Revised_SOW_4-22-2015.docx

U. S. MARITIME ADMINISTRATION

JAMES RIVER RESERVE FLEET

PG-201 - 53’ ALUMINUM CREW BOAT

DTMA92Q1500020

Statement of Work (Attachment #1)

U. S. MARITIME ADMINISTRATION

JAMES RIVER RESERVE FLEET

PG-201

53 FOOT ALUMINUM CREW BOAT

SPECIFICATIONS FOR DRYDOCK, RE-POWER, AND REPAIRS

(January 28, 2015 / 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.

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.

Craft Particulars:

53 FOOT CREW BOAT

Operating Displacement Includes: Fuel, water, lube oil Crew 3 39,850 lbs.

3,410 lbs.

540 lbs.

Operating Displacement Includes: Fuel, water, lube oil Crew 3 39,850 lbs.

3,410 lbs.

540 lbs.

PROPULSION

PROPELLERS

PROPELLER SHAFTS

MATERIALS

Contents

· INTENT

· This Statement of Work (SOW) encompasses the following tasks:

· Dry-dock, clean and paint hull

· Remove main engines, and reduction gears

· Replace deteriorated framing in engine room

· Install new engines and reduction gears

· Complete miscellaneous repairs

· SERVICES

· The contractor shall provide all personnel, management, components, parts, tools, materials, equipment, and all other items necessary to perform dry docking, renew hull framing, and upgrade the (2) two main propulsion engines of one (1) MARAD Watercraft PG-201 vessel located at James River Reserve Fleet, Fort Eustis, Va.

· The contractor’s facility where all work is performed shall be located within a 125 mile radius of James River Reserve Fleet, Fort Eustis VA to accommodate progress inspections by the owner’s representative.

· MATERIALS SPECIFICATIONS

· GENERAL: All material used in the overhaul of the PG-201 shall meet the following specifications, unless otherwise stated:

· Aluminum:

· Plate and sheet: ASTM-B209, alloy 5086-HI16 or 5086-H117; for nonwelded applications alloy 6061-T6 or 6061-T651 may be substituted.

· Extrusions: ASTM-B221, alloy 5086-HI 11; for non-welded applications alloys 6061-T6 or 6061-T52 may be substituted.

· Drawn tube: ASTM-B210, alloy 5086-H32; for non-welded applications alloy 6061-T6 may be substituted.

· Corrosion-resistant steel (CRES) or stainless steel:

· Plate and sheet: ASTM-A167, type 316L shall be used in all strength critical welded components. ASTM-A167, type 316 to be used in nonwelded applications and in non-strength critical welded applications.

· Bars and shapes: ASTM-A276, type 316L; for non-welded applications types 316 or 304 may be substituted. Applicability of 304 is subject to approval by the Government's representative.

· Tubing: ASTM-A269, seamless, type 316L for heavy wall welded applications; for non-welded applications type 316 may be substituted

· Pipe: ASTM-A312, seamless, type 316L shall be used in all strength critical welded components. ASTM-A312, type 316 to be used as noted on the drawings, in non-welded applications, and in non-strength critical welded applications.

· SPECIFICATIONS

· The following specifications, together with the Description of Work, define the basic guidelines to be followed. In general, the requirements in these specifications apply only to the material supplied, and work performed, by the Contractor to complete the work described in the Description of Work. No departure is permitted unless specifically approved by the Government.

· GENERAL REOUIREMENTS

· GENERAL

· Unless otherwise noted in these specifications, all materials, equipment, and machinery shall be installed in accordance with manufacturer's recommendations. All installed equipment shall operate and perform within the tolerances stated in these specifications and those recommended by the manufacturer.

· Piping and wiring shall be, run to allow only minimum exposure to weather. Bulkhead and deck penetrations shall be as close, as practicable, to the equipment being served.

· Systems, equipment, and components shall be installed to facilitate accessibility, operating efficiency, inspection, adjustment, and repair. Permanent fittings and structure shall be designed and installed to allow for non-invasive removal of machinery and equipment. The space behind certain equipment may be inaccessible after installation. This factor must be considered when providing access for equipment and in selecting the location of pipes, wire ways, and other permanent fittings behind such equipment. Nooks, cracks, and openings where water, dirt, dust, or foreign material can accumulate shall be avoided.

· The Contractor may propose alternative designs to those detailed in the Description of Work, subject to the approval of the Government Representative. The Contractor shall submit specific details for Government approval.

· The Contractor may propose, in writing, equivalents for the items required in these specifications by manufacturer's name, make and model number. The Contractor shall demonstrate that the proposed item is in all ways equal to the specified item. Substitution shall not be permitted until the equivalent is specifically approved in writing by the Government.

· All materials and articles used in the overhaul shall be new, of the best commercial marine quality and suitable for the intended service. All defective material shall be corrected or replaced at the Contractor's expense.

· All undamaged items that the Contractor removes in order to gain access to areas during the overhaul must be replaced in at least original condition and in working order. The method used for reinstalling items must match that used in the original installation unless otherwise specified.

· Where manufacturer's type, model, or other commercial designation is referred to herein, the characteristics in effect on the date of these specifications shall apply. Where model numbers or other commercial designations have been superseded since the date of these specifications, new model numbers or designations may be utilized provided the equipment characteristics associated with the new designation are the same as those associated with the superseded designation.

· WORKMANSHIP

· Workmanship shall reflect the best marine quality, methods and practices available

· Structure shall be fair and free from objectionable buckles or uneven sight edges.

· All joints are to be neatly and accurately made. Faying surfaces shall be free from gaps, hollows or warping. Except where specifically permitted, shims or filling compounds shall not be used to correct improper fit.

· All sharp edges exposed to personnel shall be dressed, ground or rounded to avoid injury.

· Metal parts shall be completely fabricated before installation on the craft. Internal corners shall be filleted and external corners shall be rounded- off.

· CORROSION CONTROL

· All items used in the overhaul of this craft shall be fabricated of non-corrosive materials or shall be suitably protected against corrosion for service in a marine environment. Dissimilar metals, with the exception of stainless steel fasteners, shall not be joined directly except as specifically allowed herein. Galvanic corrosion shall be prevented by insulating dissimilar metals from each other with suitable gaskets, washers, sleeves, bushings and hose of insulating material; insulating materials shall be non-porous, with mechanical properties suitable for the application. Faying surfaces between mechanically fastened metal components and between metals and laminates, except machinery foundation shims, shall be protected by the use of adhesive.

· WELDING

· All weldments shall be continuously welded, on both sides wherever practicable, with welds sized on the basis of the thinner member to be welded unless specifically shown otherwise on the drawing. Additionally, welds on the exterior of the craft shall be of a neat and regular appearance, with no undercut, spatter or other unsightly defects. Grinding shall not be used as a remedy for welding of unsatisfactory appearance

· THREADED FASTENERS

· This section defines general threaded fastener requirements applicable to Contractor-assembled joints and attachment of machinery and components to their foundation or to the craft structure. Specific requirements stated elsewhere in the Specifications or the Description of Work shall take precedence.

· All equipment and fittings shall be through-bolted. Substantial backing plates shall be used. The only exceptions allowed are the use of self-tapping screws for mounting lightly loaded equipment, such as cable straps. All threaded fasteners shall be stainless steel, ASTM-A276, TYPE 316; ASTM-A582, TYPE 304 may be substituted except where the fastener may be submerged in water. All nuts shall be the Nyloc type. One stainless steel flat washer shall be used under each bolt head, except counter-sunk types, and under each nut if backing plates are not possible. Mechanical thread locking devices and methods shall not be used. Nyloc acorn nuts shall be used where nuts or bolt ends may constitute a hazard. Stainless steel fasteners installed into through painted aluminum parts shall first be coated with Ultra Safety Systems "TEF-GEL" and installed with a suitably sized nylon washer.

· Bolt and machine screw sizes of 5/16 inch in diameter and greater shall be used for all structural applications. The size of fastener used for hardware shall match the size of the predrilled holes in the part.

· Bolt hole diameters shall not exceed bolt diameters by more than 1/32 inch for bolts up to and including 314 inch diameter and by more than 1/16 inch for bolts over 314 inch diameter. Counter-sinking for fasteners shall be as specified by the fastener manufacturer. Fastening patterns shall be well-arranged and consistent.

· Threaded fasteners of standard lengths shall be used. Male threads on threaded fasteners shall protrude at least one thread beyond the top of the nut or plastic locking element. Excessive protrusion (four or more threads showing) shall be avoided, particularly where necessary clearances, accessibility, or safety are effected.

· Self-tapping screws may be used as an aid in the assembly of parts to be joined by some other means. Lead holes shall be drilled with an appropriately sized drill. These screws shall be removed when no longer required.

· PAINTING:

· Application: Unless otherwise noted, the preparation and application of all coatings shall be in strict compliance with the manufacturer’s recommendations. All equipment used for the application of the paint system shall be as recommended by the manufacturer. Paint. Sealers, cleaners, lubricants and hand cleaners containing silicone should not be used in or around the paint shop. Where at all possible, spray equipment shall be used to apply the paint system.

· Finish: The boat shall be repainted to match the color of the existing paint system except it shall have a high gloss finish. The finished top coat shall be hard with a mirror-like finish and shall show no signs of pin holing, orange peel dry spray, solvent popping, craters, fish eyes, corn flaking/mud cracking, crazing and/or other imperfections.

· Shop Conditions: The paint system shall be applied and cured (minimum of 24 hours) indoors, within a controlled environment. The temperature and humidity of the paint booth shall be maintained at the level specified by the paint manufacturer during the first cure cycle (24 hours minimum) - Temperature: 70 - 85°F; Humidity: 45 - 65% RH. Paint, including primer and top coat, shall be stored at the same temperature to be maintained during application for a minimum period of 48 hours prior to application. The space shall be clean and free of contaminants. Machinery exhaust shall not be allowed in the paint shop. Air supply lines shall have oil and water separators a minimum of 30 feet from the compressor. Check and clean all filters, traps regulators and drain compressor prior to application. The space shall be well ventilated.

· Tack Rags: Cleaning and wiping rags shall be clean, lint-free, absorbent cloth rags. Commercial shop towels shall not be used. Clean cloth gloves shall be worn during all stages of surface preparation and application to prevent contaminating the painting surface with skin oils and perspiration.

· Inspections: All phases of paint removal and application shall be inspected by a certified National Association of Corrosion Engineers (N.A.C.E.) inspector [Known local source: Global Systems International, Norfolk VA (757)440-7737] and U.S. Paint field representative inspector. The Contractor shall be responsible for arranging scheduling all inspections and shall bear all costs incidental to these inspections. Inspections shall provide expert, third party quality assurance of all aspects of the job and a documented history record of the process. All possible factors that may affect the performance of the final coating system shall be witnessed, monitored, recorded and assessed. The N.A.C.E. inspector shall be present to witness all aspects of the job. The U.S. Paint representative shall inspect the surfaces to be painted prior to application to insure adequate surface preparation. The batch lot number of all coatings used shall be recorded. Application equipment shall be cleaned and checked by the inspector prior to use. Wet film thickness measurements shall be made by the N.A.C.E. inspector during application to verify adequate, consistent thickness. Prior to start of work, the Contractor shall arrange a meeting to review and discuss the necessary procedures, equipment, materials and QA inspections. The meeting shall be attended by the Contractor, the N.A.C.E. Inspector, the U.S. Paint service representative and a Government Representative. Following the meeting, the Contractor shall draft a plan for repainting the dive boat. The plan shall delineate all the steps to be followed, in sequential order, to complete the job. The plan shall he broken down into projected work days, including projected inspection points. The plan shall detail the exact paint schedule to he followed during the application. Blank copies of all inspection reports and checklists shall he included. The plan be endorsed by the U.S. paint representative and the N.A.C.E. inspector and approved by the Government Representative prior to the start of work. Coatings shall be mixed and applied in accordance with the manufacturer's recommendations and witnessed by the N.A.C.E. inspector. The results of all inspections shall be documented in a report. The final report shall be endorsed by the N.A.C.E. inspector as being accurate and complete. The report shall then be submitted to the U.S. Paint representative for review and acceptance. The accepted report shall be provided to the Government Representative following completion of work.

1. ENGINE REMOVAL:

1.1. This work item describes the requirements for the contractor to remove existing GM 12V71 main engines and attached Allison reduction gears.

1.2. Disconnect and remove raw water supply hose from strainer to raw water pump.

1.3. Remove all raw water hoses and piping to include existing auxiliary overboard discharge piping to through hull fitting.

1.4. Remove existing exhaust risers.

1.5. Remove existing exhaust system including all pipes , hoses and mufflers in engine room and lazarette.

1.6. Remove all electrical wiring to engine including starter cables, alternator wiring, gauge sending units, engine cut off solenoid, and any associated wiring.

1.7. Remove engines, and reduction gear from vessel, and provide covered storage.

1.8. Remove existing exhaust from manifolds to transom.

1.9. Remove existing fuel lines including all existing filters, valves, and other hardware. Plug or cap lines at both fuel tanks.

1.10. The contractor shall clean and inspect interior hull plating in bilge of lazarette and engine room, and compartments for any structural damage or severe pitting. The contractor shall provide the COTR with written report of findings within 1 day after cleaning and inspection

1.11. The contractor shall remove the MARAD approved hull plating identified in the report of findings (para. 6.10) that is damaged or severely pitted and replace with same type and gauge of aluminum plating identified in Vessel Characteristics according to American Boat & Yacht Council (ABYC) Standards. Any hull plating replaced will be completed prior to preserving underwater body and primed and painted with the same type of antifouling paint and primer applied to the remainder of the vessel according to the manufacturer specifications.

2. REMOVE AND INSPECT BOTH PROPELLOR SHAFTS:

2.1. This work item describes the requirements for the Contractor to remove, inspect, and reinstall the port and starboard propeller shafts.

2.2. The Contractor shall mark and disconnect the shafts from the associated shaft couplings. Disassemble and remove the PSS dripless packing cooling hoses, hose clamps and attached components according to manufacturer’s instructions.

2.3. Remove the shafts from the vessel and transport to a suitable repair facility.

2.4. Protect the shafts from weather and damage during removal, storage, and reinstallation.

2.5. Ensure each shaft is properly supported at all bearing journals while being transported or stored.

2.6. The Contractor shall clean the propeller shafts and all disassembled components to remove any marine growth, dirt, and grease. Set up the shafts in a lathe, providing supports at each bearing surface, and conduct the following inspections:

1.1.1. Complete a visual inspection for mechanical defects.

1.1.2. Measure the shaft taper and shaft run out at the taper.

1.1.3. Measure the coupling end diameters and run out. Fit each shaft coupling to each shaft in the shop and check using Prussian blue. Install new, contractor supplied couplings to match ZF 360 marine transmission on the shafts and check face and bore run outs on couplings. The maximum face or bore run out shall be no more than 0.002" TIR. Visually inspect the thrust pin.

1.1.4. Visually inspect and measure all keyways, keys and shear pins for excessive wear.

1.1.5. The Contractor shall conduct non-destructive inspection of all shaft tapers, keyways, keys, drive-saver bolts, and coupling bolts, in accordance with Std Spec 0740_STD, Appendix C.

1.1.6. Check the shafts on rollers for straightness. Conduct a dial indicator run-out survey at every 20 inches of the shaft. Plot the run-out readings on an appropriate scale to detect any shaft bending.

1.1.7. Submit a CIR of all findings from the above inspections and any recommended repairs to the Contracting Officer's Technical Representative (COTR) within 24 hours of completing each inspection and test.

2.7. Stern tube. The Contractor shall accomplish the following for the port and starboard stern tubes:

1.1.8. Clean and visually inspect the stern tube interior surfaces for defects. Submit a written report of findings to COTR within 24 hours after inspection.

1.1.9. Install two, properly sized, PSS dripless shaft seal maintenance kits, one for each shaft seal.

2.8. After completion of all authorized repairs, the Contractor shall reinstall the propeller shafts, and all disassembled components to their original configuration.

2.9. Provide and install four 2 ¾” shaft zincs, two on each shaft.

2.10. Shaft change-out. The Contractor shall be aware that the Government reserves the right to furnish a new propeller shaft(s) for installation in-place of the one(s) removed. When the Government exercises this right, the Contractor shall turn over the removed propeller shaft(s) to the Contracting Officer's Technical Representative (COTR) as an MTI item.

1.1.12. Operational testing. In the presence of the Contracting Officer's Technical Representative (COTR) the Contractor shall thoroughly test and prove to be in satisfactory operating condition without any abnormal vibration and/or binding the propulsion shafting system. There shall be no leakage at the shaft stuffing tube or mechanical seals.

3. RENEW PORT AND STARBOARD WATER-LUBRICATED SHAFT BEARINGS:

3.1. Related work item. The Contractor shall accomplish this work item in conjunction with "Remove, Inspect and Reinstall Both Propeller Shafts", which is a separate work item in this specification package.

3.2. Initial measurement. Prior to removing shafts, the Contractor shall:

1.1.13. Measure bearing clearances at 90-degree intervals around the shaft at forward and aft ends of each bearing.

1.1.14. Submit a CFR after taking the measurements.

3.3. Remove the existing water-lubricated bearings.

1.1.15. Measure the inner diameter of each bearing housing at forward, middle and aft positions.

1.1.16. The Contractor shall submit a CFR for the completed inspection and measurements.

1.1.17. Machine the new contractor-furnished bearings to fit the bearing housings in accordance with the manufacturer's installation recommendations.

1.1.18. Install the water-lubricated bearings with a light press fit, secured with headless cup point set screws.

1.1.19. Dispose of the existing bearings.

1.1.20. Measure final bearing clearances at 90-degree intervals around the shaft at forward and aft ends of each bearing.

1.1.21. Submit a CFR after taking the measurements.

1.1.22. Visually inspect the new bearings and record bearing clearances, after shaft reinstallation.

1.1.23. Submit a CFR upon completion of inspection and test.

4. REMOVE, INSPECT, AND REINSTALL PORT AND STARBOARD PROPELLERS

4.1. Protect propeller blade edges and blade roots with suitable covers, at all times until reinstallation, to prevent damage.

4.2. Removal. Loosen and remove the propeller nut and jam nut. Remove each propeller from the shaft taper and transport to a suitable repair shop.

4.3. NOTICE! If it becomes necessary to apply heat to facilitate propeller removal, ensure that the hub temperature never exceeds 500 degrees Fahrenheit; in addition, ensure that gland, packing ring, fill and vent plugs are removed, and the adjacent shafting and canvas under the blade edge guards are protected from flame impingement.

4.4. Inspection. Visually inspect each propeller for any damage, cracks, and other defects. Examine and record the suction and pressure face thickness, blade tip profiles, leading and trailing edges, contours, track, width, diameter, taper, pitch, weight, and keyway of the propeller in accordance with ISO 484/2. Submit a written CFR to the COTR within 24 hours after the inspections.

1.1.24. Polish each propeller to a uniform 63 micro- inch RMS finish.

1.1.25. With the key in place, carefully check the fit of the propeller hub bore to the shaft taper by applying Prussian blue to the shaft taper.

1.1.26. Obtain a uniform fit of 60 percent contact over the taper, with a slightly heavier fit on the larger end. Do not heat the shaft taper to compensate for a poor fit.

1.1.27. If the fit is less than 60 percent, hand grind/stone the propeller hub bore to achieve the required fit.

1.1.28. Do not machine the shaft taper.

1.1.29. When 60 percent fit has been obtained, make a small inscription on the shaft to mark the propeller location. Use this mark as a reference in final assembly.

4.5. Propeller installation.

1.1.30. Cleaning. For the final assembly, the propeller bore and shaft taper surfaces shall be clean and free of bluing, lubricants, dirt, foreign particles, or any other substance, which would hinder/facilitate moving the propeller along the taper.

1.1.31. Install each propeller with dry metal-to-metal contact to obtain the maximum frictional force for torque transmission.

1.1.32. Assembly. With the propeller installed on the taper in the same position as when fitted, install the propeller nut and drive up the propeller until it is advanced forward about 1/16" beyond the inscribed mark as specified in 9.4.6 (Location inscription). Lock each nut in place with a stainless steel cotter key.

1.1.33. It is prohibited to use grease, oil, or other substances on the taper to help drive the propeller.

1.1.34. Adhere to the following warnings:

4.5.1.1. Do not heat the propeller hub, to compensate for a poor fit on the shaft taper.

4.5.1.2. Do not machine the shaft taper to achieve the required fit.

4.6. Propeller change-out. The Contractor shall be aware that the Government reserves the right to furnish a new propeller to be installed in-place of the one(s) removed. If the Government exercises this right the Contractor shall perform the inspections listed in 9.4 above prior to installation. Turn over the existing propeller(s) to the COTR as an MTI item.

5. HULL PENETRATIONS:

5.1. All unused penetrations in the hull bottom and sides shall be sealed. Unused thru-hulls shall be removed. A circular blank shall be welded over each penetration, the thickness of which shall be as least as thick as the hull plating in way of penetration.

6. STRUCTURAL REPAIRS:

6.1. Clean, and remove all water from engine room bilges.

6.2. Inspect engine stringers, and hull framing in engine room bilge, and provide condition report detailing recommended repairs or alterations if necessary.

7. DRY DOCKING

7.1. The Contractor shall furnish the necessary labor, material and equipment to safely Dock and undock MARAD fleet craft PG-201 for cleaning, tendering, examination and repairs as required. The contractor is responsible for providing their proposed dry-docking plan showing blocking arrangement prior to dry docking the vessel.

7.2. Abrasive blast hull of vessel below rub rail including bottom surface of rub rail and support gussets including, skegs, struts, and keel.

7.3. Prior to re- coating, contractor shall perform a hull bottom condition survey. All exterior welds shall be visually inspected, and any damage, corrosion or pitting noted. The results of the survey shall be noted in a written report and submitted to the Government representative.

8. ULTRASONIC THICKNESS SHOT INSPECTION:

8.1. The contractor shall perform a minimum of 100 hull thickness measurements in locations designated by the Government representative.

8.2. The ultrasonic testing apparatus, procedure requirements, and report shall be in accordance with ASTM E797.

8.3. Upon completion of all UT shots the contractor shall submit a report containing the following information:

8.4. The location of all UT shots

8.5. Original metal thickness

8.6. Measured metal thickness

8.7. Percent deterioration (calculation based on original metal thickness)

9. PRESERVE UNDERWATER BODY:

9.1. The contractor shall prepare and coat the designated surfaces as follows:

Exterior Surfaces to be Preserved Surface Preparation / (Anchor Profile in mils)

U/W Body and Boot-Top, Aluminum Hull, High Speed (>30 knots) Abrasive blast to bare metal with clean, fine aluminum oxide, garnet or equivalent inert material conforming to CID A-A-59316, Type I & IV / (1.5-2.5)

- or -

SSPC-SP 12/NACE NO. 5, WJ-2/L

1) MIL-PRF-24647 Anti-corrosive Epoxy

2) MIL-PRF-24647 Anti-corrosive Epoxy

3) Antifoulant, Non-copper, High Speed

4) Antifoulant, Non-copper, High Speed

5) Antifoulant, Non-copper, High Speed

5.0-6.0

5.0-6.0

3.0-4.0

3.0-4.0

3.0-4.0

Follow Manuf.

Instructions

- or -

SSPC-SP WJ-2/NACE WJ-2

9.2. For coating purposes, the bilge keel, sea chest, gratings, and skegs are treated as part of the underwater body.

9.3. Total removal of antifouling coatings is not required. Total dry film thickness encountered during removal may exceed specified thicknesses.

9.4. When applying a foul release coating system, contact the manufacturer for application instructions and require the manufacturer's technical representative to be present while the coating is applied. The final coat shall have an almost gloss or wet sheen finish. Areas with a flat finish must be repainted to a wet sheen finish. Fouling release coatings must not be scraped or cleaned with a stiff brush. Once scratched, the topcoat must be reapplied to prevent fouling adhesion.

9.5. The final coat of Antifoulant on high speed (>30kts) aluminum craft shall be allowed to cure for 48 hours before putting the vessel back into the water. . Follow the coating manufacturer’s instructions if more than 48 hours are required depending on temperature and humidity.

9.6. Upon completion of all blasting and coating remove all covers, masking, plugs, and other protective material. Wash down the vessel to remove all dusts and grit.

9.7. The Contractor shall repair all damages, including overspray, incurred to surfaces not covered by the scope of this work item, during surface preparation and paint application procedures.

10. ENGINE INSTALLATION:

10.1. Provide and install two new John Deere 6135AFM85 13.5L, 500HP Marine Diesel Engines with ZF 360 Marine Gear, 1.966:1 ratio.

10.2. Provide and install properly sized shaft coupling to mate with ZF 360 Marine gear as installed.

10.3. Install new fuel piping, supply and return including necessary valves from tank to engine. Fuel system shall include properly sized spin on type fuel filter and turbine type fuel and water separator unit for each engine. All fuel system installations shall meet or exceed ABYC requirements.

10.4. Gauge Panel Installation. The contractor shall:

1.1.35. Modify dash as necessary for new gauges

1.1.36. Install gauges, key switches, and start/stop buttons at helm

1.1.37. Fabricate mounting panels for engine interface boxes

1.1.38. Install mounting panels and engine interface boxes

1.1.39. Pull wiring harness from engine room up to control helm for alarm system, gauges, vessel view, and start/stop panel

1.1.40. Wire engine interface boxes and gauges per Cummins installation drawings for proper operation

1.1.41. Test for proper operation

11. EXHAUST SYSTEM:

11.1. Provide custom stainless steel exhaust riser to maximum height allowed in engine space and meet engine manufacturer’s requirements.

11.2. Provide and install correctly sized fiberglass exhaust pipe between riser and muffler, connected at each end with Trident blue silicone exhaust bellows fastened at each end with two stainless steel t-bolt clamps.

11.3. Provide and install properly sized muffler for water cooled exhaust for each engine, mufflers to be located in the lazarette to match the original configuration.

12. RAW WATER SYSTEM:

12.1. Sea Strainers. Remove the above listed sea strainers to a suitable repair facility.

12.2. Install blank flanges and gaskets or caps (as applicable) over all openings and secure with at least two bolts 180-degrees apart to prevent debris from contaminating the open piping and hoses.

12.3. Ensure that the blank flanges/caps are installed immediately after the sea strainers are removed and remain in-place until the sea strainers are reinstalled.

12.4. Strainer disassembly and inspection. Completely disassemble and thoroughly clean all components to bright metal without injury or deformation. Inspect all disassembled components, including the packing gland. Submit a written CFR.

12.5. Reassemble the strainer, using a new Contractor-furnished basket and new packing gland fasteners. Lubricate the valves with plug valve grease conforming to AMS-G

12.6. Hydrostatically test the plug valve of the duplex strainers to each strainer chamber, at a water pressure of 15 psig. To determine leakage rate the strainer shall have the outlet blanked and the unpressurized side top cover removed (two tests per duplex strainer).While maintaining the test pressure at the inlet side, the non-pressurized side shall not fill within ten minutes.

12.7. NOTICE! Ensure that the drain valve for each chamber is closed.

12.8. Provide a written report of the test results, which shall include, but not be limited to the following information:

12.8.1. Grease type, including batch number and manufacturer.

12.8.2. Time elapsed for chamber to fill, if less than ten minutes.

12.9. The Contractor shall renew designated hose assembly(ies) with new Contractor-furnished material. Renewal shall include fabrication of a new hose assembly with new hose end fittings using the existing hose as a template.

12.10. Reinstallation. After completion and acceptance by the Coast Guard Inspector, the Contractor shall reinstall all hoses and strainers to their original location.

12.11. Renew all gaskets, as applicable, with material conforming to ASTM D1330 of the same size and configuration as those gaskets removed.

12.12. Strainer renewal. If a Change Request has been authorized and released by the ACO, the Contractor shall renew designated strainer(s) with new Government-furnished strainer(s) and dispose of the existing strainer.

12.13. The COTR will have final approval of all overhauled sea strainers prior to their reinstallation.

12.14. Perform testing on the new Government-furnished strainer in accordance with (17.6 testing). Submit CFR in accordance with (17.8 Final report.).

12.15. The Contractor shall preserve the new Government- furnished strainer(s) in lieu of the removed strainer(s) in accordance with (3.2.6 (Preparation and painting

12.16. Overhaul approval. The Coast Guard Inspector will have final approval of all overhauled sea strainers prior to their reinstallation.

12.17. After all authorized repairs of mechanical (i.e. threaded, bolted, etc.) joints, the Contractor, in the presence of the Coast Guard Inspector, shall perform an operational test of the sea water system using the system fluid at normal operating pressure. Be aware that no visible leakage or deformation is acceptable. Repair all leaks and discrepancies found, see (17.18 (Equipment operation).

12.18. Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests.

12.19. The terms ‘duplex’ and ‘simplex’ as used in this work item refer to the generic strainer type, not a manufacturer’s brand name.

12.20. Replace existing sea valves with contractor provided FORESPAR “Marelon” reinforced nylon ball valves threaded directly on to standpipes.

12.21. Install and route new raw water hose from strainers to engine

12.22. Install and route new raw water hose from strainers to sea valves

12.23. Install and route water hose from engine to custom exhaust risers.

13. ENGINE CONTROLS:

13.1. Remove existing hydraulic engine control system.

13.2. Install ZF 9000 Series control system utilizing ZF 463-4 control levers mounted on pilot house dash and aft control station, locations of control levers to be approved by Government representative.

13.3. Install ZF 9000 series Clear Command processor in engine room to include wiring of DC power supply and bonding of unit. Processor shall be configured for electronic throttle control with mechanical shift control and include installation of new 33C shift control cables. Installation shall be performed to manufacture’s specifications. Mounting Location of processer and routing of cable runs to be approved by COTR.

14. Welding Repairs – Flat Plate Renewal (3/8” Aluminum)

14.1. Submit unit price per pound (Estimate upto 100-lbs) for renewal of aluminum in various locations as designated by the Owner's Representative. Cut and remove aluminum, supply, fit and install new aluminum as per ABS and USCG rules and regulations. Sandblasting, priming, painting and testing shall be included in the price. All new and disturbed aluminum shall be prepared and coated as directed as appropriate. Interior surfaces shall be prepared and coated with 2 coats of surface tolerant epoxy. Repaired areas shall be tested with a vacuum box where practical or otherwise hose tested. Prepare disturbed areas after installation and testing and prime. Apply remainder of coating system.

15. Welding Repairs – Flat Plate Renewal (5/16” Aluminum)

15.1. Submit unit price per pound (Estimate upto 100-lbs) for renewal of aluminum in various locations as designated by the Owner's Representative. Cut and remove aluminum, supply, fit and install new aluminum as per ABS and USCG rules and regulations. Sandblasting, priming, painting and testing shall be included in the price. All new and disturbed aluminum shall be prepared and coated as directed as appropriate. Interior surfaces shall be prepared and coated with 2 coats of surface tolerant epoxy. Repaired areas shall be tested with a vacuum box where practical or otherwise hose tested. Prepare disturbed areas after installation and testing and prime. Apply remainder of coating system.

16. Welding Repairs – Flat Plate Renewal (1/4” Aluminum)

16.1. Submit unit price per pound (Estimate upto 100-lbs )for renewal of aluminum in various locations as designated by the Owner's Representative. Cut and remove aluminum, supply, fit and install new aluminum as per ABS and USCG rules and regulations. Sandblasting, priming, painting and testing shall be included in the price. All new and disturbed aluminum shall be prepared and coated as directed as appropriate. Interior surfaces shall be prepared and coated with 2 coats of surface tolerant epoxy. Repaired areas shall be tested with a vacuum box where practical or otherwise hose tested. Prepare disturbed areas after installation and testing and prime. Apply remainder of coating system.

17. Welding Repairs – Frames and Internals

17.1. Submit unit price per pound (Estimate upto 100-lbs) for renewal of aluminum in various locations as designated by the Owner's Representative. Cut and remove aluminum, supply, fit and install new aluminum as per ABS and USCG rules and regulations. Sandblasting, priming, painting and testing shall be included in the price. All new and disturbed aluminum shall be prepared and coated as directed as appropriate. Interior surfaces shall be prepared and coated with 2 coats of surface tolerant epoxy. Repaired areas shall be tested with a vacuum box where practical or otherwise hose tested. Prepare disturbed areas after installation and testing and prime. Apply remainder of coating system.

18. Welding Repairs, Crack Repair (Aluminum)

18.1. Submit unit price per pound (Estimate upto 100-lbs) for renewal of aluminum in various locations as designated by the Owner's Representative. Cut and remove aluminum, supply, fit and install new aluminum as per ABS and USCG rules and regulations. Sandblasting, priming, painting and testing shall be included in the price. All new and disturbed aluminum shall be prepared and coated as directed as appropriate. Interior surfaces shall be prepared and coated with 2 coats of surface tolerant epoxy. Repaired areas shall be tested with a vacuum box where practical or otherwise hose tested. Prepare disturbed areas after installation and testing and prime. Apply remainder of coating system.

19. WEATHERTIGHT DOORS

19.1. Remove two existing weather tight doors, one located on each side of pilot house.

19.2. Install two Government furnished weather tight doors one on each side of pilot house.

19.3. Doors are of aluminum construction and shall be welded in place with a continuous bead around complete circumference of door.

20. VESSEL CLEANING

20.1. Upon completion of all tasks, the contractor shall clean the watercraft, to include engine and lazarette compartments. The contractor shall remove all dirt, dust, pollen, grease, oils, coolants, and debris shall be removed from the exterior and interior to include bilge areas.

21. DOCK AND SEA TRIALS.

21.1. The contractor shall provide a slip for arrival and storage when needed during repower. A travel lift capable of safely lifting the watercraft and securing on the yard trailer provided by the government will be utilized when removing from or placing back into the water.

21.2. The contractor shall provide the following components in addition to all necessary parts to complete installation:

21.2.1. Replace fuel.

21.2.2. Antifreeze

21.2.3. Motor Oil

21.3. The contractor shall conduct sea trials. The contractor shall:

21.4. Fill engine with oil and coolant

21.5. Have engine manufacturers authorized service dealer perform engine start up and installation audit.

21.6. Conduct the first sea trial with the John Deere technician and have the manufacturers authorized service dealer perform sea trial and document the sea trial..

21.7. Obtain approval from the government Contract Officer Technical Representative (COTR) prior to departure if more than one Sea Trial is needed to work out adjustments or any other issues. If scheduling permits, COTR shall be present during each Sea Trial.

21.8. Perform an acceptance sea trial with the COTR

22. CURRENTLY INSTALLED ENGINES

22.1. Contractor will dispose of two 12V71 Main Engines, reduction gears, and all associated piping and electrical wiring removed from craft, and not serviceable for use in new engine installation.

23. SUPPLEMENTAL MATERIAL

23.1. Contractor shall provide an allowance for up to $3,600 in Supplemental Material charges. There shall be no burden on these charges for either subcontracted costs or material charges. If Supplemental Material is required, it will be allocated by the COR via Delivery Orders. The Contractor shall provide to the COR invoices for goods or services applicable to Supplemental Material charges for each Delivery Order with material charges in excess of $250. Negotiations based on material estimates will be credited or debited accordingly, once the actual material invoice is received by the COR. All material invoices must be received no later than the completion of each Delivery Order. Retainage will not be released until all material invoices have been received and approved by the COR. The contract cannot be closed out until all material invoices are submitted, or Delivery Orders will be debited accordingly.

24. Supplemental Labor

24.1. Contractor shall furnish a unit price offer for 200 man-hours of supplemental labor. This shall be a fully burdened labor rate, and is applicable seven days a week (i.e. no overtime, penalty time or other escalations will apply). These hours will only be allocated for industrial labor. Supervision, management, QA, yard maintenance and other such labor is considered part of the rate burden. When Supplemental Labor is required by the MARAD, a Contractor-submitted Condition Report with fully documented price proposals shall be documented by a work structure breakdown on a Contractor-developed estimating form, as an attachment to the Condition Report. Supplemental hours, if authorized, will be allocated by the COR via Delivery Orders. No oral directions shall be accepted by the Contractor or its personnel from any individual other than the COR. Any oral direction provided by the COR other than guidance on existing tasking shall be documented via Delivery Order Request for Pricing within 24 hours. All tasking provided by the COR will normally be in writing, and no work shall begin on any tasking of and other than emergency nature until received by the Contractor, negotiated and settled by the COR and/or the Contracting Officer. Any questions, concerns or disputes of tasking given (including challenges as to whether ITEMs are within scope or genuine new work) shall be presented to the Contracting Officer in writing for resolution.