GU_FY13_DD_Repair_Specifications_(Rev_2).pdf

NOAA Ship Gordon Gunter

FY13 Drydock Repair Specifications

(Rev 2)

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FY 2013 Drydock Repairs to NOAA Ship Gordon Gunter

TABLE OF CONTENTS

DESCRIPTION/TITLE PAGE

1. SCOPE 2

2. GENERAL 2

3. BASE ITEMS 7

3.1 TEMPORARY SERVICES 7

3.2 DRYDOCKING AND ROUTINE DRYDOCK WORK 12

3.3 ABS SPECIAL PERIODICAL SURVEY – HULL 5 21

3.4 UNDERWATER HULL COMPLETE PAINT SYSTEM 32

3.5 SEA VALVE OVERHAULS 34

3.6 BOW THRUSTER INSPECTION AND SERVICE 41

3.7 BALLAST TANK PRESERVATION AND REPAIRS 43

3.8 STEERING GEAR HYDRAULIC CYLINDER OVERHAUL 48

3.9 SEWAGE SYSTEM PIPING RENEWAL 50

4. ADDITIONAL WORK 56

4.1 ADDITIONAL WORK 56

5. OPTION ITEMS 57

5.1 FREEBOARD BLAST AND PAINT 57

5.2 A-FRAME AND J-FRAME MODIFICATIONS AND REPAIRS 58

5.3 FAN ROOM 1-34-2-Q VENT DUCT RENEWAL 62

5.4 WATERTIGHT/WEATHERTIGHT DOOR REFURBISHMENT 64

5.5 WATERTIGHT SOFT PATCH (BERP)RENEWAL 65

5.6 OUTRIGGER KINGPOST PRESERVATION 68

5.7 FLYING BRIDGE DECK PRESERVATION 73

5.8 BRIDGE (0-3) DECK PRESERVATION 75

5.9 STACK REPAIRS 78

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1. SCOPE. These Detail Specifications contain the requirements for drydock repairs and modifications to the NOAA Ship Gordon Gunter.

2. GENERAL.

2.1 References

2.1.a NOAA Standard Specification No. AMC-000-1G, “General Requirements for Ship Repair Work on NOAA Ships.”

2.1.b NOAA Standard Specification S1600, “Structural Access Cuts.”

2.1.c NOAA Standard Specification, S2906, “Arc Welding on Waterborne Vessels.”

2.1.d Dwg. No. GU-830-002, “Booklet of General Plans” 2.1.e NOAA Ship Gordon Gunter Drawing Index List 2.1.f NOAA Ship Gordon Gunter Technical Publication Index List 2.1.g Dewg. No. GU-801-001, “NOAA Ship Gordon Gunter Tank Sounding Tables.”

2.1.h NOAA Weight Report Form, Microsoft XL Format, “Weight Report.xls” 2.1.i NOAA Standard Specification MOC-631-2D, “Coating Systems for Steel Surfaces.”

2.2 Requirements

2.2.1 Reference 2.1.a forms a part of these Detail

Specifications. All provisions and requirements contained therein are applicable to all work items, including all additional work items which are authorized by the Contracting Officer.

2.2.2 References 2.1.b and 2.1.c are amplifications of the

requirements contained in reference 2.1.a sections 4.17 and 4.21.

2.2.3 References 2.1.e and 2.1.f will be available for

review during scheduled pre-bid inspection and during the performance period of the contract.

2.2.4 Some of the ship’s drawings have not been updated to

reflect modifications to the ship following re-activation and conversion in 1999. Contractor shall be responsible for verifying all current configuration, construction, and arrangement changes, as necessary, to comply with and

Page | 3 perform the work requirements of these specifications.

Contractors are encouraged to review ship’s drawings and to perform a field inspection of the ship and her equipment prior to submitting a bid proposal.

2.2.5 Ship’s drawings and technical publications may be

borrowed during the performance period. All reference materials borrowed by the Contractor shall be signed for, and then returned to the COTR after no further use of the reference materials is required.

2.2.6 Provide and maintain a status report of all American

Bureau of Shipping (ABS) inspections and technical reviews required by ABS, during the course of this contract, to ensure the ship’s ABS certification requirements are in compliance. Submit weekly ABS status reports to the COTR, along with the preliminary weekly progress reports.

2.2.7 All visual examinations, hydrostatic testing, and

non-destructive testing shall be in accordance with ABS Rules for Building and Classing Steel Vessels, Survey After Construction 2005, Part 7. All contractors performing NDT and hull gauging shall be certified under the ABS external specialists program.

2.2.8 On a weekly basis (on the day preceding the Weekly

Progress Meeting) provide the COTR revised and updated copies of the production schedule reflecting actual work progress.

2.2.9 All new equipment and furnishings purchased by the

Contractor for installation on the vessel shall be provided with factory supplied technical manuals, or data sheets, complete with parts listings. Faxed copies of this information are not acceptable. This documentation shall be turned over to the COTR after installation is completed.

Equipment technical manuals shall provide detailed information necessary to operate, maintain, troubleshoot, and repair the equipment. The manuals shall include detailed procedures for disassembly of equipment, parts lists, drawings, inspection criteria, troubleshooting, and test procedures. Provide four paper copies of each manual, plus one electronic copy in Abode Acrobat .pdf format.

2.2.10 All inspection, test, and quality reports shall be

submitted to the COTR in Corel WordPerfect or Microsoft

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Word electronic software formats, in addition to providing hard paper copies.

2.2.11 Whether specified in the individual specification

item or not, all surface preparation and painting shall be accomplished by a SSPC QP1 certified painting contractor.

2.2.12 Weigh all materials and items removed, installed, or relocated on the ship. Provide a summary report to the COTR indicating the total weight in pounds of items and a breakdown of their locations by space, deck, frame, distance from centerline, and height above the deck.

Reference 2.1.h is provided for the Contractor to identify, record, and document all weight changes and submitting the summary reports. Contractor may use their own weight report form for documenting weight changes. All the information required must be tracked and documented on any form provided.

2.2.13 Unless otherwise stated in the individual work

items, prepare and coat all new steel, all existing steel surfaces identified to be cleaned and painted, and all paint systems disturbed while accomplishing work items, in accordance with reference 2.1.i. Finish coat colors shall match those of the surrounding, unmodified area. In addition, all power tools used to prepare internal spaces for painting shall be fitted with dust collecting equipment to keep airborne contaminants to a minimum. This does not relieve the Contractor from using protective coverings on equipment in those spaces.

2.2.14 Ship’s force will maintain a minimal presence

during accomplishment of work to these specifications.

Their availability to operate ship’s equipment will be limited. Crew availability is generally limited to the hours of 0800 and 1500 local time, Monday through Friday.

Unless otherwise specified, provide a minimum of two working days’ prior notice for any equipment operations.

2.2.15 All new and disturbed machinery and services shall

be operated for a period sufficient to indicate satisfactory performance, but not less than one hour, after all adjustments and deficiency corrective actions have been made, without further adjustment. All operational testing of equipment shall be performed dockside (Dock Trials) prior to any scheduled Sea Trials.

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2.2.16 Provide manufacturer’s technical representatives

where required in the individual work items, to witness and to provide technical guidance during operational testing of equipment and systems. All tests and trials of equipment or systems shall be witnessed by the COTR, ABS, and/or USCG as applicable, to ensure compliance with regulatory body requirements to maintain the ship’s ABS class certification, and to complete all requirements of these specifications.

2.2.17 Following satisfactory completion of dock trials, the Contractor shall schedule and participate in a one-day sea trial near the end of the work performance period to witness testing of all repaired or newly installed equipment and machinery. The sea trial shall be an underway at-sea condition for a duration of at least eight hours, departing from and returning to the Contractor’s facility. Transits in a river and/or channel, to and from the contractor’s facility shall not constitute an underway at-sea condition. The COTR may elect to shorten the duration of the sea trial in consultation with the ship’s command, dependent on the performance of all ship’s equipment and systems to be operated and tested. The Contractor shall coordinate the sea trial date with manufacturers’ technical representatives as required, and provide at least 72 hours notice.

2.2.18 These Detailed Specifications are a combination of

“performance specifications” and “design specifications.”

Whenever possible, the Government has provided performance specifications, giving the Contractor the opportunity to accomplish the work requirements as best as he or she sees fit, while providing a fully functional repair and/or equipment/system installation in accordance with all work requirements. When specific details are required, the Government will provide design/detail specifications; this will be more the exception, than the rule.

2.2.19 Frame numbers and space names are derived from

ship’s drawings. Equipment changes and space modifications over the ship’s life span may not all be reflected in the referenced drawings. Contractors are encouraged to review all referenced drawings and to perform a field inspection of the ship prior to submitting a bid. Copies of drawings and technical manuals not included herein may be made available for review during any scheduled pre-bid inspection and during the performance period. During the

Page | 6 pre-bid inspection, Contractors may review available drawings and technical manuals on board ship or at the Port Engineer’s office at NOAA’s Gulf Marine Support Facility, 151 Watts Ave., Pascagoula, MS.

2.3 Notes

2.3.1 The following descriptive data of the ship is

provided for information:

Length, Overall.....................................224’ 0” Length, BP..........................................194’ 0” Beam, Molded.........................................43’ 0” Mean Draft, Loadline.................................15’ 1” Displacement, Loadline..............................2328 LT Displacement, Lightship...........................1557.2 LT Cruising Speed.....................................11 knots Officer & Crew Size Electric Service......450 VAC, 60 Hz, 3 PH, 800 Amp Service Propulsion......................Diesel electric, twin screw

2.3.2 NOAA Ship Gordon Gunter is ABS classed A1, Ice

Class C, E, AMS, and ACCU and is identified with ABS ID Number 9000291, IMO Number 8835255, Official Number 023674, and Hull Number 1128.

NOAA Ship Gordon Gunter (R-336)

GOVERNMENT FURNISHED MATERIAL/EQUIPMENT

ITEM QTY DESCRIPTION EST COST

3.2.2.1 3 ea. copper anode (part no. EL40012-9) $3,000

3.2.2.2 3 ea. iron anode (part no. EL40014-9) $2,500

3.5.2.1 1 ea. 8-inch SS 150# check valve $4,000

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3.0 BASE ITEMS

3.1 TEMPORARY SERVICES

3.1.1 References

3.1.1.1 NOAA Standard Specification AMC-000-2C, "Temporary Services at Contractor Facilities"

3.1.2 Government-Furnished Material

3.1.2.1 None

3.1.3 Requirements

3.1.3.1 Provide all temporary services required in

accordance with Reference 3.1.1.1.

3.1.3.2 The following additional information and

requirements apply:

(a) Electric power: Provide two 450 VAC, 3 Phase, 60 Hertz, 400 Amp circuits [800 amps total]. Providing properly rated shore power cables and NATO plugs shall be the Contractor’s responsibility. All power supplied to the ship shall be clean, with no indications of ground faults on the ship’s main switchboard. All ground fault deficiencies associated with the Contractor’s power supplied to the ship, shall be corrected at the Contractor’s expense. Such expense shall include housing allowance for ship’s crew, if the ship is still habitable at the time the deficiency is noted.

(b) Telephone lines: Provide six telephone lines. Connect two voice lines to the ship's telephone connection box above the shore power station at frame 72, 01-deck.

Connect two voice lines to the shore offices (one in the COTR's office and one in the ship's office). Connect two data lines for service on two fax machines (one in COTR’s office and one in Ship’s Office).

(c) Fax machines: Provide two Fax machines (one in the COTR’s dockside office space and one in the ship’s office).

(d) High-Speed Internet Service: Provide high-speed, broadband internet connectivity via a local Internet Service Provider (ISP), or privately owned, internal

Page | 8 internet connection. High-speed, broadband internet is defined as Digital Subscriber Service (DSL), Cable Network, or Fiber Optic Network services with minimum download speeds of 320 Kbps. The service provided shall be a business-type account that supports Virtual Private Network (VPN) connections, if available, Provide the proper number of connections necessary to satisfy the ship’s wet berth and drydock locations, as well as the ship and COTR’s dockside office space(s). All necessary cabling, DSL or Cable modem(s), or fiber translators shall be provided for an RJ-45 network connection to the ship and office(s) routers. Provide a minimum of one Internet Protocol (IP) address with Directory Name Server (DNS) service for each of the ship and dockside office(s) locations. The ship’s electronic technician (ET), will provide the necessary routers and switches needed.

(e) Security Service: In addition to Reference 3.1.1.1 requirements, increase security round frequency from two-hour intervals to one-hour intervals.

(f) Air: Provide 125 psi dry, filtered compressed air to a manifold on deck. No connection shall be made to the ship’s compressed air distribution system.

(g) Cooling Water: Provide 300 gpm @ 80 psig capacity, with a separately priced option for an additional 300 gpm @ 80 psig if needed, for ship’s auxiliary sea water system which supports all refrigeration plant cooling water, air conditioning plant cooling water, and sanitary system toilet flushing needs (NOTE, the ship’s sea water system provides 600 gpm for full load). In the event, the sea water or cooling water provided to these systems is disrupted or disabled, an alternate means of providing water service to these systems shall be the contractors responsibility. Provide a pressure regulator on the discharge side of the contractor’s cooling water supply to the ship’s systems capable of regulating pressure between 25 psig and 80 psig. Contractor may provide separate cooling water service connections to meet the ship’s cooling water systems needs at designated hook-up locations. Note: A 4-inch piping line was installed on the auxiliary sea water cooling system branch line to the ship’s forward AC machinery space in 2003. Cooling water may be supplied at this location in the forward port side main generator room, just outboard of the port distilling plant. See ship’s Chief Engineer for individual cooling

Page | 9 water service hook-up locations and pressure requirements for the separate systems. Contractor shall make-up temporary by-pass hose and/or piping arrangements to support the ship’s AC and refrigeration plant cooling water needs, in conjunction with the work requirements of other items in these specifications.

(h) Protective Coverings: In addition to the protective coverings specified in paragraph 4.5.1 of Standard Specification AMC-000-1G, place a layer of heavy duty (minimum 4 mils) plastic sheeting between the deck and the protective covering.

(i) Parking Spaces: Provide seven reserved vehicle parking spaces within 100 feet of the dockside office spaces.

Identify additional parking spaces for up to 15 cars, within or outside the shipyard, which may be available for parking by ship’s personnel and other NOAA representatives.

(j) Office Spaces: Provide three secure locked office spaces (one office space for the COTR, one for ship’s office space, and one for the ship’s server). Increase office size to 12-feet x 20-feet. Provide three sets of keys to each space to the COTR. COTR’s office shall be made available 2 days prior to the ship’s arrival at the Contractor’s facility and shall remain so until 2 days after the ship has departed.

(1) COTR's dockside office space shall contain one desk, one 48-inch high by 36-inch wide bookshelf, and three chairs. Provide two phone lines [described above]: one voice and one fax. Provide high speed internet service as required in paragraph 3.1.3(2)(d) above. Provide one fax machine. Provide one 4-drawer file cabinet with lockset, and one 3 foot wide x 4 feet high x 12 inches deep book case. Provide one copy machine capable of multiple copying, sorting, and paper size conversion (enlarging/reducing) of documents, in paper size ranges from letter (8.5 x 11 inches), legal (8.5 x 14 inches), and “D“ size drawings (11 x 17 inches).

(2) Ship’s dockside office shall contain three desks along with six chairs. Two phone lines shall be provided [described above]: one voice and one fax.

Provide high speed internet service as required in paragraph 3.1.3.2(d) above. Provide one fax machine.

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Provide one 4-drawer file cabinet with lock set. Add one fire proof safe for ship’s security documents.

The minimum interior size of the safe shall be 14-inches long by 18-inches deep by 12-inches high.

(3) Ship’s server office space requires only air conditioning, uninterruptable 120VAC power, and high speed internet service as required in paragraph 3.1.3(2)(d) above.

(k) Storage Container: Provide a closed, lockable storage container, or space, for ship’s personnel use, with minimum nominal dimensions of eight feet high by eight feet wide by twenty feet deep. Provide COTR three sets of keys to the lock for this storage container.

(l) Tank Pumping: Pump the bilge oily water holding tank 4-60-1-F (estimate 500 gallons on board, up to 1500 gallons maximum), the dirty oil tank 4-6-2-F ( estimate 500 gallons on board, up to 1500 gallons maximum), the sludge tank 3- 50-2-F (estimate 50 gallons on board, up to 100 gallons maximum). Pumping the bilge oily water holding tank, the dirty oil tank, and the sludge tank shall be done at the beginning of the contract performance period. Additional pumping will be required whenever liquid is added to these tanks or spaces as a result of contractor washing down in order to maintain gas-free certification, or other incidental liquid drainage into these spaces as a result of the performance of work.

(m) Bilge Cleaning/Pumping: Pump generator room and propulsion motor room bilges at the beginning of the contract period and at the end of the period. Pressure wash, pump, and clean all debris from the bilge at the end of the contract period. Protect all electrical controllers and machinery from over spray and debris prior to pressure washing. Clean out bilge rose boxes after pressure washing.

(n) Crane Service: Provide and make available, crane service including operator and riggers for ship's force equipment and material lifts as needed during normal working hours. Provide crane lifts with a 5-ton minimum capacity. The COTR will provide a minimum of four hours notice prior to any lifting required for ship’s force needs. For bidding purposes, assume 25 hours of crane service in total. In addition, provide adequate pier space and vehicle access for staging mission equipment and

Page | 11 loading provisions during the last two weeks of the contract period.

(o) Toilet Facilities & Sewage Disposal: Provide temporary toilet facilities and perform sewage system effluent and turbid water disposal at any time the ship’s sanitary system and marine sanitation plant and gray water system operation is disrupted, due to work performance on any other item of these specifications where disruption of these systems will be required.

(p) Grey Water Disposal: Provide a connection for the ship’s grey water overboard discharges, located on the starboard hull side, just forward of the Plimsoll mark.

Collect and properly dispose of all grey water overboard discharges which shall meet the same requirements for sewage and turbid water disposal, in accordance with paragraph 3.10 of NOAA Standard Specification AMC-000-2C.

(q) Disruption of Temporary Services: In the event temporary services are reduced due to the extent of contract work and disruption to services provided to the ship, rendering the ship uninhabitable, an equitable adjustment to the contract shall be negotiated. The daily temporary service charge for all services as bid, but not provided shall be reduced and a credit provided to the government for the remainder of the contract period.

Contractor shall make every effort to maintain all facilities and services required by this specification in a safe manner, so as not to render the ship uninhabitable.

3.1.5 Notes

3.1.5.1 The ship will provide its own NATO plugs with pig

tail cables. Each cable assembly is rated for 400 amp service, for plug in to the dual shore power connection box on the 01-deck at frame 72.

END OF ITEM

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3.2 DRYDOCKING AND ROUTINE DRYDOCK WORK

3.2.1 References

3.2.1.1 NOAA Standard Specification AMC-997-1A, "Drydocking

and Routine Drydock Work"

3.2.1.2 Dwg. GU-085-01 (Rev A), “Docking Plan”

3.2.1.3 NOAA Standard Specification S1205, “Zinc

Protectors”

3.2.1.4 Drawing No. 243-6233870, “ Main Propeller Shaft

Installation Arrangement & Details”

3.2.1.5 Drawing No. 543-6233930, “Stern Tube & Shaft

Bearing Lube Oil System Arrangement”

3.2.1.6 Dwg. 633-6233582, “Zincs Arr & Details”

3.2.1.7 ELINCA Technical Manual, “The ELINCA Anti-

Biofouling System”, Series P-000 (US), Manual No. 154 in Ship’s Technical Publication Index (see Note 3.2.5.1).

3.2.2 Government-Furnished Material

3.2.2.1 3 ea. copper anode (ELINCA part no. EL40012-9)

3.2.2.2 3 ea. iron anode (ELINCA part no. EL40014-9)

3.2.2.3 The Government will provide the following special

tools for temporary use by the Contractor:

(a) Propeller nut wrench

(b) Bow thruster hub nut wrench

(c) Bearing wear down gauges

(d) Tailshaft coupling nut spanner wrench

(e) Plastic “bullet” for threads on fwd end of tailshaft (permits pulling shaft without damaging stern tube)

3.2.3 Requirements

3.2.3.1 Provide drydocking and routine drydock work in

accordance with References 3.2.1.1 and 3.2.1.2. Drydock the vessel within the first 72 hours of the contract performance period.

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3.2.3.2 The following information and requirements apply:

(a) Connect electrical power and cooling water in the drydock in accordance with paragraphs 3.1.3.2 (a) and

(g) prior to the ship being lifted out of the water.

(b) Block the ship with a minimum of four feet clearance under the keel in Docking Position No. 2.

Provide two additional keel blocks, one between frames 86 and 91, and one below the bow thruster between frames 9 and 11.

(c) When the vessel is set on the keel blocks, prior to lifting it out of the water, have divers ascertain that the bilge blocks are contacting the hull properly and not landing on the bilge keels. The divers shall inform the Dockmaster and COTR and then lifting shall continue.

(d) Provide rudder clearance readings to the COTR within the first seven days of ship drydocking during the contract performance period.

(e) Open drain plugs on rudders and bilge keels.

Drain liquid, if any, from rudder and bilge keel interiors. Conduct a 2 psi air test on rudders and bilge keels. Apply an environmentally friendly float coat to rudder and bilge keel interiors by the fill and drain method. See Note 3.2.5.1.

(f) Clean the propeller and bow thruster blades to bright metal by power brushing. See Note 3.2.5.4.

3.2.3.3 All work on the tail shafts, stern tube seals, liners, and bearings shall be accomplished under the guidance of a manufacturer's technical representative from Wärtsilä Defense, Inc. Provide the services of a manufacturer's technical representative from Wärtsilä Defense, Inc. to oversee bearing weardown readings and perform a check of the stern tube seals. It is imperative that the manufacturer’s technical representative provided have experience inspecting and servicing the stern tube bearing assemblies installed aboard NOAA Ship Gordon Gunter, in order to properly obtain bearing wear down measurements and evaluate the condition of the bearings and seals.

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3.2.3.4 Schedule the services of an American Bureau of

Shipping (ABS) surveyor to the extent necessary, to accomplish any required inspections or technical reviews to maintain compliance with ABS class requirements. NOAA will pay ABS for survey costs under a separate purchase agreement.

3.2.3.5 Under the guidance of the Wärtsilä technical

representative, take bearing wear down readings on both tailshafts, using the bearing wear down gauges provided by the ship’s Chief Engineer. All readings taken shall be witnessed by the ABS surveyor, COTR, Chief Engineer, and the Wärtsilä technical representative. In addition to providing recorded readings in an inspection report, readings shall also be entered in the ship’s wear down record, to be retained with the wear down gages. Return the wear down gages to Chief Engineer after recording all measurements are taken.

3.2.3.6 Remove the port and starboard propellers from

their respective tailshafts and inspect the threads for damage. Expose the forward ends of the tapers and perform an NDT examination by surface crack-detection method (magnetic particle or dye penetrant), all around the shafts in way of the forward portion of the taper sections, including the end of the keyways.

3.2.3.7 Remove and dispose of all oil and water, if any, from both port and starboard stern tube lube oil systems, including stern tube and forward seal head tanks and sumps.

Open port and starboard sumps and head tanks. Clean each tank of all dirt, rust, sludge, and sediment using lint free rags and solvent.

3.2.3.8 Remove the portion of the port side stern tube

lube oil piping which penetrates the bulkhead between frames 93 and 94 from the tunnel into the “Array Fluid Leakage Collection Tank 2-92-2-F”, continues into the 4-86- 2-W Ballast Tank, then penetrates bulkhead 94 into the 3- 94-2-W Ballast Tank below the Steering Room deck. The following portion of Drawing 543-6233930, “Stern Tube & Shaft Bearing Lube Oil System Arrangement” shows the removal in red hash marks.

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3.2.3.9 Plug weld all bulkhead and deck penetrations

opened as a result of the stern tube lube oil pipe removal in accordance with ABS rules. Test welds with a vacuum box and magnetic particle testing.

3.2.3.10 Install new 1-1/4 inch IPS Schedule 80 Grade 8

seamless pipe and fittings meeting ASTM A53, from the point at which the pipe was cut in the tunnel, penetrating bulkhead 94 into the Steering Room, running outboard and penetrating the Steering Room deck and reconnecting with the stern tube lube oil system at the point at which the existing pipe coming from the 4-86-2 Ballast Tank was cut.

Note (1): All new bulkhead and deck pipe penetrations shall be sleeved. Note (2): A cofferdam was installed within the 3-94-2-W Ballast Tank in January 2012, isolating the stern tube lube oil piping from the surrounding ballast water. A manhole in the Steering Room deck provides access to that cofferdam.

3.2.3.11 Prime and paint all new and disturbed surfaces to

match surroundings.

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3.2.3.12 Disconnect the tailshaft couplings from the port

and starboard propulsion motor output flanges. Slip the tailshafts aft approximately two feet to permit removal of the couplings. Remove couplings from the tailshafts. See Note 3.2.5.8.

3.2.3.13 After all work to relocate the stern tube lube

oil piping is complete, remove the port tail shaft from the stern tube. Isolate and flush the entire port side stern tube and its lube oil pipe system using the old Hydrox Vickers Bio 68 oil drained from the system, heated to at least 140oF, through 10 micron filters. Flush for a minimum of 8 hours or until no slag or any other type of residue can be found in the oil. Reinstall the tail shaft.

3.2.3.14 Disassemble and clean the forward and aft stern

tube seal assemblies (port and starboard). Perform an inspection of the tail shafts’ forward and aft stern tube seal assemblies under the guidance of the manufacturer’s representative.

3.2.3.15 Provide and install new 240 MKII Aft Seal Kits, including Viton O-rings, Garter Springs, Gaskets, and Lock Washers, P/N A32-A024-2147K. Provide and install new 240 MKII Fwd Seal Kits, including Viton O-rings, Garter Springs, and Gaskets, P/N MKII-F024-0190K. Only genuine Wärtsilä parts may be used. Note: The most current information from Wärtsilä Defense at the time this specification was prepared, indicates delivery to be approximately three weeks after receipt of order (ARO).

Verify seal kit delivery from the supplier, and ensure that new seal kits are ordered in time to perform seal renewals while the ship is on drydock. Provide a report to the COTR for any additional parts or repairs needed, if any.

3.2.3.16 After all inspections and repair work are

completed, fill the entire stern tube, including lube oil head and sump tanks, with new environmentally friendly, readily biodegradable stern tube oil having an ISO viscosity rating of 68 (SAE 30) which has been approved for use by Wärtsilä. See Note 3.2.5.3 for one such approved oil. New oil shall be filtered through a filter cart with a 10 micron filter and gravity fed, not pumped, into the stern tube lube oil systems. Capacity of each stern tube lube oil system is approximately 200 gallons.

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3.2.3.17 Renew hull, sea chest, bow thruster tunnel, and

shaft strut zinc anodes as designated by the COTR in accordance with References 3.2.1.2 and 3.2.1.3. See Note 3.2.5.5.

(a) Remove and scrap 84 existing zinc anodes. Clean, prime and paint the areas behind the zincs per Underwater Body Coating item prior to installing the new zinc anodes.

(b) Install 84 new zinc anodes type ZHC-23 conforming to MIL-A-18001K, same size and type, and in the same location as those removed. The new finished zinc plates shall weigh twenty three (23) pounds each.

Provide certification to the COTR that the new zinc anodes are in conformance with MIL-A-18001K.

(c) Zinc attachment points and damaged hull paint shall be cleaned and painted after installation in accordance with Underwater Body Coating item. No paint or other permanent coatings are to be applied to the exposed zinc surfaces, which shall be clean bare metal. The underwater body side of the zinc shall not contact the hull.

(d) After completion of all zinc anode renewals, visually inspect each new zinc anode to determine proper attachment, and to ensure that the anodes were not painted during painting of the hull.

3.2.3.18 Perform the following work on the ELINCA system

in accordance with Reference 3.2.1.7, and under the guidance of an on-site manufacturer’s field engineer (see Note 3.2.5.6):

(a) Renew one Government-furnished copper anode (ELINCA part no. EL40012-9) and one Government-furnished iron anode (ELINCA part no. EL40014-9) in each of the ship’s 3 main sea chests – two located port and starboard in the Main Generator Room 3-34-0- E, and one in the Main Propulsion Motor Room 3-60-0-E.

(b) Inspect the operation of the ELINCA system prior to undocking while the vessel is still waterborne, and after all work is completed.

(c) After installation of the new anodes and

Page | 18 refloating of the ship, test the ELINCA system’s control cabinet for proper voltage adjustments to the newly installed anodes.

3.2.3.19 Perform the following service on the Sigma Oily

Water Separator under the guidance of an on-site manufacturer’s field engineer (see Note 3.2.5.7):

(a) Perform initial as-found inspection and test run.

(b) Disassemble and clean the Sigma tank; inspect the internal coating. Remove old coalescer beads and install new beads and bead box gaskets.

(c) Open and inspect the 3 solenoid valves.

(d) Reassemble the Sigma tank using new tank cover gasket.

(e) Operationally check motor and pump.

(f) Operationally check the function of the two motor controlled valves.

(g) Check function of, and calibrate, oil content monitor.

(h) Test run the unit, in the presence of the ship’s Chief Engineer or port engineer; demonstrate proper operation of unit including all functions

(i) Submit a condition report to COTR if inspections or tests reveal need for any additional repairs.

(j) Prepare and submit a final field service report, listing all parts used and repairs made to the system.

3.2.3.20 After all modifications and repairs to the

underwater hull are completed, including all underwater hull modifications required in other items of these specifications, provide the COTR a final marked-up copy of the ship’s docking plan in accordance with Reference 3.2.1.1, section 3.5.6. Contractor shall also document repairs and alterations made on the a final docking report form and submit the report with the marked-up copy of the ship’s docking plan.

3.2.4 Quality Assurance

3.2.4.1 As required by References 3.2.1.1, 3.2.1.2, 3.2.1.3, and 3.2.1.5.

3.2.4.2 Conduct an operating test of the stern tube lube

oil system for each tail shaft to the extent practicable, under the guidance of the Wärtsilä representative, to check the system for leaks prior to undocking the ship.

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3.2.4.3 Conduct a dock trial, once the ship is waterborne, to prove both propulsion shafts and propellers are operating within design parameters, and the shaft seal systems are functioning properly without any leaks.

3.2.4.4 Check the stern tube lube oil seal systems for

leaks at normal system operating pressures prior to undocking and at undocking to ensure no oil leaks when getting underway for sea trials.

3.2.4.5 Engage the services of a vibration analysis

service (see Note 3.2.5.9) to take vibration readings of the following equipment during sea trials while they are operating under load:

(a) Ship’s service diesel generators

(b) Main propulsion motors

(c) Auxiliary sea water pumps

(d) Steering pumps

Provide COTR a report of vibration readings.

3.2.4.5 Provide the COTR with two copies of the Wärtsilä

technical representative’s service reports, and the ABS surveyor’s field inspection reports.

3.2.4.6 Provide certification documents for the ELINCA

field engineer’s service reports with test results.

3.2.5 Notes

3.2.5.1 The following products are acceptable

environmentally friendly float coats for rudder interiors:

Eureka Fluid Film NAS Kellsport Products 22 Boomer St.

Fall River, MA 02720 Tel: (888) 341-4600

Cortec® M-645 Float Coat Cortec Corporation White Bear Mountain, MN Tel: (800) 426) 7832 Fax: (651) 429-1122

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3.2.5.2 Parts ordering information and manufacturer’s

service representative arrangements for the tailshaft stern tube seals and bearings can be obtained from the following source:

Wärtsilä Defense, Inc.

3617 Koppens Way Chesapeake, VA. 23323 Tel: (757) 485-5275 Fax: (757) 558-3627 Attn: Scott Miller

3.2.5.3 The following is one environmentally friendly

stern tube oil approved for use on NOAA Ship Gordon Gunter by Wärtsilä, the stern tube seal manufacturer, and is the oil currently used in the stern tube lube oil systems:

Vickers Hydrox Bio 68 Vickers Oils 6 Clarence Road Leeds LS10 1ND, England Tel: +4(0)113-386-7654 Fax: +4(0)113-386-7676 E-Mail: inbox@vickers-oil.com

3.2.5.4 The ship’s propellers are an anti-singing design.

The leading and trailing edges of these propellers are finely finished, and care must be taken not to damage these areas. Exercise caution when polishing the propeller surfaces to minimize removal of metal.

3.2.5.5 Reference 3.2.1.3 shows type ZHS-23 (weld-on strap

type) zincs. These were subsequently replaced by type ZHC- 23 (bolt-on) zincs as specified in paragraph 3.2.3.16.

3.2.5.6 The manufacturer’s representative for the ELINCA

system is Admiral Filter. The following address and telephone numbers are provided to purchase parts and to arrange for field engineer service:

Admiral Filter 239 Route 206 S Branchville, New Jersey 07826 Attn: Robert Sarro Tel: (973) 948-3252 Fax: (973) 948-3657 Email: resarro@admiralfilter.com

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3.2.5.7 Admiral Filter is also the manufacturer’s

representative for the ship’s Sigma Oily Water Separator.

3.2.5.8 Recommended source for removing and reinstalling

tails shaft couplings:

Williams Machine Works, Inc.

5624 Main Street Moss Point, MS 39562 Attn: David Hicks Tel: (228) 475-7651 e-mail: DCH_WMW@bellsouth.net

3.2.5.9 Recommended sources for vibration analysis:

John Boland Boland Industrial Consulting Services, Inc.

619 Delmas Avenue Pascagoula, MS 39567 Tel: (228) 762-3172 e-mail: johnboland@pavcoind.com

James Pipkin Magnetech Industrial Services, Inc.

701 Bill Myles Drive West Mobile River Industrial Park Saraland, AL 36571 Tel: (251) 675-0855

3.3 ABS SPECIAL PERIODICAL SURVEY – HULL 5

3.3.1 References

3.3.1.1 NOAA Standard Specification MOC-100-1A, "ABS Load

Line Survey"

3.3.1.2 NOAA Standard Specification AMC-581-1A, “Inspection and Preservation of Ground Tackle”

3.3.1.3 Drawing No. 801-001, “Tank Sounding Tables.”

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3.3.1.4 Drawing No. GU-830-002, "Booklet of General Plans"

3.3.1.5 Drawing No. 101-6233544, “Scantlings Main Deck and

Below”

3.3.1.6 Drawing No. 101-6233545, “Scantlings Focsle Deck

and Above”

3.3.1.7 Drawing No. 101-6233546, “Scantlings Inboard

Profile”

3.3.1.8 Drawing No. 101-6233547, “Scantlings Midships”

3.3.1.9 Drawing No. GU-101-6233605, "Scantlings Typical

Sections"

3.3.1.10 Drawing No. 581-6233594, “Anchor Handling

Arrangement & Details”

3.3.1.13 Technical Manual T9581-AH-MMC-010/76727, “Description, Operation, and Maintenance, Anchor Windlass and Capstan”

3.3.1.14 American Bureau of Shipping (ABS), “Rules for

Survey After Construction 2005", Part 7.

3.3.1.15 American Bureau of Shipping (ABS) Rules for

Building and Classing Steel Vessels, Section 2/1.13, “Anchor Chains”

3.3.1.15 NAVSEA Standard Item 09-32, “Cleaning and

Painting Requirements, accomplish.”

3.3.1.16 NOAA Standard Specification AMC-533-1, “Potable

Water Tank Disinfection.”

3.3.2 Government-Furnished Material

3.3.2.1 None.

3.3.3 Requirements

3.3.3.1 All work shall be conducted in accordance with

References 3.3.1.1 and 3.3.1.2.

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3.3.3.2 Schedule services of an American Bureau of

Shipping (ABS) surveyor to accomplish all inspections required under Special Periodical Survey – Hull 5. All inspections shall be accomplished with COTR, or other government representative present. Government will compensate ABS for survey costs under a separate purchase order. Contractor shall prepare vessel for various survey parts and bear cost of re-survey due to improper/inadequate vessel preparation. Neither Government nor Contractor shall be compensated by the other for delay of a scheduled survey if delay is caused by ABS for which neither Contractor nor Government is at fault.

3.3.3.3 Assist chief engineer in transferring fuel oil, lube oil, ballast water and potable water between ship’s fuel oil tanks, ballast tanks, and potable tanks as required to accomplish tank boundary inspections. Boundary inspections must be accomplished under a full head of liquid. Boundary inspections may be accomplished dockside or while vessel is on drydock at Contractor’s discretion.

If accomplished while on drydock, identify sequence to ensure transfer of fluids will not cause instability or damage to vessel or drydock. The Chief Engineer of Gordon Gunter uses only fresh water in the ship’s ballast tanks, therefore use only existing ballast water, or fresh water provided by Contractor, for ballast tank boundary inspections.

3.3.3.4 Handle all shipboard diesel oil, lube oil, and

water in accordance with all requirements of reference 3.3.1.2, section 3.4, “Tank Inspections”. In addition to “safe for entry” requirements of paragraph 3.4.1, all tanks and voids scheduled for opening and inspection shall be certified “safe for hot work” by a Marine Chemist.

3.3.3.5 Remove all residual oil from manifolds and piping

to and from each respective tank, to ensure no oil drains back to the tanks, effectively voiding any gas-free certification obtained. Connect compressed air to ship’s oil storage tank manifolds, and blow back through the suction lines serving the tanks to clear any residual oil in the piping lines and manifolds.

3.3.3.6 Provide the services of a Marine Chemist to

certify all tanks scheduled for opening and inspection to be "safe for hot work" in addition to the “safe for entry“ requirements of paragraph 3.4.1 of Reference 3.3.1.1.

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3.3.3.7 If diesel or lube oil is to be removed from the

ship and later to be returned to the ship, pump the fuel or lube oil through a ten micron filter system with a hygroscopic (moisture absorbing) component when it is returned to the ship. Fuel or lube oil removed and returned shall be sampled and tested by a chemist prior to being removed and prior to being returned to ensure the fuel is in good condition. Provide sample results to the COTR.

3.3.3.8 Facilitate inspection of the tanks in accordance

with Reference 3.4.1.1, section 3.4 “Tank Inspections.“ In compliance with survey schedule and the requirements of the ABS surveyor for tank openings and inspections, and in a coordinated sequence with other work requirements in these specifications, perform the following:

3.3.3.9 Open and prepare the following tanks and voids for

inspection. Information on tank locations, capacities, and structure is available on References 3.3.1.4 through

3.3.1.10. Erecting scaffolding or temporary staging inside

tanks, if required, will be accomplished as additional work. Voids have the same inspection requirements as tanks, but do not have to be power washed. Disinfect potable water tanks after inspection and closure in accordance with Reference 3.3.1.16.

(a) Diesel oil fuel tanks:

4-6-1-F, 4-6-2-F, 4-14-1-F 4-14-2-F 4-52-1-F 4-52-4-F, 4-52-3-F (day tank), 4-52-4-F (day tank), 4-60-1-F, 4-60-2-F, 4-72-1-F, 4-72-2-F, 4-72-3-F, 4-72-4-F.

(b) Lube oil tanks:

2-60-1-F, 2-60-2-F, 3-54-2-F.

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(c) Ballast tanks:

4-B-0-W (fore peak tank), 4-23-0-W 4-23-1-W, 4-23-2-W, 4-40-0-W (anti-roll dump tank), 4-52-0-W, 4-60-0-W, 2-72-0-W (anti-roll tank), 4-86-1-W, 4-82-2-W, 3-94-1-W (aft peak tank), 3-94-2-W (aft peak tank).

(d) Potable water tanks:

3½-52-1-W, 3½-52-2-W.

(f) Slop tanks:

4-60-3-FF,

4-60-4-FF.

(g) Voids, trunks, cofferdams:

4-34-0-V, 4-34-01-V, 4-23-1-T (transducer trunk) 4-32-1-T (transducer trunk)

3.3.3.10 Prepare and accomplish ultrasonic testing (UT) on

the following areas, in accordance with Reference 3.3.1.2, section 3.3, “Ultrasonic Tests (UT) for Thickness Gaging.”

Thickness gaugings shall not be taken before the hull has been water washed, and shall be completed before painting of the underwater body. For estimating purposes, assume a total of 1,200 thickness gaugings will be taken on hull plating, 500 gaugings on webs and flanges of frames, and 500 gaugings on decks, bulkheads, hatch covers, coamings, and other miscellaneous areas. Provide scaffolding or lifting arrangements for contractors and Surveyor to prepare and survey exterior parts of hull and decks as required. If the total amount of gaugings is greater or less than 2,200, a contract modification shall be made to increase or decrease the total on a per-unit basis based on original proposal for 2,200 gaugings:

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(a) Three (3) transverse sections within the amidships 0.5L, as determined by Surveyor.

(b) Internals in forepeak and after peak tanks

(c) All hatch covers and coamings (stifferners and plating)

(d) Wind-and-water strakes, port and starboard, full length.

(e) All exposed main deck and superstructure deck plating.

(f) Flat keel plating full length. Also, additional bottom plates in way of cofferdams, machinery spaces and aft end of tanks.

(g) Plating of seachests and shell plating in way of overboard discharges.

(h) Chain lockers.

3.3.3.11 While fuel oil tanks 4-60-1-F and 4-60-2-F are

open and gas-freed, renew the existing manholes in the tank tops (two in 40-60-1 and three in 4-60-2). Existing manholes have flush-mounted covers with stainless steel flat-head screws. Crop out the bolt rings in the tank tops; fabricate and install new raised rings such that new manhole covers will be approximately 1-½ inches above the tank top. New bolt rings shall have a minimum of 24 ½-inch stainless studs. Fabricate new manhole covers; install covers with new ½-inch stainless nuts and cork gaskets.

3.3.3.12 While fuel oil tanks 4-72-1-F and 4-72-2-F are

open and gas-freed, renew one tank gooseneck vent in each tank. Exposed portions of the goosenecks are located on the main deck, just forward of bulkhead 86 (the fwd bulkhead of the mission deck void space).

(a) Crop out the vent pipes 24 inches below the main deck level deck penetration.

(b) Using new seamless 2½-inch Schedule 40 Grade B steel pipe and new 2½-inch NPS gooseneck tank vent valve, Tate Temco 52-25V or equal, fabricate and install a new vent pipe, same configuration as that

Page | 27 removed. Install a new steel sleeve at the deck penetration. Sleeves shall be continuously welded on both sides of the deck penetration. The vent pipe shall be continuously welded to the sleeve top and bottom. All materials, welding, and fabrication shall be in accordance with ABS Rules for Building and Classing Steel Vessels.

(c) Provide the services of an independent (3rd party) non-destructive testing contractor to test the welds using the magnetic particle method.

(d) Apply one coat (min 5 mils DFT) of Intertuf 262 or equal, followed by two coats (2-3 mils DFT each) of Interthane 990 or equal to all new and disturbed surfaces.

3.3.3.13 While fuel oil tanks 4-6-2-F and 4-14-2-F are

open and gas-freed, accomplish the following repairs to the fuel oil containment bin surrounding the gooseneck vents for these tanks, located on the 0-1 deck, port side. Note:

the containment bin is raised approximately 10 inches above the deck. Two photos follow paragraph (c) below.

(a) Crop out and renew the bottom of the containment bin.

The containment bin bottom is approximately 20 inches x 62 inches. Using new ¼-inch steel plate, fabricate and install a new bottom plate, cutting and fitting around the goosenecks.

(b) Crop out the bottom 12 inches of 3 x 4 inch angle iron within the containment bin, aft end. Do not renew.

(c) Apply one coat (min 5 mils DFT) of Intertuf 262 or equal, followed by two coats (2-3 mils DFT each) of Interthane 990 or equal to all new and disturbed surfaces.

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3.3.3.14 Crop out and renew in kind (provide new or

fabricate) the three vents (raised knife edges and hinged covers) for the mission deck void space, located on bulkhead 86 just above the main deck level. See photograph of one of the vents, below. Provide 316 stainless steel hinges, dogging bolts and fasteners. Provide the services of an independent (3rd party) non-destructive testing contractor to test the welds using the magnetic particle method. Perform a chalk test and hose test to ensure no leakage. Hose test consists of using a 1½ inch hose with a minimum nozzle diameter of ½ inch at 50 psig nozzle pressure at a maximum distance of 10 feet from the surface being tested. Direct the water stream against the structure in a manner most likely to disclose leakage.

Allowable leakage: None. Apply one coat (min 5 mils DFT) of Intertuf 262 or equal, followed by two coats (2-3 mils DFT each) of Interthane 990 or equal to all new and disturbed surfaces.

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3.3.3.15 Perform routine service of the anchor chains and

both anchors in accordance with the requirements of References 3.3.1.2 and 3.3.1.14. If the ship is in a graving dock, all work on the anchors and anchor chain must be accomplished off the dock, where a dry work surface may be maintained.

3.3.3.16 Remove, prepare, inspect, and test the anchors

and anchor chain (eight shots port and seven shots starboard) in accordance with Reference 3.3.1.2. In accordance with Reference 3.3.1.2, the anchor chain shall be cleaned via abrasive blasting and painted with a primer coat prior to testing.

3.3.3.17 After all anchor chain inspections have been

completed, provide a condition report to the COTR for additional anchor chain repairs required and/or any anchor chain shots requiring renewal. Anchor chain requiring renewal will be handled as a growth item.

3.3.3.18 Prepare and paint anchors in accordance with

Table 5, line 14 of Reference 3.3.1.4.; color: black.

3.3.3.19 Prepare and paint the retained and new anchor

chain, if any, in accordance with Table 5, line 15, 16, 17, or 18 of Reference 3.3.1.14; color: in accordance with Reference 3.13.1.2.

3.3.3.20 Detergent power-wash, to an SSPC-SP-1 standard, all inside surfaces of both chain lockers. Remove deckplates at bottom of lockers and clean surfaces and chain locker sump below plates. Route-out, then flush chain locker sump overboard drain piping. Demonstrate operation of chain locker sump overboard drain piping to ABS surveyor, Chief Engineer, and COTR. Note: chain locker drain piping runs in common with bow thruster cooling water discharge piping.

3.3.3.21 Following ABS inspection and ultrasonic testing, touch up paint in chain locker interiors as follows:

(a) One stripe coat MIL-PRF-23236, Type VII (6-10 mils dft) color: red;

(b) One full coat MIL-PRF-23236, Type VII (6-10 mils dft) color: black.

3.3.3.22 Reassemble the chain, marking it in accordance

with Reference 3.3.1.2. Reinstall on the ship.

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3.3.4. Quality Assurance

3.3.4.1 Per Reference 3.3.1.1, provide initial ABS survey

schedule prior within 48 hours of start of the contract performance period, clearly identifying loading conditions that correlate to initial tank boundary inspections. Update survey schedule at weekly progress meetings.

3.3.4.2 Submit a written report containing the results of

inspection and testing required by Reference 3.3.1.2. The report shall contain the test date, time, results, and names of witnesses.

3.3.4.3 Submit documentation for new anchor chain shots

provided, if any, certified ABS Grade 2 in accordance with Reference 3.3.1.14.

3.3.4.4 COTR will witness cleaned and painted chain

lockers prior to reinstalling the preserved and new anchor chain.

3.3.4.5 Submit the reports required by Reference 3.3.1.1, section 3.3, “Ultrasonic Tests (UT) for Thickness Gaging.”

3.3.4.6 Submit the ABS reports and new Load Line

certification required by Reference 3.3.1.1, section 3.5, “ABS Documents.”

3.3.5 Notes

3.3.5.1 A Drydocking Survey, which is part of Special

Periodical Survey – Hull 5, shall be carried out under basic item 3.2.

3.3.5.2 The ship carries…