-00-00-A

2 22,254.38

4 N **Set of bevel gears

19:28, Mfr: Schottel

NSN: 3020-01-618-1133

PN: 1088301

1st. 10,378.13

5 N **Anode, Corrosion, Elliptical

NSN: 5340-99-400-2561

PN: PPEC1202-MM50

2 ea. 1,900.00

N **Silver/Silver Chloride

Reference Electrode Cell

NSN: 6630-99-553-5405

PN: PPR100019

2 ea. 1,625.00

*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 viii (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 3.2.6.5

(Inspection report particulars)):

Work

Item Title

1 Propulsion Shafting System, Inspect and Repair (DD1)

2 Rudder Assemblies, Inspect and Repair

3 Stabilizing Fins, Inspect and Repair

4 Bow Thruster Propeller and Tunnel, Inspect and Repair

5 Impressed Current Cathodic Protection (ICCP) and Anti-Fouling System, Inspect and Maintain ix (Rev-0)

PRINCIPAL CHARACTERISTICS

154' WPC (SENTINEL CLASS)

PHYSICAL

Anchor ROCNA, anchor, 150 KG/ 331 LB, Stainless Steel

Bulkheads (7), Watertight Bulkheads located below the Main Deck

Displacement, delivery, light ship 302 Metric Tons

Draft, full load 2.58 Meters (8.46 Feet)

End of service life displacement 353 Metric Tons

Framing Longitudinal

Full load displacement 353 Metric Tons

Height of highest projection 17.22 Meters (56.5 Feet)

Length overall (loa) 46.80 Meters (153.5 Feet)

Maximum beam 7.75 Meters (25.43 Feet)

Minimum operating displacement 314 Metric Tons

Waterline length (lwl) 44.35 Meters (145.5 Feet)

HULL

Hull/main weatherdeck material AH-36 Steel

Superstructure 5456-H1111 Aluminum

MACHINERY

Bow thruster Schottel STT 60 LK

Diameter of propeller 1900 mm

Emergency service generator (edg) Cummins 6BTA5.9-DM Diesel with Stanford 93KW Generator

Fin stabilizer (2), Quantum QC1500

Main propulsion (2), MTU 20V4000 M93L, Sequential Turbo-Charged Diesels

Number of blades 6

Number of propellers (2) Michigan Wheel Marine

Propeller pitch capability Fixed

Propulsion shafts (2), Electralloy Nitronic 50HS (9430mm) Shafts

Reduction gears (2), ZF 23560C/D Series

Rudders (2), 316L Stainless Steel

Shaft rotations per minute 478

Shaft(s) bearing, aft (2), Duramax Bearings

Shaft(s) bearing, intermediate (2), Duramax Bearings

Shaft(s) diameter 8 Inches

Shaft(s) Seal (2), Wartsila Mechanical Seals

Ship service generators (2), Cummins QSM11-DM Diesels with Stanford 317KW Generator

TANK CAPACITIES AT 95% LIQUID LOAD (22,958 TOTAL GALLONS)

Fresh water tank, port (3-38-2-w) 708 gal

Fresh water tank, stbd (3-38-1-w) 756 gal

Fuel oil edg day tank (1-10-1-f) 134 gal

Fuel oil gen. ovrflw tnk, ctr. (3-40-0-f) 1,159 gal

Fuel oil overflow tank, center (3-10-0-f)

616 gal

Fuel oil service tank, #1 port (3-17-2-f) 1,750 gal

Fuel oil service tank, #1 stbd (3-17-1-f) 1,750 gal

Fuel oil service tank, #2 port (3-40-2-f) 890 gal

Fuel oil service tank, #2 stbd (3-40-1-f) 890 gal

Fuel oil storage tank, #1 center (3-11-0- 5,040 gal x (Rev-0) f)

Fuel oil storage tank, #2 center (3-23-0-f)

5,350 gal

TANK CAPACITIES AT 95% LIQUID LOAD (22,958 TOTAL GALLONS)

Grey water tank, (3-17-0-w) 2,668 gal.

Lube oil storage tank, (2-35-2-f) 146 gal.

Oily water tank, (3-34-1-w) 336 gal.

Sewage collection tank, (3-6-0-w) 429 gal.

Waste oil tank, (3-34-2-f) 336 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 Contractor-provided fire watch personnel. The Contractor shall provide fire watch personnel and equipment.

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

(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, 3 (Rev-0) 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)

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

5 (Rev-0)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

VESSEL NAME HULL #

WORK ITEM

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

6 (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 /

7 (Rev-0)

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)

11 (Rev-0)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

VESSEL NAME HULL #

WORK ITEM

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

12 (Rev-0)

24300_JLW_0219_154

WORK ITEM 1: Propulsion Shafting System, Inspect and Repair (DD1)

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform:

propeller visual inspections (3.2.1) propeller 3-D Scans (3.2.2) shaft bearing visual inspections and measurements (3.2.3) shaft seals expendables renewal (3.2.4) stern-tube zinc anode renewal (3.2.3.3).

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PART NO. QTY COST

($/UNIT)

Y **Propeller Shaft NSN: 2010-01-605-7516 2 103,000

Y **LH Propeller NSN: 2010-01-628-0276

PN: 531915

1 190,000

Y **RH Propeller NSN: 2010-01-627-9761

531914

1 190,000

N **Stave Kit

(each kit contains 8 reg. Romor staves, 2 rubber locking staves, 2 Romor staves w/keeper slot)

NSN: 3120-01-605-7400

P/N: 80920203000003

4 2430

N **FWD Bearing Split External Retaining Ring Kit

(each kit contains 1ea retaining ring, 10ea socket head cap screws)

NSN: 3120-01-605-7345

P/N: 80920203000004

2 1970

N **AFT Bearing Split External Retaining Ring Kit

(each kit contains 1ea retaining ring, 10ea socket head cap screws)

NSN: 3120-01-605-7510

P/N: 80920203000005

2 2575

N **Kit, Installation Part-Replacement

(see note 4.1 for kit contents)

NSN: 2010-01-629-4693

P/N: 950700 2 1900

Y *Kit, Propeller – Removal/Installation Tools and

Equipment

(see note 4.2 for kit contents)

NSN: 2010-01-632-2198/

P/N: 999120 1 22,970

N Shaft Seal Overhaul Kit

(see table 7-5 of TP-8081, pg 7-9, “Service Kit C”)

NSN: 5330-01-618-5276

P/N: H76214-8

2 4896

*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.

13 (Rev-0)

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 154 WPC 161-301, Rev B, Skegs and Stern Tubes Support Structures

Coast Guard Drawing 154 WPC 243-201, Rev A, Main Propulsion Shafting A&D

Coast Guard Drawing 154 WPC 204-301, Rev E, Equipment Removal Plan

Coast Guard Drawing 154 WPC 245-304, Rev -, Propeller Plans and Data Six Blade Propeller

COAST GUARD PUBLICATIONS

Coast Guard Technical Publications (TP) 6632, Reduction Gear – Model ZF 280-1

Coast Guard Technical Publications (TP) 8081, Stern Tube Seal with Emergency Packing Gland

– Type PSE, Model H76214 with Emergency Packing Glad Model 78479

Coast Guard Technical Publication (TP) 8913, Sep 2014, Technical Repair Standard For

Propellers

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

OTHER REFERENCES

American Bureau of Shipbuilding (ABS) Rules for Survey After Construction, Part 7

3. REQUIREMENTS

3.1 General.

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

“3.2.5 Submit report.”

NOTE

Similar qualifications to those specified below in paragraph 3.1.2 are specified in the work item titled to those applicable “Hull Plating, Inspect (DD1)”

3.1.2 Qualifications for performing Three-dimensional (3-D) Coordinate Measuring Machine (CMM) requirements. If requested by the KO, submit evidence that one or more on-site technicians has successfully operated the 3-D CMM being used in this contract during at least one prior similar contract and has prior experience performing all tasks specified under the paragraph titled “3-D Scan” below.

3.1.3 Qualifications for performing shaft seal maintenance and repairs. If requested by the KO, submit evidence that one or more on-site technicians has successfully overhauled, renewed, or repaired the shaft face seal, or a similar model of face seal manufactured by the same company, and further describe all knowledge, experience, and training contributing to being qualified to disassemble/reassemble the shaft face seal. 3.2.4, 3.3.4

3.1.4 Qualifications for performing propulsion system alignment. . If requested by the KO, submit evidence that one or more on-site technicians has successfully performed alignment measurements using and optical or laser system.3.6

14 (Rev-0)

3.1.5 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.

3.1.6 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 following:

Propellers

Rudders

Shaft couplings

Shaft seals

Stern tube access plates

Rope guards

3.2 Mandatory recurring maintenance. Using the references listed under Section 2 as guidance, the

Contractor shall accomplish the following:

3.2.1 Propeller visual inspections.

3.2.1.1 Ensure the propellers are thoroughly cleaned to a bright metal finish to facilitate visual inspections.

3.2.1.2 Visually inspect each propeller for all discrepancies such as:

blade bends, deformation, torn material, and/or missing material;

out-of-tolerance discontinuities per ABS Part 7, Appendix Section 10, Table 1;

other operationally-adverse abnormalities.

3.2.2 New or re-used propellers 3-dimensional (3-D) scans.

3.2.2.1 Using portable 3-dimensional coordinate measuring machine (CMM) technology, accurate to

0.001”, scan all visible hub and blade surfaces of each re-used (cleaned) or new Government-furnished propeller.

NOTE

No propeller failing visual inspection shall be scanned.

3.2.2.2 Using the point cloud data collected, develop CAD models of the propellers’ as-scanned conditions.

3.2.2.3. Propeller scan comparison versus design. Using Coast Guard Drawing 154 WPC 245-304 as guidance, develop a propeller CAD model based on the drawing. Using the obtained propeller scan and the design CAD model, digitally inspect the propeller for all applicable ISO 484/2, Class I measurements.

Provide a report within one week of activation of the Change Request authorizing this task herein. The report shall indicate all (if any) out-of-tolerance measurements per ISO 484/2, Class I. Each out-of-tolerance measurement shall be identified (type, location and value) and provided with a comparison

15 (Rev-0) against the allowable parameters. All out-of-tolerance measurements shall be shown in a tabulated format accompanied with a model image showing the measurements.

3.2.2.4 For each propeller, via editable/unprotected compact disc (CD), submit to the USCG all point cloud data and subsequent CAD models. Label the CDs, serialized by propeller serial number and inspection date. Within two weeks of scan completion, all CDs shall be sent to the following address:

United States Coast Guard

SFLC-Patrol Boat Product Line

ATTN: SES Chief

300 East Main Street

Norfolk, VA 23510

3.2.2.5 Renew each Government-furnished propeller zinc plate and associated fasteners.

3.2.3 Shaft and stern tube cleaning, bearing visual inspections and measurements.

3.2.3.1 Remove growth and fouling from all accessible all stern tube and shaft areas prior to performing inspections. Then, with the rope guards and all stern tube access covers removed, visually inspect the shaft bearing staves for excessive and/or abnormal wear in the propeller and forward bearings.

3.2.3.2 Measure, to the greatest extent practicable, and record the clearance between the bearings and shafts, comparing obtained values to those shown in Coast Guard Drawing 154 WPC 243-201, General

Notes 20 and 21.

NOTE

In areas where bearing-shaft diametrical clearances are greater than half the figures shown on Coast Guard Drawing 154 WPC 243-201, General Notes 20 and 21, as applicable, the worn staves shall be renewed.

3.2.3.3 Following propulsion system inspections and all authorized repairs (if any), renew all stern tube access cover anodes (including forward access anodes as shown on Coast Guard Drawing 161-301, Sheet

4, Section 27-F). Reinstall the rope guards and stern tube access covers.

3.2.4 Shaft seals expendables renewal. Using TP 8081 as guidance, renew the expendable shaft seal components using the Government-furnished shaft seal service kits (Kit C). Ensure the non-expendable seal pieces are thoroughly cleaned and inspected prior to renewing the expendable pieces.

3.2.5 Submit report. For each inspection required under 3.2 and subparagraphs, Submit a CIR detailing all findings and proposed action(s), if any, for each inspection, for concurrence.

3.3 Conditional inspection and repair task requirements. If a Change Request has been authorized and released by the KO and specifies growth repairs to correct discrepancies, the Contractor shall perform the work specified in the Change Request and conform to the following requirements, as applicable.

3.3.1 Removed shaft inspection. Using Coast Guard Drawings 154 WPC 204-301, 154 WPC 243-201, 154 WPC 245-301, TP 8081 and TP 8913 as guidance, accomplish the following:

3.3.1.1 Remove the propulsion shaft and associated interferences.

16 (Rev-0)

3.3.1.2 Mount the removed shaft in a lathe, supported by lathe centers or rollers within 24 inches of each end, only, and remove any minor memory set in shaft by spinning in lathe for 2hrs at a slow rotation.

3.3.1.3 After two hours of rotation, conduct propulsion shaft run-out measurements via dial indicator to determine shaft straightness. Take measurements at the small and large ends of the propeller taper, the fore and aft ends of each bearing position, three equally spaced locations between the bearings, and four equally spaced locations forward of the forward bearing. Mark the position of the maximum run-out on the periphery of the shaft for each measurement taken. TIRs are limited to 0.005” in the shaft taper, .008” in bearing areas and 0.015” in all remaining locations.

3.3.2 Propeller renewal. Using Coast Guard Drawings 154 WPC 204-301, 154 WPC 245-304, and TP

8913 as guidance, renew the propeller with the Government-furnished propeller. Perform the 3-D scan on the new propeller after installation and submit reports as specified above in the paragraph titled “New or re-used propellers 3-dimensional (3-D) scans”.

3.3.3 Propulsion shaft bearing stave renewal.

3.3.3.1 Forward bearing stave renewal. Using the procedure per Coast Guard Drawing 154 WPC 243-

201, Sheet 1, Section B, renew worn bearing staves in the forward bearing.

3.3.3.2 Propeller bearing stave renewal. Using the procedure per Coast Guard Drawing 154 WPC 243-

201, Sheet 1, Section B, renew worn bearing staves in the propeller bearing.

3.3.4 Shaft seal renewal. Using TP 8081 as guidance, the Contractor shall renew the shaft seal with the

Government-furnished shaft seal.

3.3.5 Reduction gear to shaft coupling alignment inspection. Using Coast Guard TP 6632 as guidance, with the vessel waterborne and liquid laden for 24 hours, inspect and measure the angular and parallel alignment between the shaft coupling and reduction gear coupling. If necessary, provide recommendations for alignment correction. Submit a CFR.

3.3.6 Shaft line alignment survey. Conduct the alignment check via optical or laser methods; measure and record the vertical and horizontal bearing positions and seal flange position. Make a definitive alignment assessment and provide a report on the alignment condition. If necessary, provide recommendations (movement magnitude/direction) for alignment correction. Submit a CFR.

NOTES

Piano wire may NOT be used unless done in conjunction with either the optical or laser method.

Minimize thermal effects by performing the following late in the evening or before sunrise.

3.4 Government’s option for equipment renewal. The Government reserves the right to furnish new

Government-furnished equipment to be installed in place of existing at no additional cost to the

Government. The Contractor shall turn over the existing equipment to the Coast Guard PA, for final disposition.

3.5 Operational tests – post repairs. During sea trials, the Contractor shall demonstrate proper operation of both propeller shaft systems via sea trials throughout the entire range of running speeds and directions.

17 (Rev-0)

Verify no unusual noise, vibrations, binding, shaft seal anomalies, etc. exist in each propulsion system.

Submit a CFR.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

4. NOTES

4.1 Contents of Government Furnished “Kit, Installation Part-Replacement” See Coast Guard Drawing

154WPC 245-304

QTY

per prop

PC# PN Description Matl Price Ea Price per set

1 3 950733 Anode Zinc Plate Zinc $413.26 $413.26

1 4 950724 Cover Plate 2205 SS $83.54 $83.54

1 5 950726 Retaining Ring 304L SS $180.50 $180.50

1 6 950746 "O" Ring Fwd End FW Cap Buna-N $27.84 $27.84

1 7 950744 "O" Ring Aft End FW Cap Buna-N $27.16 $27.16

4 8 950756 M16 X 2 X 50mm SS SHCS SS $5.70 $22.80

3 9 950755 M10 X 1.5 X 25mm SS SHCS SS $1.46 $4.37

2 10 950714 SS Hex "O" Ring Plug SS $41.54 $83.09

3 11 950738 Lifting Eye Bolt Carbon Steel $60.98 $182.93

6 12 950736 Plug - Lifting Hole NiBrAl $73.72 $442.32

1 13 950748 "O" Ring-Hub Fwd Propeller Buna-N $11.34 $11.34

3 14 950759 Anti Vibration Lock Washer SS $10.76 $32.28

8 15 950757 M6 X 1 X 20mm SS SHCS SS $1.28 $10.26

4.2 Contents of Government Furnished “Kit, Propeller – Removal/Installation Tools and Equipment”

QTY PC# PN Description Matl Price Ea Price per set

1 999130 SPANNER WRENCH

1 950742 SPACER]INSTALLATION

1 999122 HYD. INSTALLATION NUT

1 999124 SKF HYDRAULIC PUMP

15,000 PSI

2 999125 ENERPAC HYDRAULIC

PUMP 10,000 PSI

1 999142 MCDANIEL GAGE

1 999144 HYD.SWIVEL FITTING

1 999146 HYD. STRAIGHT FITTING

2 999148 WASHER]HYD. FITTING

18 (Rev-0)

2 999135 SKF QUICK CONNECTING

NIPPLE

2 999136 SKF QUICK CONNECTING

COUPLING

2 999137 10-FOOT WEAT

HYDRAULIC HOSE

1 999128 INSTRUCTION MANUAL

INST. ROD ] HYD.

INST. NUT(5/8 DIA X 9

19 (Rev-0)

56200_JLW_0219_154

WORK ITEM 2: Rudder Assemblies, Inspect and Repair

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to remove, inspect, and reinstall the port and starboard rudder assemblies.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PART NO. QTY COST

($/UNIT)

Y **Rudder NSN: 2040-01-618-2412 2 19,350

N Shaft Seal Overhaul Kit

(Service Kit A from TP-8153, pg 7-5, Table 7-2)

NSN: 5330-01-595-4647

PN: H785252-01-6

2 9722

N Shaft Seal Overhaul Kit

(Service Kit B from TP-8153, pg 7-5, Table 7-3)

NSN: 5330- 01-596-7760

PN: H78525-01-7

2 6,170

N Locknut

PC5 154WPC 562-002

NSN: 5310-33-201-6431

PN: KM32

4 100.00

N Lock Washer

PC6 154WPC 562-002

NSN: 5310-33-201-5247

PN: MB 32

2 150.00

N Upper Roller Bearing

PC7 154WPC 562-002

NSN: 3110-01-597-3537

PN: 23032 CC/C2W33

2 502.11

N Oil Seal

PC8 154WPC 562-002

NSN: 5330-01-618-5091

PN: CR70028 CRWH1R

2 60.00

N Lower Bearing

PC9 154WPC 562-002

NSN: 3120-01-631-4104 2 $1,162

*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.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 154 WPC 204-301, Rev B, Equipment Removal Plan

Coast Guard Drawing 154 WPC 561-202, Rev -, Steering Arrangement & Details

Coast Guard Drawing 154 WPC 562-201, Rev A, Rudder Details

Coast Guard Drawing 154 WPC 562-202, Rev A, Rudder Arrangement & Details

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 8153, Type EL + IS Rudderstock seal Model H 78525-

01, Installation, Operation and Maintenance Manual

20 (Rev-0)

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

OTHER REFERENCES

ASTM International (ASTM) D5363, 2008; Standard Specification for Anaerobic Single-

Component Adhesives (An)

MIL-PRF-16173, Sep 2006, Corrosion Prevention Compound, Solvent Cut-Back, Cold-

Application

MIL-S-45180, 1998; Sealing Compound, Gasket, Hydrocarbon Fluid and Water Resistant

MIL-C-16173, Jan 1993, Corrosive Preventative Compound, Solvent Cutback, Cold Application

3. REQUIREMENTS

3.1 General.

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

“3.2.4 Submit inspection and test report.”

3.1.2 Qualifications for performing rudder seal maintenance and repairs. If requested by the KO, submit evidence that one or more on-site technicians has successfully overhauled, renewed, or repaired the rudder face seal, or a similar model of face seal manufactured by the same company, and further describe all knowledge, experience, and training contributing to being qualified to disassemble/reassemble the rudder face seal.

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.

3.1.3.1 Protective measures- rudder specific. Provide suitable covering to protect all exposed rudder and vessel components against contamination during the performance of the work specified herein. Ensure that rudder stock/shaft surfaces are supported in a minimum of two locations, at all times, until reinstallation.

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

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.2 Mandatory/recurring tasks. The Contractor shall:

3.2.1 Perform an initial inspection and witness an operational test. Prior to commencement of work, witness Coast Guard personnel perform an operational test of the steering gear and rudder systems to

21 (Rev-0) demonstrate existing operational condition. Ensure the carrier housing is not deflecting while taking readings. Measure and record full port and full starboard rotation angles of both rudders, note all discrepancies. Verify that port and stbd rudder movement is synchronized, that both rudders move in tandem, and both hold the same respective rudder angles while rotating. Prior to disassembly and while the rudder indicator is at zero degrees, mark the tiller arm, steering arm, autopilot potentiometer base and wheel with alignment marks for reinstallation. Measure and record vertical and horizontal movement of the rudder.

NOTE

5 feet of clearance between the bottom of the rudder and the drydock floor is required for rudder removal. Rudder interior surfaces have been coated with a corrosion inhibitor, handle all fluids in accordance with all Federal, state and local regulations. Take care not to damage the installed lower bearings during the removal of the rudder stocks.

3.2.2 Remove, clean, inspect, internally preserve, and test both rudders. Referring to the documents listed in Section 2 as necessary, remove both rudders. Clean and visually inspect all exposed components and surfaces (e.g. rudder stock/shaft and blade surfaces, bearings, bearing housing, seals, and grease passages) for discrepancies (e.g. excessive wear or corrosion, cracked welds, deformation, etc.). Verify rudder stocks are not bent; make note of any evidence that a rudder blade was struck or otherwise hit bottom.

Verify there are no cracked weld joints on rudder blades, bearing housings, and all other associated weldments. Inspect all associated machined surfaces (e.g. rudder stock journals/sleeves, keyways, lower bearing surfaces, etc.) for unusual or excessive wear; measure and record dimensions of those worn areas to the nearest 0.001”.

3.2.2.1 Pressurize rudder voids to 2.5 psig and hold for 10 minutes in accordance with SFLC Std Spec

0740, Appendix C, verify no leaks.

3.2.2.2 Perform a dye penetrant test in accordance with SFLC Std Spec 0740, Appendix C on all rudder stock/nut threads, keys, and keyways; note all discrepancies.

3.2.3 Submit inspection and test report. Submit a CIR to document all noted discrepancies and measurement data taken above; include a description of recommended repairs if appropriate.

3.2.4 Preserve rudder internal surfaces. Preserve rudder internal surfaces by filling all appendage interior surfaces with a rust preventive compound conforming to MIL-PRF-16173, Class II, Grade 3. Drain, collect, and dispose of remaining compound in accordance with all applicable Federal, state, and local regulations. Chase all rudder blade plug female threads prior to reinstalling plugs. Renew drain plugs

(with either stainless steel, Type 316 or Monel). Coat new plugs prior to installation with a sealing and locking compound conforming to ASTM D5363-AN0123 or a flexible joint compound conforming to

MIL-S-45180, Type II.

NOTE

Preservation of rudder blade external surfaces is covered under Work Item

16 U/W Body, Preserve (100%).

3.2.6 Renew components. Using TP 8053 as guidance, renew the expendable pieces of each rudder shaft seal (sea water seal) using Government-furnished seal service kits. Ensure the non-expendable seal pieces are thoroughly cleaned and inspected prior to renewing the expendable pieces. Renew both upper roller bearings and lower sleeve bearings using government furnished property.

22 (Rev-0)

3.2.7 Reinstall rudder assemblies. Upon completion of all inspections and authorized maintenance and repairs, reassemble and reinstall the port and starboard rudder assemblies. Ensure each rudder is installed using original match-marks and is aligned to within plus or minus 1/2 degree of the pilothouse rudder angle indicator.

NOTE

3.3 Sub-paragraphs are describe requirements for performing conditional tasks that may be initiated by change request/modification pending inspections.

3.3 Conditional repair task requirements. If the KO approves a change request that specifies growth repairs to correct discrepancies, the Contractor shall conform to all aforementioned requirements, and the following requirements.

3.3.1 Lower bearing renewal. Pending inspection results lower bearing renewal may be authorized. The

Government reserves the…