IDIQ_Hawaii__presolicitation_sample_task_order_SOW.pdf

NOAA Ship HI’IALAKAI FY15 DOCKSIDE REPAIRS i

STATEMENT OF WORK

FY15 DOCKSIDE REPAIRS

NOAA Ship HI’IALAKAI

Vessel Particulars

Year Built: 1984 Builder: Tacoma Boatbuilding Tacoma, Washington

ABS ID: 8404452

IMO Number: 8835619 Construction: Welded Steel Propulsion: Diesel-Electric Twin Fixed Propellers 800 HP per shaft Bow Thruster: 550 HP Length Overall: 224 Feet Beam: 43 Feet Maximum Draft: 15 Feet 0 Inch Displacement: 1,489 Tons Light Ship

TABLE OF CONTENTS

Appendix A Detailed Statement of Work

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

Basic – Class A Items

101 Ship Ventilation Cleaning 102 Ship Service Diesel Generator (SSDG) Overhauls 103 Replace Generator Room Supply Fans 104 Repair Generator/Propulsion Room Ducting 105 Replace Fire Detection System (FDS) 106 Inspect Ship Service Air Tanks 107 Replace SSDG Resilient mounts 108 Replace Ship Service Compressors 109 Replace Start Air Compressors 110 Piping Repairs CHT and Refrigeration Rooms 111 Protective Coverings and Cleaning 112 Weight Control

Optional – Class B Items

201 Additional Government Requirements

Optional – Class C Items

301 Renew Deck Covering in Main Deck Passageway 302 Renew Deck Covering 2nd Deck Passageway 303 Replace After Steering Escape Hatch 304 Install 220V Panel for Galley Equipment 305 Enlarge Vent to Dive Air Compressor Room 306 Flush Crane Hydraulic System 307 Clean & Inspect MSD Tank 308 Clean & Inspect Sewage Lift Station Tanks 309 Replace Galley Equipment 310 Install Baxter Bolts on Aft Work Deck 311 Replace Reach Rod

Appendix B Specific Contract Work Definitions and Requirements

Appendix C

NOAA Standard Specifications

S0100 Implementation and Conduct of Checkpoints S2906 Arc Welding on Waterborne Vessels S4800-2 Piping Systems, General Requirements S6900 General Requirements for Electrical/Electronic Items 1402 Terrazzo Deck Covering Installation S1904-1 Cleanliness Requirements for Hydraulic Piping Systems S-7003 40,000 Hour Overhaul of Caterpillar D 398 Engines

Appendix D

Technical Publications

No technical publications are provided with the solicitation. All technical publications are available on board the ship and at the Honolulu Port Office or at NOAA Marine Operations Center, Newport Oregon.

Technical Manual HA 235-01, Model D398B Engine Generator Set

Technical Manual HA-556-02; Hydraulic System Modifications Technical Manual HA-593-06 Omnipure 12 MC MSD Dex-O-Tex Products Catalog Application specification – Available from Manufacturer Information data sheets for type 5B5000H Machinery Mount NAVSEA Manual S9073-A2-HBK-010, 5B5000H Machinery Mount

Appendix E

Industry Standards and Public Documents

No Industry Standards or Public Documents are provided with the solicitation. Referenced Industry Standards and Public Documents are:

IEEE Standard 45-1983; Recommended Practice for Electric Installations on Shipboard Code of Federal Regulations Title 46, Subchapter J; Electrical Engineering Steel Structures Painting Council SSPC 10; Near White Metal Blast Cleaning Steel Structures Painting Council SSPC-SP-15; Commercial-Grade Power Tool Cleaning Steel Structures Painting Council SSPC-3; Power Tool Cleaning American Bureau of Shipping, Rules for Building and Classing Steel Vessels

Appendix F

Drawings

512-0000208-2C STALWART Class, Ventilation System HA-807-001 NOAAS HIIALAKAI Booklet of general plans HA-512-5987509 Ventilation Arrangements Zone 310 183-6233564 (Rev. F) Diesel Generator Foundations

Appendix G Government Furnished Material

Item 103 - Two (2) Ventilation Fans Item 107 – Sixty Four (64) Resilient Mounts Item 303 – One (1) Escape Scuttle Item 312 – One (1) Reach Rod Actuator Cable

APPENDIX A

Detailed Statement of Work

Basic – Class A Items

Item No. 101 Title: HVAC Duct Cleaning W/R No. N/A

1 SCOPE

1.1 Objective - Cleaning of all supply and exhaust ducting, fans, chillers, heaters, and that feed all staterooms, the bridge, offices, shops, storerooms, fan rooms, compressor / hydraulic room, labs, lounges, exercise rooms, passageways, laundry room, mess deck and galley.

2 REFERENCE DOCUMENTS

2.1 Appendix B Specific Contract Work Definitions and Requirements

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

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

2.4 Drawings HI-512- HVAC SYSTEM

3 GOVERNMENT FURNISHED MATERIAL (GFM)

3.1 None

4 REQUIREMENTS

4.1 General Requirements

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

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

4.1.3 The HVAC system includes any interior surface of the ships air distribution system for conditioned spaces and/or occupied zones. This includes the entire heating, air-conditioning and ventilation system from the points where the air enters the ship to the points where the air is discharged from the system. For the purpose of this specification, the sections cleaned shall begin at the suction side of the supply fan and end at the terminus is the individual space served. The return air grilles, return air ducts to the air handling unit (AHU), the interior surfaces of the AHU, mixing box, coil compartment, condensate drain pans, humidifiers and dehumidifiers, supply air ducts, fans, fan housing, fan blades, air wash systems, spray eliminators, turning vanes, filters, filter housings, reheat coils, cooling coils, and supply diffusers are all considered part of the HVAC system.

4.2 HVAC System Cleaning Contractor shall meet the following requirements:

4.2.1. Membership: The HVAC system cleaning contractor shall be a certified member of the National Air Duct Cleaners Association (NADCA), or shall maintain membership in a nationally recognized non-profit industry organization dedicated to the cleaning of HVAC systems.

4.2.2 Certification: The HVAC system cleaning contractor shall have a minimum of one (1) Air System Cleaning Specialist (ASCS) certified by NADCA on a full time basis, or shall have staff certified by a nationally recognized certification program and organization dedicated to the cleaning of HVAC systems.

4.2.3 Supervisor Qualifications: A person certified as an ASCS by NADCA, or maintaining an equivalent certification by a nationally recognized program and organization, shall be responsible for the total work herein specified.

4.2.4 Experience: The HVAC system cleaning contractor shall submit records of experience in the field of HVAC system cleaning as requested by the COTR. Bids shall only be considered from firms which are regularly engaged in HVAC system maintenance with an emphasis on HVAC system cleaning and decontamination.

4.2.5 Equipment, Materials and Labor: The HVAC system cleaning contractor shall possess and furnish all necessary equipment, materials and labor to adequately perform the specified services.

4.2.6 The contractor shall assure that its employees have received safety equipment training, medical surveillance programs, individual health protection measures, and manufacturer’s product and material safety data sheets (MSDS) as required for the work by the U.S. Occupational Safety and Health Administration, and as described by this specification. For work performed in countries outside of the U.S.A., contractors should comply with applicable national safety codes and standards.

4.2.7 The contractor shall maintain a copy of all current MSDS documentation and safety certifications at the site at all times, as well as comply with all other site documentation requirements of applicable OSHA programs and this specification

4.2.8 Contractor shall submit to the COTR all Material Safety Data Sheets (MSDS) for all chemical products proposed to be used in the cleaning process.

4.2.9 Licensing: The HVAC system cleaning contractor shall provide proof of maintaining the proper license(s), if any, as required to do work in this state. Contractor shall comply with all Federal, state and local rules, regulations, and licensing requirements.

4.3 HVAC System shall be cleaned in accordance with the following requirements:

4.3.1 Containment: Debris removed during cleaning shall be collected and precautions must be taken to ensure that Debris is not otherwise dispersed outside the HVAC system during the cleaning process.

4.3.2 Particulate Collection: Where the Particulate Collection Equipment is exhausting inside the ship HEPA filtration with 99.97% collection efficiency for 0.3-micron size (or greater) particles shall be used. When the Particulate Collection Equipment is exhausting outside the ship, Mechanical Cleaning operations shall be undertaken only with Particulate Collection Equipment in place, including adequate filtration to contain Debris removed from the HVAC system.

4.3.3 Controlling Odors: Measures shall be employed to control odors and/or mist vapors during the cleaning process.

4.3.4 Component Cleaning: Cleaning methods shall be employed such that all HVAC system components must be Visibly Clean. Upon completion, all components must be returned to those settings recorded just prior to cleaning operations.

4.3.5 Air-Volume Control Devices: Dampers and any air-directional mechanical devices inside the HVAC system must have their position marked prior to cleaning and, upon completion, must be restored to their marked position.

4.4 Cleaning of Supply & Exhaust Ventilation Ducts and Component.

4.4.1 Clean all supply and exhaust ducting, fans, chillers and heaters that feed all staterooms, the bridge, offices, shops, storerooms, fan rooms, compressor/hydraulic room, labs, lounges, exercise rooms, passageways, laundry room, mess deck and galley, from the inlet side of the supply fan to the terminus of the exhaust vent for each space. HVAC components are located on the 2nd deck, main deck, focsle deck and 02 and 03 deck. Remove riveted or screwed sheet metal access panels and terminal screens as required. Remove and reinstall ceiling sections to gain access to HVAC systems during the cleaning process. Disassemble components as required to effect cleaning of internal components and attached ducting which includes but is not limited to the fan housings, blower’s scrolls, blades, dampers, heating/cooling coils, pre-heaters, etc.

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

4.4.2 Reassemble equipment and components. Energize equipment and check for correct operation and air leakage.

4.5 Balance system flow rates to designed specifications. See references 2.4 – 2.9 for required flow rates.

Correct any problems and demonstrate operation of the system to the COTR.

4.6 Gaylord Hood Exhaust System Cleaning.

4.6.1 Clean and de-grease the exhaust system from Gaylord Hood to 01 level STBD walkway exhaust port.

Clean and degrease the recirculation system from the 70” X 1/8” (adjustable) overhead terminal at FR 47 through and past the re-heater at FR 47. .

4.6.2 Restore Gaylord Hood, clean out ports, screens and access panels used to gain access to the system. Restore any electrical equipment, or fire suppression piping interferences dis-connected to provide access. Replace any disturbed gaskets with new.

4.7 Galley Recirculation System 1-37-2 Cleaning

4.7.1 Disassemble the approx. 70” long x adjustable (currently approx. 1/8”) terminal in the galley overhead at approx. frame 47-48. Remove lighting or other interferences as required.

4.7.2 Disconnect and remove the reheater in the system inboard of the above terminal, located in galley overhead at approx FR 47.

4.7.3 Clean and de-grease the terminal the reheater, their connecting ducting, and the ducting to the next clean out port.

4.7.4 Restore 70” long adjustable terminal, and re-establish initial width gap. Restore reheater, ducting, clean out ports, screens and access panels used to gain access to the system. Replace any system filters within this boundary with new. Replace any disturbed gaskets with new.

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

5 QUALITY ASSURANCE

5.1 None

6 NOTES

6.1 Ship will be inhabited during the repair period and stateroom cleaning will need coordination.

Item No. 102 Title: Ship Service Diesel Generator (SSDG) Overhauls

1 SCOPE:

1.1 Perform 40,000 hour overhauls of number 1 and 2 SSDGs.

2 REFERENCES:

2.1 NOAA Standard Specification S-7003, 40,000 Hour Overhaul of Caterpillar D 398 Engines (attached)

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

2.3 Rules for Building and Classing of Steel Vessels Under 90 Meters in Length, American Bureau of Shipping, 1997 Edition, Section 1/3.11.4

2.4 Technical Manual HA 235-01, Model D398B Engine Generator Set

2.5 NOAA Reference GENERATOR ALIGNMENT PROCEDURE (attached)

2.6 Appendix B Specific Contract Work Definitions and Requirements

3 GOVERNMENT FURNISHED EQUIPMENT:

3.1 None.

4 REQUIREMENTS:

4.1 All work shall be performed by an authorized Caterpillar repair facility or performed by a qualified Caterpillar technician as determined by the COR, and shall be performed in such a manner that the manufacturer's warranty on parts and labor is not voided. All parts and labor supplied by the Contractor shall be fully warranted. Work shall be completed in 15 days or less. A possible vendor to complete the work is:

Mr. Joe Scholtz Timberline Tractor and Marine

P.O. Box 36443 • Canton, Ohio 44735

(330)966-6623 • 1-800-827-2702 • FAX (330) 966-6615

jrscholtz@nls.net

4.2 Provide the ABS Surveyor with the schedule and opportunity to inspect any or all portions of the work required by this work item.

4.3 Accomplish 40,000 hour overhauls on # 1 and 2 SSDG in accordance with 2.1.

4.4 Accomplish an operational test of #1 & 2 SSDGs (under load if possible) and check for any unusual noises, leaks, or operating parameters.

4.4.1 Accomplish an operational test of each governor

4.4.2 Submit a written report to the COR detailing what additional repairs are required as a result of the inspection of 4.5.

5 QUALITY ASSURANCE:

5.1 As required by 2.1.

6 NOTES:

6.1 The SSDG serial numbers are as follows:

#1 35Z00962 #2 35Z00919

NOAA Standard Specification S-7003

CATERPILLAR D398 40,000 HOUR ENGINE OVERHAUL

1.0 SCOPE. This specification contains requirements for the 40,000 hour overhaul for Caterpillar D398 engines on NOAA T-AGOS class vessels.

2.0 REFERENCES.

2.1 Technical manual T9312-AG-MM0-010/11083 Engine Generator Set Model D398B T-AGOS 13-18

2.2 Caterpillar Maintenance Management Schedule for Marine Engines (SEBU6102)

2.3 Caterpillar Operations and Maintenance Manual (SEBU5698)

2.4 Caterpillar Service Manual (SEBR0511)

2.5 Generator alignment procedure (attached).

2.6 Technical Manual T6265-AA-MMC-010, Kato 600 KW A/C Generator

3.0 REQUIREMENTS.

3.1 General. The following requirements apply to all work.

3.1.1 Except as otherwise specified, the contractor shall provide all labor, material, services, tools, supervision, manuals and technical expertise needed to accomplish the work required by this specification within the specified time limits. NOTE: The 21-day performance period shall be strictly adhered to. Unless otherwise specified, the contractor shall provide a copy of the applicable manuals, amendments, and service manuals at the job site. All repairs shall be made according to the manufacturer’s engine specifications, clearances, tolerances, and procedures.

3.1.2 All work shall be accomplished by a authorized repair facility or by a qualified Caterpillar technician. All such work shall be performed in accordance with Caterpillar service, maintenance, and overhaul technical manuals (including all current and applicable amendments and service bulletins), and in such a manner that the manufacturer's warranty on parts and labor is not voided.

3.1.3 Provide and install "mandatory-renewal" parts and components as required by this specification. Other parts found to be in need of renewal may be provided by Government (if available) and installed by the contractor. Such additional parts or components which are not provided by the Government will be negotiated by the Contracting Officer as an additional cost.

3.1.4 Except where rebuilt components are authorized or specified, all components and parts used in the engines shall be new original equipment manufacturer (OEM) non-surplus components and parts. Prior to installing new or rebuilt components or parts, perform visual and dimensional inspections to verify that the components or parts are acceptable for use.

3.1.5 Where remanufactured components are provided (as authorized or specified), existing components shall be replaced on an exchange basis with components remanufactured at the Caterpillar factory, and the existing components become the property of the Contractor in their as-found condition. When factory-remanufactured components are not available, the existing components shall be disassembled, cleaned, inspected, repaired (including renewal of all parts needed), reassembled, and calibrated at the Caterpillar factory or Caterpillar-authorized repair facility. Rebuilt components shall meet the manufacturer’s rebuild specifications and shall be restored to a condition of reliability equivalent to new components and parts. The only parts renewal for which additional costs will be negotiated are component bodies and casings.

3.1.6 Disassemble the engine components, and parts to the extent specified herein and in other procurement documents. Whenever the extent of disassembly is not specified, disassembly shall be to the extent required to perform the required inspections, repairs, and parts renewal.

3.1.7 Interferences shall be removed and reinstalled, as required, at no additional cost to the Government.

Contractor is responsible for removing piping to or from the engine, engine heat exchangers, air motors, etc.

3.1.8 Thoroughly clean, then conduct visual inspections of all disassembled parts, checking for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability. Ensure all passages and holes are open and clear. Whenever hydraulic, fuel, lube oil, water, or air lines are disconnected, clean the point of disconnection and cap or plug the hoses or pipes and their connection points.

3.1.9 After inspections have been completed and prior to reassembling components, submit a report of all inspection findings and test results to NOAA. Report shall include a record of all measurements and readings taken as well as recommendations for additional repairs, inspections or testing. Do not proceed with any additional work until authorized by the Contracting Officer.

3.1.10 After the report has been accepted and all additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed. Reinstallation of all components throughout will be with new gaskets, seals, grommets, and o-rings.

3.1.11 At the end of each work day, clean up all debris incidental to the performance of the required work. Upon completion of all work, clean all work sites to their as-found condition.

3.2 40,000 Hour Overhaul. Accomplish following work for the 40,000 hour overhaul:

3.2.1 Engines will be drained of jacket water and oil (to the lowest level allowed by the installed piping arrangement) by ship’s force prior to start of repairs. Any residual jacket water drained into bilge and will be disposed of by Government. The contractor shall be responsible for removing and disposing of any residual fuel and lube oil.

Upon reassembly, the contractor shall clean all filter housings and install new Government-furnished filters, using new gaskets and o-rings.

3.2.2 Perform an inspection for wear by checking all dimensions and tolerances on the following components. All components shall be properly cleaned and prepared for inspection and re-installation. Submit a written condition report stating each component’s condition and recommendations for renewal due to the component being out of Caterpillar specification. Include material and labor costs to renew that component.

a. Connecting rods

b. Cam followers

c. Fuel transfer pump

d. Pre-lube pump

e. Fuel injection system and governor

f. Main oil pump and relief valve

g. Governor drive group, Woodward EG-3P actuator & linkages, manual shutdown linkages

h. Vibration damper

i. Gear train bushings

j. Gear train

k. Drive unit alignment, generator

l. Rocker arm assembly and bushings

3.2.3 Take and record crankshaft deflection readings and end thrust readings.

3.2.4 Renew the following "mandatory-renewal" parts and components on each engine. Where "remanufactured" is added in parenthesis after a component, a remanufactured or “unit exchange” component may be provided in lieu of a new component.

a. Complete turbo groups, couplings, clamps

b. Camshaft kit (shaft, lifters)(remanufactured)

c. Camshaft bearings

d. Front gear bushings

e. Governor linkage

f. Actuator (remanufactured)

h. Thermostats and water temperature regulators

i. Cylinder head assemblies with valves (remanufactured)

j. Cylinder packs

k. Dampers

l. Fuel nozzles

m. Fuel pump assemblies

n. Fuel transfer pump

o. Oil relief valve and spring

p. Fuel injection pump group yoke screw and lock nuts

q. Main bearings, (complete, including thrusts)

r. Rod bearings, complete

s. Front and rear cover seals and gaskets*

t. Front and rear hydromechanical seals - directional

u. Jacket water pumps (remanufactured)

v. Jacket water heater hoses

y. Jacket water thermostats

w. Sea water pumps (rebuild kit and new impeller)

x. Lube oil coolers, non-removable core (remanufactured)

y. All fuel injection pump to fuel nozzle tubing, with fittings; new fuel tubing shall be double-walled.

z. All thermocouples and thermocouple wiring. Install new wiring to thermocouple box on bracket on aftercooler.

aa. New zinc anodes in pumps and heat exchangers (Government to provide zincs)

3.2.5 The procedure to renew the rear seal requires disconnecting the attached generator from the flywheel and engine block and skid. Before disassembly, take and record generator shaft runout readings and deflection readings of the generator fan to flex plate. Upon reassembly, readings are once again to be taken and the generator adjusted in accordance with Caterpillar specifications. Provide the ship’s Chief Engineer and the COTR at least 24 hours prior notification so they may witness these readings.

3.2.6 Reseal pre-lube pumps.

3.2.7 Remove piping to aftercooler. Remove cores for industrial cleaning. COTR will bring cores to a local radiator shop and will pay the shop separately for the cleaning. Reinstall/reseal water sides.

3.2.8 Adjust all piston cooling jets to proper spray angle.

3.2.9 Reset tappets, check valve rotators, check and adjust fuel timing. Adjust fuel rack actuator by setting turnbuckle adjustment to middle of range. Adjust position of arm on actuator spine such that when engine is running at rated speed under no load, voltage at actuator is 1.5 VDC. Voltage is best measured in switchboard, however the voltage drop across the fuse must be considered.

3.2.10 Inform the Chief Engineer, in a timely manner, when the engine jacket water system is ready to be refilled and tested for water-tightness. Re-fill coolant system with fresh water and the appropriate amount of jacket water treatment (to be supplied by ship’s force).

3.2.11 Renew the lube oil sump pan gasket on Engine #1 (Serial Number 35Z01564). NOTE: This requires generator end removal/reinstallation/realignment per paragraph 3.2.5, above.

3.2.12 Thoroughly clean and inspect the lube oil sump pan on each overhauled engine. Notify the Chief Engineer, in a timely manner, when the engine sumps are ready to be refilled with new lube oil. The government will provide the new oil and ship’s force will be responsible for adding the appropriate amount following an inspection of the oil sump pans.

3.3 Tests and Reports. Notify the Chief Engineer in a timely manner when the overhauled engines are ready to be tested under electrical load. Test operate engines after overhaul using ship’s dockside hotel load for a period of not less than two hours. Test all alarm and shutdown systems prior to starting. Ship’s force will line up and start engines.

Provide technicians to observe operation, verify joints are leak-free, make adjustments, and record data. Operate engines at no-load until normal no-load operating temperatures are reached, then increase load incrementally up to full load and operate for one hour. Temperatures and pressures shall be monitored and compared to manufacturer's recommended limits. If a temperature or pressure exceeds or falls below manufacturer's recommended upper or lower limits, testing shall be stopped and the cause determined and corrected before continuing.

3.3.1 Record the following information near the end of full load test; provide test instruments as required:

a. cylinder exhaust temperatures

b. lube oil temperatures

c. water temperatures

d. fuel oil pressure

e. lube oil pressure

f. water pressures

g. electrical load on generator prime mover

h. turbo outlet air pressure

3.3.2 Submit a report of all test data collected. Report shall include manufacturer's recommended limits for each measured parameter.

3.3.3 After all work is accomplished, submit a cost breakdown of parts used for the overhauls.

3.4 Final Adjustments and Tune-up. After satisfactory completion of operational test, reset valves and accomplish final adjustments and tune-ups as required to provide smooth, efficient, and reliable operation.

3.5 Touch-Up Paint. Touch-up paint all disturbed surfaces to standard Caterpillar paint scheme; surfaces to be painted shall be free of dirt and grease prior to application.

3.6 Notes.

3.6.1 American Bureau of Shipping (ABS) survey of the 40,000 hour overhauls is required for credit toward the ship’s Continuous Machinery Survey. Contractor shall inform ABS of progress and arrange for inspections as required by the local office.

3.6.2 Ship’s force is available to provide shipboard crane service during normal working hours to lift parts between the pier and aft deck. 24 hour notice is required. Actual rigging of parts and moving parts to/from the aft deck and engine room shall be the responsibility of the Contractor.

END OF SPECIFICATION

Reference 2.5 GENERATOR ALIGNMENT PROCEDURE

The Contractor shall take the following readings before disassembly:

a. generator fan angular deflection,

b. generator shaft runout (TIR),

c. crankshaft end play,

d. crankshaft deflection.

Above readings shall be taken again upon reassembly, after the generator to engine alignment relationships have been re-established.

Record all results on condition reports and report the results to the attending NOAA Port Engineer, or assigned representative.

Before performing the parallel and angular alignment checks, ensure that the natural clearance between the base and its foundation is properly gapped with shims at all mounting locations and check that all base- to- foundation bolts are tightened to their final torque. If deflection of the base is noted, loosen base-to- foundation bolts at affected locations, shim as necessary to eliminate deflection, and re-tighten base-to- foundation bolts to their final torque.

Inability to attain repeatability of readings may be due to cocking of the flywheel by the turning tool. An end-supporting turning tool has proven to be superior to free-gear types for taking these particular reading. If an end-supported tool is not available, good results are attainable with a free-gear type if tooth engagement is reduced to the bare minimum necessary to turn the flywheel.

The deflection dial indicator must not have a leash attached since it may change readings.

PARALLEL ALIGNMENT (SHAFT RUNOUT)

Ensure that the generator shaft surface, which is to be measured with the dial indicator, is clean. Solvent and or light sanding with emery cloth should remove any dirt or rust accumulation. Place the base of a dial indicator on the uppermost generator adaptor frame rib and position the indicator finger, which requires extensions, on the generator shaft. Preliminary readings can be taken on the coupling; final readings will be taken on the shaft only. Zero the dial indicator at the 12 o'clock position. It is essential to ensure that the dial indicator base does not move during the run-out check. Any movement will result in erroneous readings.

Rotate the shaft one revolution starting at the 12 o'clock position, checking and recording the dial indicator readings every 90 degrees. To validate the readings, at the completion of the revolution, the dial indicator must return to 0 at the original 12 o'clock starting position. In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft.

Desired reading is 0.000 inch. Total indicator readings shall not exceed .005 inches. Adjust drive flex plate pack (discs) to flywheel installation as necessary to bring parallel alignment into tolerance. Adjustment is accomplished by changing the diesel engine flywheel to generator drive flex plate pack relationship. If total indicator readings exceed

0.005 inches, adjustment is accomplished by removing the drive flex plate pack to flywheel bolts and turning the engine flywheel with the turning gear. The generator can be prevented from rotating with the engine by installing a capscrew in the generator coupling and then holding the generator with a 36" long pinch bar or angle iron placed on the capscrew and generator web. The engine to flywheel relationship is changed one or more bolt holes at a time.

Reinstall the drive flex plate pack to flywheel bolts and take runout readings. Adjust as necessary to bring TIR readings into tolerance.

GENERATOR ANGULAR ALIGNMENT

Place a deflection dial indicator at the 12 o'clock position between the forward face of the fan and the drive flex plate at a point as far away as possible from the centerline of the shaft. The contact points for the deflection dial indicator fingers should be lightly punch marked.

Starting at the 12 o'clock position, rotate the shaft one revolution checking and recording readings every 90 degrees.

To validate readings, at the completion of the revolution, the deflection dial indicator must return to zero at the 12 o'clock starting position. In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft. Desired generator angular alignment readings are as follows:

12 O'CLOCK: 0.000 (starting point)

3 O'CLOCK: 0.000 TO +0.004

6 O'CLOCK: 0.000 TO +0.008

9 O'CLOCK: 0.000 TO +0.004

12 O'CLOCK: 0.000 (original starting point)

Adjust as necessary to bring angularity readings into compliance with paragraph 3 above. If adjustment is effected, a final set of angularity readings must be obtained after all bolts securing the generator to the engine and the generator to base are tightened to their final torque.

CRANKSHAFT DEFLECTION

Measure between faces of connecting rod throws of the crankshaft next to the center main bearing #4 and within .250 in. of the counterweight in accordance with Caterpillar Instructions. Record readings.

CRANKSHAFT END PLAY

Measure crankshaft end play in accordance with Caterpillar instructions. Record readings.

Item # 103 Title: Replace Generator Room Supply Fans W/R No. HA-07-5021

1.1 Objective – Replace two (2) intake fans for the generator room with new GFM.

2.2 NOAA Standard Item S6900; General Requirements for Electrical/Electronic Item

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

2.4 Ship Drawing HA-512-5987509 – Ventilation Arrangements Zone 310

2.5 Steel Structures Painting Council, Surface Preparation Specification No. 10, Near White Metal Blast

Cleaning (SSPC SP-10)

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

3.1 Two Van axial fans.

3.2 Two motor control units

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

4.1.2 All new ducting shall be primed and have two coats of epoxy finish paint to match the surrounding area. Priming may be eliminated if the manufacturer of the finish paint does not recommend a primer.

4.2 Remove and dispose of existing supply fans and fan motor controllers.

4.2.1 Inspect fan wiring for signs of damage and check wires for continuity. Inspect exposed ducting for signs of corrosion. Provide a report to the COR with results of the inspections/testing. If additional repairs are required, work will be accomplished via a change order.

**** CHECK POINT****

4.3 Install new fans and motor controllers.

4.3.1 Prior to fan install, ducting shall be repaired per recommendations of item 4.2.1.

4.3.2 Fabricate mounting plates/flanges/adapters, etc as required to mount the new fan to the existing ducting. Adapter pieces shall be of the same material/thickness of existing ducting and insulated/painted as the existing ducting if required.

4.3.3 Install new motor controls in the same location as the existing units.

4.4 Testing – Operate the new fans to insure proper alignment and flow.

**** CHECKPOINT****

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

5.1 Submit written reports of the results of the inspections/testing required by paragraphs 4.2.1 and 4.4. The reports must contain as a minimum date, time, results and names of witnesses

6.1 The fans are not an exact match to the existing units and some modification to the ventilation ducting and mounts will be requires.

Item No. 104 Title: Repair/Modify Generator/Propulsion Room Supply Ducting

1.1 Background - Several sections of ventilation ducting require replacement and/or removal in the generator and propulsion room.

1.2 Objective - To replace damaged sections of ducting and assist the ship’s crew in removals/modification of existing ducting.

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

2.3 Steel Structures Painting Council, Surface Preparation Specification No. 10, Near White Metal Blast

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

4.1.1 The contractor shall perform all work in accordance with the requirements of the documents cited in

4.1.2 New ducting will be the same material as original, be painted and lagged as appropriate per the original item being replaced.

4.2 Propulsion Motor Room – Remove the damaged section of intake ducting on the discharge line in the propulsion motor room (Figure 1 & 2). Using the removed duct as a template and fabricate a replacement.

4.2.1 New ducting shall be constructed of the same material as the original.

4.2.2 Install the new ducting and apply paint and lagging as the original.

4.3 Generator Room – Assist the ship’s crew in removals/relocation/repair of existing supply and exhaust ducting.

4.3.1 Provide labor support for 120 hours of work.

4.3.2 Provide support for materials needed for modification and repairs made to the ducting system.

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

6.1 Figures 1 & 2

Figure 1

Figure 2

Damaged Area

Vent Section

Item No. 105 Title: Title: Replace Fire Detection System (FDS)

1.1 Background The current FDS on board is out dated, cannot be expanded and is no longer supportable.

1.2 Objective Replace the FAD with a USCG/ABS approved addressable system to current USCG/SOLAS requirements.

2.2 Appendix B Specific Contract Work Definitions and Requirements

2.3 Ship’s Drawing HA-436-02, Fire and Smoke Detection System

2.4 Ship Drawing HA-436-00003235, Fire and Smoke Detection System Elem and ISO W.D.

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

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

2.7 Code of Federal Regulations, Title 46, Subchapter J, Electrical Engineering

2.8 NOAA Standard Item S2906, Arc Welding on Waterborne Vessels

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

2.10 NOAA Standard Specification 0100; Conduct of Checkpoints

4.1 General Requirements - The contractor shall perform all work in accordance with the requirements the documents cited in paragraph 2 above.

4.2 The contractor shall furnish all labor and materials required to remove the current FAD system and replace it with an analogue addressable FDS equal loop based system capable of supporting three loops, such as a Consilium Salwico Cargo Al F400 or equal. Each loop shall be capable to address up to 254 devices per loop, in any combination of detectors, manual call points, I/O interface, points, short circuit isolators, or other addressable devices. One source acceptable to NOAA that has successfully installed this system on other NOAA T-AGOS vessel is:

Consilium Marine US

4370 Oakes Road #721 Ft Lauderdale - FL 33314

Brian Carmichael Training Manager & Navy Projects Phone: +1(561)-906-7041 bcc@consiliummarineus.com mailto:bcc@consiliummarineus.com

4.3 System Hardware - The system is to include the control unit on the bridge as well as a remote control unit in the Central Engine Control Room (CERC). Based on ships drawing and current regulatory requirements, approximately 110 of the following addressable devices will be needed:

69 Optical smoke detectors 6 Short circuit isolators 6 Thermal heat detectors 30 Manual call boxes

1 Machine shop timer

A detailed device list is included in section 6 and is subject to change.

4.4 System Removal – Removals shall include all components of the existing FDS system except existing alarm bells or rotating beacons. All unused junction boxes vacated by the system and any extraneous shall be removed. All removed component shall be saved and turned over to the COR.

4.5 System Instillation – New devices shall be installed at locations a closes a possible to original system components. Installations shall include new wiring, mounting boxes, foundations, stuffing tubes/transits, terminations, loop checks, addressable devices, main and remote panels and repacking of all bulkhead and deck transits. In some instances with the COR approval, existing junction boxes /foundations/wiring may be re-used. New wiring shall be USCG/ABS type approved for use in FDS systems. A new secondary wire conduit shall be established from the main deck to the control module on the bridge. The COR will determine the location of the new wire conduit.

4.6 System Engineering & Support - Shall Include system setup, programming, and commissioning; Provide a detailed cabling riser diagram; Provide an equipment component arrangement diagram; USCG certification documentation of the system and components ; As-built ship drawings complete with loop diagrams, addressable point locations, and database suitable for and USCG and ABS submittals; Five copies of the AI-F400 installation/operation/ programming manuals; 4 hours of on-site training; and 10% spares per for one year of operation per the manufactures recommendations.

5.1 Accomplish an operational check of all new sensors and call boxes upon completion of instillation in accordance with the manufacture’s technical representative and section 095 of part. Submit a written report of the results of the all testing and inspections required by this item. The report must contain the date, time, results, and names of the witnesses.

6.1 Preliminary Device List:

Heat Sensor Locations Laundry Room (2-24-1) Galley (1-42-1) General Workshop (1-62-0) Emergency SWBD & Generator Room (01-6-0) Engineer Storeroom (01-1-2) Steward Storeroom (01-2-01)

Smoke Sensor Locations Main Generator Room (3-34-0) (2 each) Propulsion Motor Room (3-52-0) (4 each) Tunnel (3-72-1) Bowthruster Motor Room (2-6-0) A/C Machinery Room (2-24-4) Sewage Machinery Room (2-24-3) Main Control Room (2-52-0) (2 each) Steering Gear Room (2-94-0) Steward Storeroom (1-E-0) Dry Provision Storeroom (1-6-3) Ship’s Store (1-6-4) Passage (1-9-0) Crew Stateroom (4 person) (1-14-2) Crew Stateroom (4 person) (1-22-3) Crew Stateroom (1-24-2) Crew Stateroom (1-29-2) Hospital (1-29-1) Crew Lounge (1-34-1) Fan Room (1-34-2) Crew Stateroom (1-43-2) Crew Stateroom (1-49-2) Crew Mess (1-52-1) Crew Stateroom (1-53-2) Crew Stateroom (1-58-2) Crew stateroom (1-63-2) Crew Stateroom (1-67-2) Fan Room (1-67-1) HPU Room (1-75-0) Compressor Room (1-75-4) Bosun Storeroom (01-E-0) Emergency SWBD & Generator Room (01-6-0) Passageway (01-10-0) Crew Stateroom (01-14-1) Crew Stateroom (01-14-2) Crew Stateroom (01-18-1) Crew Stateroom (01-21-2) Crew Stateroom (01-23-1) Crew Stateroom (01-27-2) Crew Stateroom (01-29-1) Crew Stateroom (01-34-2) Crew Stateroom (01-34-3) Exercise Room (01-40-1) Crew Stateroom (01-43-2) Bosun Locker (01-44-3)

Crew Stateroom (01-47-1) Vestibule (01-54-2) Computer Room (01-54-3) Survey Office (01-54-3) ET Shop (01-57-2) Dry Lab (01-61-0) (2 each) Hydro/Chemical Lab (01-68-0) Bosun Locker (01-69-1) C.O. Stateroom (02-14-3) Chief Engineer Stateroom (02-14-2) Passage (02-20-0) Ship’s Office (02-22-1) Officer Stateroom (02-22-2) Officer Stateroom (02-29-1) Officer Stateroom (02-29-2) Officer Stateroom (02-36-2) Officer Stateroom (02-35-1) Fan Room (02-42-1)

Call Box Locations

Main Generator Room (3-34-0) (2 each, one at each exit next to door) Main Control Room (2-52-0) (2 each, one at each exit next to door) Propulsion Motor Room (3-60-0) (2 each, one at forward exit next to door, one at top of ladder aft) Passage (2-24-01) (Starboard BHD at approximately Fr 298) Tunnel (2-86-1) (Next to door at Fr 86) Steering Gear Room (2-94-0) (Next to door at Fr 94) A/C Machinery Room (2-24-2) (1 at door Fr 32)

Passage (1-9-0) (2 each, one at Fr 24 on port BHD, and one at approximately Fr 70 on starboard BHD)

Galley (1-42-0) (3 each, one at each exit next to door) HPU Room (1-75-0) (1 at exit door)

Passage (01-10-0) (4 each, one on BDH 14, one at Fr 26 on port BHD, one at Fr 48 on stb BHD, one on BHD 52 port, next to door)

Dry Lab (01-61-0) (3 each next to port/stb and aft exit doors) Hydro/Chemical Lab (01-68-0) (2 each, one at each exit next to door)

Passage (02-20-0) (4 each, one next to doors at Fr 20 (P & S), one at Fr 26 on port BHD, and one next to aft door at Fr 42)

Pilot House (03-15-0) (1 at top of inclined ladder)

Item No. 106 Title: Inspect Ship Service Air Tanks

1.1 Objective – Open and inspect and hydrostatically test the ship air pressure flasks per regulatory requirements.

2.2 NOAA Standard Specification AMC-505-2, Hydrostatic Pressure Tests.

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

4.1.1 The contractor shall perform all work in accordance with the requirements of the documents cited in

4.1.2 Work shall be performed by licensed and/or certified personnel.

4.2 Open and perform visual inspections of the two (2) ship starting air storage tanks. Notify the COR/Chief Engineer when conducting inspections. Provide a written report and recommendations upon completion of inspections.

****CHECKPOINT****

4.3 Perform hydrostatic test of the two (2) cylinders per reference 2.2. Tank working pressure is 250 psi.

4.4 Test and reset system relief valves per reference 2.2

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

5.1 Submit a written report indicating the results of the visual inspection and hydrostatic testing. The report must contain as a minimum date, time, results and names of witnesses.

None

Item No. 107 Title: Replace Resilient Mounts on Four (4) Diesel Generators

1.1 Objective: To replace the 64 resilient mounts of the four ship service diesel generators (SSDG).

2.3 Information data sheets for type 5B5000H Machinery Mount

2.4 NAVSEA Manual S9073-A2-HBK-010, 5B5000H Machinery Mount

2.5 Drawing No. 183-6233564 (Rev. F), Diesel Generator Foundations

3.1 Sixty four (64). 5B5000H Machinery Mount, 6-hole version, NSN 5342-00-543-3867 (original NSN 5340-00-543-3867).

3.2 Sixty -four (128) decelerator cones.

3.3 Sixty-four (64) Spacer ring kit for 5B5000H mount

4.1.1 The contractor shall perform all work in accordance with the requirements the documents cited in

4.2 Prior to removing mounts, engage the services of vibration analysis service to take vibration readings of the diesel engine and generator above and below each mount. Repeat vibration readings upon completion of all work. Provide ship’s force a minimum of 24 hours notice of need to run engine(s).

Provide COR a report of before and after vibration readings.

4.3 Provide all labor and materials to remove the 64 existing machinery mounts on Ship’s Service Diesel

Generators install 64 new mounts. The new mounts, along with spacer kits, are provided as Government Furnished Material (GFM). Existing fasteners, which are Monel, shall be renewed in kind.

4.4 Install new GFM machinery mounts using general information contained in References sited in section 2 above. The contractor shall accomplish and document the following:

4.4.1 After existing mounts are removed, and prior to installing new mounts, de-grease, then power tool clean structure around mounts to remove any oil or rust.

4.4.2 Verify need for shims at each mount by checking variation in heights from a true level plane. A tapered shim must be used if mount will be tilted 3 degrees or more relative to the horizontal plane of the foundations. Shim mounts as required; any existing shims can be re-used, if feasible. New shims to be cut from standard thickness of plate to nearest 1/16 inch.

4.4.3 After load has been imposed on all mounts for not less than 48 hours, adjust clearance at decelerator cones to a vertical height of not less than 0.125 inch and not more than 0.185 inch by proper selection of spacers.

4.4.4 Record height of each mount after clearance at decelerator cones has been set. Contractor shall recheck and record the final mount heights ten days after initial height measurements.

4.5 Painting – Clean all damaged paint to sound paint or bare metal. Clean all exposed metal free of foreign matter and corrosion. Spot prime all damaged paint or exposed metal. Coat all new and damaged areas with 2 coats of epoxy paint to match the surrounding area. Epoxy primer must be used over galvanized metal. No paint to be on rubber mounts

4.6 After all work is accomplish, clean areas to as-found condition.

5.1 Submit a written report of the results of the testing required by this item. The report must contain the date, time, results, and names of the witnesses. The report shall also contain the following:

5.1.1 Height readings for each mount relative to foundations; this measurement used to determine need for shims for resilient mounts. COTR will inspect locations that Contractor identifies as needing shims

5.1.2 All clearance readings taken at decelerator cones

6 Notes

6.1 Reference 2.5 - Drawing of the 5B5000H Machinery Mount

Item No. 108 Title: Replace Ship Service Air Compressors W/R No. HA 10-0022

1.1 Objective – To replace two (2) ship service air compressors. Existing Compressor skids and motors will be reused.

4.1.1 The contractor shall perform all work in accordance with the requirements of the documents cited in

4.1.2 The existing compressor skids and motors will be reused.

4.1.3 A compressor manufacturer’s technical representative shall be used to oversee the compressor instillation and commissioning to ensure warranties are valid.

4.2 Disconnect the existing compressors for all air lines, electrical cables. Drain and dispose of the oil in the compressors. Remove the belt guard and save for reuse.

4.2.1 Remove and dispose of the existing compressors.

4.2.2 Remove the motors and provide them to the COR.

4.3 Purchase and install two (2) Quincy QR-25 two stage compressors, model # 340 rated at 200 psig @25 CFM, or equal. The compressor pulleys shall be sized for use with a 7.5 hp electric motor.

4.3.1 Install the compressors on the existing skids ensuring proper alignment with the motor.

4.3.2 Attach the belts and belt guard.

4.3.3 Attach all airlines and electrical cables.

4.4 Testing - Prior to operating the compressor, a manufacturer Technical representative shall inspect the instillation and commission the system. Operate the compressors and set maximum output pressure to 125 psi. Demonstrate proper operation and pressure settings to the COR. Run the system for 15 minutes reliving system pressure to observe the system start/shutoff sequencing.

***** CHECKPOINT *****

4.5 Painting – Clean all damaged paint to sound paint or bare metal. Clean all exposed metal free of foreign matter and corrosion. Spot prime all damaged paint or exposed metal. Coat all new and damaged areas with 2 coats of epoxy paint to match the surrounding area. Epoxy primer must be used over galvanized metal. No paint to be on rubber mounts

5.1 Submit a written report of the results of the testing required by paragraphs 4.4. The report must contain as a minimum date, time, results and names of witnesses.

6.1 None

Item No. 109 Title: Replace Ship Starting Air Compressors W/R No. HA 09 0015

1.1…