Att 3 - DRAFT J-6 P-TSV Mainenance SOW.pdf

Pacific Training Vessel (P-TSV) Maintenance Statement of Work (SOW)

The following inspections, maintenance, and overhauls of equipment shall be performed as part of the vessel reactivation. This SOW covers all expected propulsion and system arrangements, the contractor shall perform the tasks applicable to the vessel.

1. Perform Top End Overhaul of Engines

All propulsion, generator, and tunnel thruster engines shall have a top-end overhaul performed by a factory authorized representative. All work is to be performed in coordination with the requirements for ABS machinery classification survey requirements taking part under this contract.

All engine overhaul parts, repairs, procedures, inspections, renewals, tolerances, torquing, adjustments and testing will be strictly in accordance with the engine manufacturer’s instructions and specifications. All engine fluid heat exchangers and coolers will be cleaned and pressure tested prior to being reinstalled.

Perform all engine inspections as outlined in the manufacturer’s recommendations. Provide an inspection report documenting the conditions found for all engine components found to be reusable, and for the condition found for all pistons, rings, liners and engine top decks.

Assemble the engines as per the manufacturer’s specifications ensuring that all torque and clearances are as specified. Adjust all system settings and parameters. Ensure only fluids meeting the manufacture specifications are added back to proper levels.

Perform all manufacture required initial start-up inspections and procedures. Start and run in each engine in accordance with the manufacturers’ schedule and procedures.

Clean all external engine surfaces and components upon completion of all work and final tuning and testing. Apply proper primers and final topcoats matching engine color scheme upon completion of all work.

2. Perform Inspection and Maintenance of Z Drives

All Z-Drive propulsion pods shall be inspected by a factory authorized representative. Conduct full manufacture’s recommended system inspections and maintenance for routine dry dock intervals. All work is to be performed in coordination with the requirements for ABS machinery classification surveys taking part under this contract.

All parts, repairs, procedures, inspections, renewals, tolerances, torquing, adjustments and testing will be strictly in accordance with the z drive manufacturer’s instructions and specifications. All fluid heat exchangers and coolers will be cleaned and pressure tested a reinstalled. The propellor shaft seal shall be removed and renewed while in dry dock.

All fluid reservoirs will be drained and inspected. Fluids used to refill the system shall meet the manufacturer's specifications.

Fixed pitch propellers shall be removed, cleaned, inspected and refurbished as described under the straight shaft propulsion section of this SOW.

Operate steering system upon completion of steering system work. Clear all discrepancies and ensure that the system is fully functional.

3. For controllable pitch propellers as fitted either to aft propulsion shafts, z-drives or tunnel thrusters

All controllable pitch propeller systems are to have an inspection and service by a factory authorized thruster service company. Conduct full manufacture’s recommended system inspections and maintenance for routine dry dock intervals. All work is to be performed in coordination with the requirements for ABS machinery classification surveys taking part under this contract.

All parts, repairs, procedures, inspections, renewals, tolerances, torquing, adjustments and testing will be strictly in accordance with the propellor manufacturer’s instructions and specifications. All fluid heat exchangers and coolers will be cleaned and pressure tested a reinstalled. The propellor shaft seal shall be removed and renewed while in dry dock. Remove all blades from hub and inspect and certify remaining hub seal surface on each blade and replace all blade seals.

All fluid reservoirs will be drained and inspected. Fluids used to refill the system shall meet the manufacturer's specifications.

Provide an inspection report documenting the conditions found and repairs made.

4. Fixed Pitch Propeller Removal Cleaning and Inspection

This work item requires the removal, refurbishment and re-installation of the fixed pitch propellers. Requirements for controllable pitch propellers are covered elsewhere. All work is to be performed in coordination with the requirements for ABS classification requirements for dry dock surveys taking part under this contract.

Remove each propeller nut locking device and hub nut. Using propeller pulling equipment, rig and withdraw each propeller from the shaft tapers. Palletize or crate each propeller to prevent damage during shipment. Transport each propeller from ship-to-shop.

Procure the services of a qualified propeller reconditioning facility. Check pitch, balance and polish each propeller. Provide propeller certificates documenting pitch/diameter, checks and repairs, if any.

Reinstall each propeller and re-install onto the shaft tapers using bluing. Inspect for proper contact fit in company with the Authorized NAVSEA Representative. A minimum contact fit of 85% is required. Hone the propeller bores as necessary to achieve this fit. Recheck and continue fit until this percentage of contact is achieved. Procure and install new keys of proper fitment. Install key and propeller onto the shaft tapers. Drive propeller hubs 1/32” onto shaft tapers past the position where correct contact fit was attained. Secure hub nuts and locking devices in the presence of the Authorized

NAVSEA Representative.

Submit a condition report documenting condition found and repairs made.

5. Tail Shaft Inspection and Shaft Seal Renewal

The main propulsion shafting shall be removed and inspected in accordance with the directions below. All work is to be performed in coordination with the requirements for ABS classification requirements for dry dock inspections taking part under this contract.

The propellers will be removed for service and inspection. Disconnect the main shafting inside of the machinery and prepare shafting for removal. After shaft disconnection, provide services for the inspection of the reduction gear.

Remove the shaft seal components from each stern tube machinery space opening and examine for damage, wear or deterioration. Replace all seals, gaskets and consumable parts. Replace all items required by manufacture for routine dry dock maintenance.

Rig each shaft and withdraw the shafts through the shaft seals, stern tubes and struts. Transport each shaft from ship-to-shop to perform all inspections. Clean and polish each shaft to remove all marine growth and deposits.

Inspect the condition of strut and stern tube cutlass bearings. Renew bearings if wear measurements exceed 50% of manufactures recommendations.

Physically inspect all shafting surfaces and material condition for wear, damage or deterioration.

Set-up shaft in lathe to perform all inspections for shaft condition, straightness, eccentricity and run out.

Acceptable tolerance shall be in accordance with NAVSEA General Overhaul Specification Section 9430.

Perform a Dye-penetrant inspection all keyways and threaded areas for cracks. Inspect the bearing journal area for scoring and/or gouges. Inspect the shafting material for corrosion, pitting or cracks.

While in the shop, inspect the coupling-to-taper-fit with Prussian Bluing in the company of the

Shipyard Engineer. Hone and refit as necessary to obtain a minimum 85% contact fit. Machine skim-cut the face and flange O.D. to ensure flange face perpendicularity and concentricity. Inspect all bolts, nuts, flange holes and companion flange face for damage, wear or deterioration.

Rig each shaft and re-install into ship’s struts and stern tubes after completion of all inspections and fit. Jack and block the shaft to true center of the reduction gear output flange. Inspect for proper bore alignment. by measuring diameter gaps at four (4) equally spaced positions on each shaft. Align engine as required to bring the marine gear output flange to within plus/minus .005” of bore alignment.

Inspect for proper angular alignment by measuring four (4) equally spaced gaps with a feeler gauge.

Move each engine as required to bring angular alignment within .0005” of companion flange diameter.

Submit a condition report documenting condition found and repairs made.

6. Rudder Removal, Inspection and Post Seal Renew

This work Item requires the removal of all steering components and rudders for inspection. All work is to be performed in coordination with the requirements for ABS classification requirements for dry dock inspections taking part under this contract.

Remove rudder tube seal assemblies. Provide all new seal assembly upon re-installation of rudder.

The rudder to steering system connections will be disassembled and inspected. Loosen each assembly inside the vessel and remove each tiller head. Lower each rudder out of the rudder tube through the bottom of the vessel.

Perform inspections on system components: jockey bars, hydraulic cylinders, bushings, pins, bearings, sleeves, etc. Inspect each rudder post and all machined surfaces for wear, damage or deterioration. Repair any discrepancies found.

Inspect each rudderpost, tapper keyways and threads for damage, wear or deterioration. Clean and hone the hub tapers with Crocus Cloth and a wire brush prior to reassembly.

Inspect each rudder for damage or deterioration. Repair any discrepancies found. If the rudder is filled with preservation fluid, drain pressure test and refill preservation.

Hoist rudders back up into the rudder tubes. Install new post sealing assemblies and reconnect all steering system components.

All fluid reservoirs will be drained and inspected. Fluids used to refill the system shall meet the manufacturer's specifications.

Submit a condition report documenting condition found and repairs made.

7. High Performance (high lift moveable flap) Rudder with Independent Rudder System

High performance rudders fitted with independent rudder post systems shall have those components disassembled, inspected and refurbished. The contractor shall obtain the services of a factory qualified technician to perform all required inspections and dry dock maintenance. All work is to be performed in coordination with the requirements for ABS classification requirements for dry dock inspections taking part under this contract.

Inspections and service shall include the rudder stock, rudder trunk, rudder support bearing and seal, main rudder blade, rudder leading edge. Movable flap, hinge system and linkage system.

Inspect each rudder component for damage or deterioration. Repair any discrepancies found. All fluid reservoirs will be drained and inspected. Fluids used to refill the system shall meet the manufacturer's specifications. If the rudder is filled with preservation fluid, drain pressure test and refill preservation.

Submit a condition report documenting condition found and repairs made.

8. Renew Sea Chest Suction and Isolation Valves

The contract shall remove, renew and pressure test all below waterline sea chest valves. These may include, main sea chest sea suction valves, fire pump suction header valve, bilge ballast pump suction header isolation valves.

Pressure-test each new valve to 50 PSI for 10 minutes to ensure the tightness of the valve discs and stem seals. Inspect valve seals and stem packing for leakage. Correct any discrepancies and re-test, as required, until a successful hydrostatic test is achieved. All valve testing shall meet ABS requirements and be witnessed and approved by Authorized NAVSEA Representative and the attending ABS surveyor.

Reinstall new valves after testing. Provide all new threaded fasteners for each valve flange connection. Fasteners shall be CRES 316 stainless-steel and sized for the service intended. Hardware shall include all bolts, nuts, flat washers and lock washers.

Inspect all valve flange gaskets and connections while the vessel is waterborne. Inspect for connection watertight integrity while the suction headers contain full sea pressure. Correct all discrepancies, if any.

Provide an inspection report documenting the conditions found and repairs made.

9. Remove, Refurbish, Inspect and Replace All Overboard Check Valves

This work item requires the removal and refurbishment of all swing-check valves, sea cocks and gate valves connected to the hull side shell plate. All valve inspection, repair and testing shall be witnessed and approved by the ABS attending surveyor prior to reinstallation.

Unfasten, disconnect and remove all side shell globe valves, gate valves and swing-check valves discharging overboard, onboard the vessel.

Thoroughly clean the interior of the valve bodies and operating mechanisms. Inspect all valve components for wear, damage or deterioration. Repair all discrepancies and reassemble.

Pressure-test each valve to 50 PSI for 10 minutes to ensure the tightness of the valve discs and stem seals. Inspect valve seals and stem packing for leakage. Correct any discrepancies and re-test, as required, until a successful hydrostatic test is achieved. All valve testing shall meet ABS requirements and be witnessed and approved by Authorized NAVSEA Representative and the attending ABS surveyor.

Reinstall each refurbished valve into its respective location with the new gaskets and threaded fasteners. Tighten all fasteners securely. Provide an inspection report documenting the conditions found and repairs made.

10. Open, Clean and Inspect Potable Water Tanks. Chlorinate and Sanitize To Return To Service

Open the covers to all potable water tanks to allow full access to inspect the interior of the potable water tanks. Services for gas freeing and safe for entry certification shall be provided by the contractor in preparation for tank and system inspections. Pressure-wash each water tank internally with clean, fresh water prior inspection. Thoroughly wash all tank surfaces and completely remove all slime/sludge, rinse water, scale, loose paint, contaminants and debris.

Inspect the internal tank structures for deterioration or damage after cleaning. The interior of the tanks must be free of bare, uncoated steel, failed coatings or any corrosion. The contractor shall repair the tank coating system to bring it back to acceptable standards as approved by the Authorized NAVSEA Representative.

After inspections are complete and any repairs completed the potable water system will be shock-chlorinated in order to return it to service. Fill each tank with a chlorine solution concentration of one gallon of chlorine for each one thousand (1,000) gallons of water. Use only non-scented NSF approved household bleach. Allow the high-concentrate chlorine solution to stand for (24) twenty-four hours to properly shock all tank surfaces. Completely flush with clean, fresh potable water after 24 hours. After flushing, thoroughly ventilate the tanks for another 24 hours.

Refill each potable water tank with clean, fresh potable water and let stand for 24 hours.

Procure the services of a qualified chemist to test all water samples. The test will be conducted for Volatile Organics, EPA Method 502.2. Take a water sample from each potable water tank (24) twenty- four hours after filling. In addition, provide a sample of the potable water source used to fill the tanks. All samples shall be taken in the presence of the Authorized NAVSEA Representative.

The results of the water test shall meet or exceed the federal minimum safe drinking water standards. Water samples tested shall also be free of VOC contaminants. The contractor shall re-chlorinate or correct deficiencies, if any, to the satisfaction of the Authorized NAVSEA Representative.

Provide an inspection report documenting the conditions found, repairs made and test results.

11. Remove, Refurbish, and Inspect All Main and Weather Deck Vent Check Pipes

Disassemble each weather deck valve assembly. Remove all paint and corrosion from valve body external surfaces. Thoroughly remove all corrosion and dirt from the ball-float, seat ring and internal surfaces of the valve.

Lay out all valve components for inspection by the ABS attending surveyor. Inspect all components for wear, damage or deterioration. Correct any discrepancies found during the inspections. Install and re-fasten each refurbished ball-check valve onto the appropriate standpipe upon completion of all repairs. Provide or fabricate new flange gaskets for all inverted ball check valve assemblies. Provide new stainless-steel threaded fasteners properly sized in length and diameter for the service intended.

Preserve all vent standpipes, refurbished inverted ball-check valves and surrounding disturbed external coatings in accordance with surface preservation requirements of this contract.

Provide an inspection report documenting the conditions found, repairs made and test results.

12. Inspect and Refurbish All Main Deck Fill Pipes and Valves

Disassemble each weather deck valve assembly for fill and discharge piping. All cam lock fittings shall be inspected for damage and deterioration. All threaded valve fittings on fill or discharge piping shall be removed and the condition of the valve and threaded potion of the standpipe inspected for damage or deterioration. All pollution containment pans will have threaded drain plugs inspected for any discrepancies. The contractor shall correct all discrepancies to the satisfaction of the Authorized

NAVSEA Representative. Reassemble all fittings with new gaskets and fasteners.

Provide an inspection report documenting the conditions found, repairs made and test results.

13. Inspect and Recertify Fixed Fire Suppression System

Provide services of a qualified fixed fire suppression system technician. The technician shall be certified to disable, disconnect, inspect, trouble-shoot, repair, test, re-certify and re-arm the existing fixed fire suppression system.

Perform inspections on all fixed fire suppression system components, alarms and fire detection control panels to determine their compliance with manufacturer’s requirements and NFPA regulations.

Re-install and re-connect all system components in accordance with manufacturer’s specifications. All work is to be performed in coordination with the requirements for ABS classification requirements for machinery inspections taking part under this contract.

Provide an inspection report documenting the conditions found, repairs made and certification documentation of system compliance.

14. Swing Magnetic Compass and Provide a Deviation Card

The contractor shall provide the services of a qualified magnetic compass technician to inspect and calibrate the compass card during or before sea trials. Perform the required calibration checks, adjust as required and submit an inspection report documenting the conditions found, repairs made and test results. Submit three (3) deviation cards for the compass to the Authorized NAVSEA Representative.

15. Open clean inspect sewage treatment system

The contractor shall completely empty the sewage system including the Type 2 marine sanitation system (MSD) and any holding tanks. Services for gas freeing and safe for entry certification shall be provided by the contractor in preparation for tank and system inspections. All work is to be performed in coordination with the requirements for ABS classification inspections taking part under this contract.

Inspect the MSD and, gray water and black water holding tanks, and service all sewage system parts in contact with sewage including filters, membranes, aeration parts, fitting, valve and check valves.

Replace all PVC or other hoses and ensure all tank level alarms and indicators are properly operating.

Reassemble and the restart system and add the manufacture’s recommended bacteria. Ensure the blower and airlift system is properly transferring oxygen into the sewage processing system. Circulate the contents and maintain aerobic conditions in the MSD unit. Ensure processed discharge effluent chlorination is within specified limits. Submit an inspection report documenting the conditions found, repairs made and test results.

16. Degrease and pressure clean machinery space bilges and deck plates

After completion of all contract work and before delivery of the vessel, the Contractor shall thoroughly clean all machinery space bilges and ensure all bilge suction strainers (rose boxes) are clear and properly operating. Prior to washing down, clean the bilge of all loose debris and trash and dispose of properly. Spray a solution of suitable chemical degreaser to clean and treat all machinery spaces.

Thoroughly apply the cleaner to all deck plate surfaces and underneath structure and hull plate in the designated bilge areas. All cleaning solution mixing and application shall be strictly in accordance with the manufacturer’s instructions for general cleaning. Power-wash and flush-off all traces of degreaser from the surfaces with clean fresh water. Pump-out, remove and strip all flushing/rinse water and properly dispose of the rinse water. Ventilate all bilge areas and allow surfaces to dry thoroughly before application of any paint surface coatings. Submit an inspection report documenting the conditions found, repairs made and test results.

17. Service Gyrocompass

The contractor shall provide the services of a qualified Gyrocompass technician to accomplish all required annual service and calibrations in accordance with manufacturer’s specifications. Disassemble, clean and inspect the gyrocompass. Renew the gyrocompass supporting liquid. Inspect electrical connections for faults. Replace all parts specified for annual or other periodic maintenance. Inspect the condition of the gyro repeaters and repair any discrepancies found to the satisfaction of the Authorized

NAVSEA Representative. Power-up the gyrocompass, initiate a normal start-up and allow the gyrocompass to stabilize. Ensure that unit settles on the target heading with proper current. Check and correct any incorrect alignment of the gyro compass heading and adjust the casing as necessary. Check and perform adjustments as necessary to fully synchronize the repeaters with the gyrocompass heading.

Ensure compass to be fully operational prior to sea trials. Submit an inspection report documenting the conditions found, repairs made and test results.