EX_FY_16_Drydock_Specs_(Rev_3).pdf

Rev 3 (March 2015)

NOAA Ship Okeanos Explorer (R-337)

FY 2015/2016

DRYDOCK REPAIR SPECIFICATION

FY 2015/2016 DRYDOCK REPAIRS to NOAA Ship Okeanos Explorer

TABLE OF CONTENTS

DESCRIPTION/TITLE PAGE

1. SCOPE 3

2. GENERAL 3

3. BASE ITEMS 7

3.1 Temporary Services 7

3.2 Drydocking and Routine Drydock Work 11

3.3 Propeller and Tailshaft Inspection And Repair 16

3.4 ABS Special Periodic Survey – Hull 6 22

3.5 Underwater Hull Preservation and Coating 29

3.6 Sea Valve Overhauls 31

3.7 Underwater Scientific Equipment Preservation 39

3.8 Forepeak Ballast Tank (4-B-0-W) Preservation 47

3.9 Motor Room Vent Trunk Repair and Preservation 49

3.10 Bilge Piping Renewal 54

3.11 Bow Thruster and Stern Thrusters Maintenance 56

3.12 Dock and Sea Trials 59

4. ADDITIONAL WORK 61

4.1 Additional Work 61

5. OPTION ITEMS 61

5.1 Freeboard Preservation 61

5.2 Port Light Renewal 64

5.3 ADCP 38 KhZ & 300 kHz Transducer Installations 65

5.4 Fan Room 1-67-3-Q Duct and Chill Water 73

Pipe Re-Insulate

5.5 Main Generator Room (3-34-0-E) Duct Renewal 75

5.6 STBD Stack Main Diesel Engine Exhaust 77

Insulation Renewal

5.7 ROV Pit Hatch Cover Fabrication 80

and Installation

5.8 EK-60 Transducer Suite Installation 81

5.9 Doppler Speed Log Renewal 87

5.10 A-Frame and J-Frame Preservation 88

5.11 #2 and #3 Air Conditioning Plant Repairs 91

1.0 SCOPE

1.1 These Detail Specifications contain the requirements for drydock repairs and modifications to NOAA Ship Okeanos Explorer.

2.0 GENERAL

2.1 References

2.1.1 NOAA Standard Specification No. AMC-000-1G, “General

Requirements for Ship Repair Work on NOAA Ships.”

2.1.2 NOAA Standard Specification S1600, “Structural Access Cuts.”

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

2.1.4 NOAA Standard Specification MOC-631-2D, “Coating Systems for Steel Surfaces.”

2.1.5 Drawing No. OE-601-101, “NOAA Ship Okeanos Explorer General Arrangement.”

2.1.6 Drawing No. OE-123-101, NOAA Ship Okeanos Explorer Tank Soundings Tables.”

2.1.7 NOAA Weight Report Form, Microsoft XL Format, “Weight

Report.xls”

2.1.8 Drydock Worksheet

2.2 Requirements

2.2.1 Reference 2.1.1 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 2.1.2 and 2.1.3 are amplifications of the

requirements contained in reference 2.1.1 sections 4.17 and 4.21.

2.2.3 Some of the ship’s drawings have not been updated to reflect modifications to the ship during activation and conversion in 2007.

Contractor shall be responsible for verifying all current configuration, construction, and arrangement changes, as necessary, to comply with and 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.

2.2.4 Ship’s drawings and technical publications may be borrowed during the performance period. It would be preferable for the contractor to make copies of these drawing and technical publications if their intended use will be outside an office environment. All reference materials borrowed by the Contractor shall be signed for, and then returned to the COR after no further use of the reference materials is required.

2.2.5 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 COR, along with the preliminary progress reports.

2.2.6 All visual examination, 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.

2.2.7 On a weekly basis (on the day preceding the Weekly Progress Meeting) provide the COR revised and updated copies of the production schedule reflecting actual work progress.

2.2.8 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 COR 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.

2.2.9 Submit all inspection, test, and quality reports to the COR in Corel WordPerfect or Microsoft Word electronic software formats, in addition to providing hard paper copies.

2.2.10 Weigh all materials and items removed, installed, or relocated on the ship. Provide a summary report to the COR 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 2.1.7 will be provided by the COR for the Contractor to identify, record, and document all weight changes for 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.

2.2.11 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 2.1.6. Finish coat colors and paint type shall match those of the surrounding, unmodified area.

2.2.12 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.

2.2.13 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.

2.2.14 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 COR, 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.

2.2.15 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.

2.2.16 Frame numbers and space names are derived from ship’s drawings.

All 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. Contractors may review available drawings and technical manuals on board ship.

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.............................2311.5 LT Displacement, Lightship............................1591.2 LT Cruising Speed......................................11 knots Officer & Crew Size Scientists and Technicians Electric Service......450 VAC, 60 Hz, 3 PH, 800 Amp Service Propulsion......................Diesel electric, twin screw

2.3.2 NOAA Ship Okeanos Explorer is classed A1, E, AMS, and ACCU and identified with the following:

Official Number - CG023672

ABS ID - 901987

IMO NUMBER – 8835114

2.3.3 GOVERNMENT FURNISHED MATERIAL/EQUIPMENT

ITEM QTY DESCRIPTION EST COST

3.2 3 ea. copper anode (part no. EL40012-9) $2,500 ea

3.2 3 ea. iron anode (part no. EL40014-9) $2,000 ea

3.3 6 drums Castrol Biostat 100 stern tube oil $2,000 ea

3.4 5 pc. Tank Level Indicator parts $7,000

3.6 1 ea. 5-inch bronze/monel globe valve $3,850 ea

3.11 6 drums Terresolve Envirologic 3046 hyd oil

5.2 15 ea. port lights, with covers $1,380 ea

5.3 1 ea. 38 kHz ADCP transducer $140,000 ea

5.3 1 ea. 38 kHz transducer cable $5,000 ea

5.3 1 ea. 38 kHz transducer dry side connector $800 ea

5.3 1 ea. 300 kHz ADCP transducer $75,000 ea

5.3 1 ea. 300 kHz transducer cable $4,000 ea

5.3 1 ea. 300 kHz transducer dry side connector $800 ea

5.3 2 ea. spare ROV tracking (USBL) cables $500 ea

5.8 1 ea. 38kHz EK-60 transducer $16,700 ea

5.8 1 ea. 38kHz mounting flange $4,000 ea

5.8 38kHz mounting bolts $100

5.8 1 ea. 38kHz transducer cable $1,600 and dry side connector

5.8. 1 ea. 70kHz EK-60 transducer $15,300 ea

5.8 1 ea. 70kHz mounting ring $3,400 ea

5.8 1 ea. 70kHz clamping ring $700 ea

5.8 70kHz mounting bolts $100

5.8 1 ea. 70kHz transducer cable $1,000 and dry side connector

5.8 1 ea. 120kHz EK-60 transducer $10,700 ea

5.8 1 ea. 120kHz mounting ring $2,700 ea

5.8 1 ea. 120kHz clamping ring $700 ea

5.8 120kHz mounting bolts $100

5.8 1 ea. 120kHz transducer cable $1,000 and dry side connector

5.8 1 ea. 200kHz EK-60 transducer $9,300 ea

5.8 1 ea. 200kHz mounting ring $2,700 ea

5.8 1 ea. 200kHz clamping ring $700 ea

5.8. 200kHz mounting bolts $100

5.8 1 ea. 200kHz transducer cable $1,000 and dry side connector

5.8 1 ea. 333kHz EK-60 transducer $8,900 ea

5.8 1 ea. 333kHz mounting ring $2,700 ea

5.8 1 ea. 333kHz clamping ring $700 ea

5.8 333kHz mounting bolts $100

5.8 1 ea. 333kHz transducer cable $1,000 and dry side connector

5.9 1 ea. SAL R1a Electronics Unit P/N 703800 $6,200 ea

5.9 1 ea. TRU R1 Transducer with 60 meter cable $4,000 ea

5.9 1 ea. Transducer mount P/N 71-21520-01 $4,500 ea

5.9 1 ea. SD4-3 digital Speed Display P/N 704043 $2,300 ea

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]. The ship will provide NATO plugs and pig tails. The Contractor shall provide properly rated shore power cables.

Any damage or loss of/to NATO plugs and pig tails shall be replaced by the Contractor. 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 on the 01-deck. Connect two voice lines to the shore offices (one in the COR's office and one in the ship's office).

Connect two data lines for service on two fax machines (one in COR’s office and one in Ship’s Office).

(c) Fax machines: Provide two Fax machines (one in the COR’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 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 COR’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 by the contractors or their subcontractors 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 Contractor’s 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. See ship’s Chief Engineer for individual cooling water service hook-up locations and pressure requirements for the separate systems. 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 Covering: In addition to the protective coverings specified in paragraph 4.5.1 of Reference 2.1.1, place a layer of heavy duty (minimum thickness of 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 vehicles, within or outside the shipyard, which may be available for parking by ship’s personnel and other NOAA representatives.

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

(1) 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.

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.

(2) COR's dockside office space shall contain one desk, one 48-inch high by 36inch 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).

(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 COR three sets of keys to the lock for this storage container.

(l) Oily Waste Disposal: Pump the bilge oily water holding tanks 4- 60-1- F and 4-60-2 F (estimate 500 gallons on board, up to 3000 gallons maximum), and the sludge tank 3-50-2-F (estimate 50 gallons on board, up to 100 gallons maximum). Pumping of the bilge oily water holding tanks 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: 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 overspray and debris prior to pressure washing. Clean out all bilge rose boxes after pressure washing.

(n) Crane Service: Provide crane operator and riggers for ship's force equipment and material lifts needed during normal working hours.

Provide crane lifts with a 5-ton minimum capacity. The COR 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 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. Ships sanitary systems are to be for ship’s crew only. All shipyard personnel and shipyard subcontractors will have their own bathroom and sanitary facilities separate from the ship.

Signs will be prominently placed to make all personnel aware of this rule.

(p) Grey and Black Water Discharge: 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 Reference 2.1.1.

(q) Service Interruption: In the event temporary services provided to the ship are reduced or disrupted due to the extent of contract work, thereby 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.

3.1.4 Quality Assurance

3.1.4.1 In accordance with Reference 3.1.1.1.

3.1.5 Notes

3.1.5.1 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

3.2 DRYDOCKING & ROUTINE DRYDOCKING WORK

3.2.1 References

3.2.1.1 NOAA Standard Specification AMC-997-1A, “Drydocking and Routine Drydock Work”

3.2.1.2 NOAA Standard Specification S1205, “Zinc Protectors”

3.2.1.3 Drawing No. OE-085-001, “Docking Plan”

3.2.1.4 Drawing No. 243-6233870, “Main Propeller Shaft Installation Arrangement and Details”

3.2.1.5 Drawing No. 562-6233911, “Rudder Stock Carrier Bearing Arrgt and Details”

3.2.1.6 Drawing No. 633-6233582, “Zincs Arr & Details”

3.2.1.7 ELINCA Technical Manual, “The ELINCA Anti-Biofouling System”, Series P000 (US), Manual No. 154 in Ship’s Technical Publication Index

3.2.1.8 Form S0700, “NOAA Docking Report”

3.2.1.9 Drydock Worksheet

3.2.2 Government Furnished Equipment

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)

3.2.3 Requirements

3.2.3.1 To allow the Government to evaluate the certification of the drydock and other services, complete the Drydock Worksheet (Reference 3.2.1.9) and submit along with the bid/proposal. Submit a separate completed drydock worksheet for each drydock Contractor may use.

3.2.3.2 Drydock the vessel within the first 72 hours of the contract performance period. Provide drydocking and routine drydock work in accordance with Reference 3.2.1.1. When washing the propellers with high pressure water per paragraph 3.4.1 of Reference 3.2.1.1, the water pressure shall not exceed 10,000 psi. Note and heed restrictions regarding protection of transducers in Item 3.7.

3.2.3.3 The following information and additional 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 six feet clearance under the keel (forward and aft of the Transducer Fairing Unit) in Docking

Position No. 2.

(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 any underwater appendages. The divers shall inform the Dockmaster and COR and then lifting shall continue.

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

(e) In the presence of the ABS surveyor, open drain plugs on rudders. Drain liquid, if any, from rudder interiors. Conduct a 2 psi air test on rudders. Apply an environmentally friendly float coat to rudder interiors by the fill and drain method. See Note 3.2.5.4.

(f) Clean the propeller, bow thruster, and stern thruster blades to bright metal by power brushing. Hard tools and wire brushes shall not be used. See Note 3.2.5.1.

3.2.3.4 Perform the following inspection on the port and starboard rudders:

(a) Jack the rudders forward and aft. Using a dial indicator, measure the amount of travel at the lower end of the lower rudder bearing.

(b) Jack the rudders port and starboard. Using a dial indicator, measure the amount of travel at the lower end of the lower rudder bearing.

(c) With the rudder centered forward and aft and port and starboard, Jack the rudder up and down. With a dial indicator, measure the amount of travel.

(d) Submit a report to the COR indicating the amounts of travel in the rudder bearings for both port and starboard rudders.

3.2.3.5 Provide the ABS Surveyor with prior notice and the

opportunity to inspect any or all portions of ongoing work ordered by this item.

3.2.3.6 Renew hull, sea chest, bow thruster tunnel, and shaft strut zinc anodes as designated by the COR in accordance with References

3.2.1.2 and 3.2.1.6. See Note 3.2.5.2.

(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. Provide and install up to 10 new studs and fasteners for those damaged or missing. The new finished zinc plates shall weigh twenty three (23) pounds each. Provide certification to the COR 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.

3.2.3.7 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 3.2.5.3):

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

3.2.3.8 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 COR 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 After the blocks have been set and before lowering the drydock for hauling the ship, conduct a final inspection of the blocking with the COR and the dockmaster. Recheck as measurements as necessary to satisfy the COR that the block locations are in accordance with the contract requirements. Acceptance of the blocking arrangement by the COR in no way relieves the Contractor of the responsibility for safely drydocking the ship without strain or damage.

3.2.4.2 Record all measurements and observations required on NOAA Docking Report, Reference 3.2.1.8.

3.2.5 Notes

3.2.5.1. 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.

3.2.5.2 Reference 3.2.1.6 shows type ZHS-23 (weld-on strap type) zincs. These were subsequently replaced by type ZHC-23 (bolt-on) zincs as specified in paragraph 3.2.3.6.

3.2.5.3 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 18C Green Pond Rd.

Rockaway, New Jersey 07866 Tel: (973) 948-3252 Fax: (973) 948-3252

3.2.5.4 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

3.3 PROPELLER and TAILSHAFT INSPECTION and REPAIR

3.3.1 References

3.3.1.1 Technical Manual "Stern Tubes, Bearings and Seals"

3.3.1.2 Drawing No. 243-6233870, "Main Propeller Shaft Installation Arrangement and Details”

3.3.1.3 ABS Rules for building and Classing Steel Vessels, Part 1, Section 1/3.11

3.3.1.4 Ship’s Stern Tube Bearing Wear Down Record (if available)

3.3.1.5 NOAA Standard Specification AMC-240-1, “Propeller Shafts and Propellers”

3.3.1.6 Propulsion Motor Thrust and Aft Journal Bearings Instruction Manual

3.3.2 Government Furnished Equipment

3.3.2.1 Six (6) drums Castrol Biostat 100 (stern tube oil)

3.3.3 Requirements

3.3.3.1 Prior to drydocking the ship, conduct operational tests of both rudders and both propeller shafts.

3.3.3.2 No sandblasting or painting shall be permitted in or near the drydock while the propeller, shaft, seals, or bearings are being worked on in the drydock.

3.3.3.3 While the ship is drydocked, accomplish the following work on the tail shafts and stern tube assemblies in accordance with References

3.3.1.1 – 3.3.1.3.

3.3.3.4 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, (approximately 150 gals per side). While draining the oil, obtain a sample from each stern tube and send out for laboratory analysis. Report the following trace metals in parts per million: Iron, Chromium, Aluminum, Lead, Tin, Copper, and Nickel. Also report TAN (total acid number).

3.3.3.5 Open port and starboard sumps and head tanks. Clean each tank of all dirt, rust, sludge, and sediment using lint free rags and solvent. Flush the stern tube lube oil piping systems with clean oil.

Re-clean the sumps and head tanks and replace the filters.

3.3.3.6 Schedule the services of an American Bureau of Shipping (ABS) surveyor to the extent necessary, to accomplish all required inspections and technical reviews to maintain compliance with ABS class requirements. NOAA will pay ABS for survey costs under a separate purchase agreement.

3.3.3.7 Perform the special periodic survey for tail shafts with oil lubricated bearings, satisfactory service record in accordance with ABS Rules for Building and Classing Steel Vessels, Part 1, Classification, Testing and Surveys, Section 1/3.11.

3.3.3.8 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 Okeanos Explorer, in order to properly obtain bearing wear down measurements and evaluate the condition of the bearings and seals.

3.3.3.9 Under the guidance of the Wärtsilä technical representative, take bearing wear down readings on the forward, intermediate, and strut bearings of both tailshafts. To the extent practicable, use the bearing wear down gauges provided by the ship’s Chief Engineer. All readings taken shall be witnessed by the ABS surveyor, COR, 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 the ship’s Chief Engineer after recording all measurements are taken. Upon completion of all measurements reinstall all plugs using a non-hardening sealer, (Permatex #2 or equal) on the threads. Tighten all plugs and install safety wire.

3.3.3.10 Using 1-1/2 inch thick steel plate, fabricate a new propeller nut wrench. When all propeller work is done, fabricate and install a bracket on the bulkhead of the 4-52-1-F tank in the upper level Motor Room to house the propeller nut wrench. Ship’s Chief Engineer will designate exact location.

3.3.3.11 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.

3.3.3.12 Propeller Shaft Inspections. Propeller inspection and polishing is accomplished under Item 3.2. While the propellers are removed from the propeller shafts, inspect all fit up areas of both ends of the shafts including tapers, threads and keyways for cracks or damage using an ABS-approved NDT method. Reinstall propellers.

3.3.3.13 If the propellers have been reinstalled prior to

sandblasting, or if they are in the drydock during blasting operations, liberally coat the propellers with grease. Remove the grease coating prior to undocking.

3.3.3.14 Port and Starboard Main Propulsion Motor Aft Bearing Inspection.

(a) All work on the thrust bearings shall be accomplished in accordance with Reference 3.3.1.6 and under the direct supervision of master mechanic who has successfully performed this work on at least one T-AGOS vessel in the past two years. See Note 3.3.5.2 for recommended source.

(b) Measure and record the air gap between the motor rotor and stator on the forward and aft ends of both the port and starboard motors. Take at least 8 readings equally spaced around the rotors. Air gaps should be approximately the same all around the rotor. Provide a written report of the Air Gap readings to the

COR.

(c) Drain and discard the oil from the aft motor bearings and the lube oil systems.

(d) Remove the end seal and upper housing. Remove the thrust and journal bearings. Accomplish a visual inspection of bearing internals to determine material condition and provide a written report of findings along with any recommended repairs. Measure and record journal diameters and journal bearing inside diameters.

(e) Chemically and/or mechanically clean each part free of contamination without causing harm or deterioration. Restore mating surface exposed by the housing removal.

(f) Thoroughly clean the lube oil sumps and system piping. Open each of the oil drain lines under the thrust bearings at the flex hose connection. Verify they are clean and there are no restrictions to oil flow.

(g) Using 316 stainless steel 3/8-inch schedule 40 pipe, fittings, and ball valve, fabricate and install a drain line in the bottom of each bearing housing in way of an existing 3/8-inch brass plug.

The following photos show the drain line before and after installation on sister ship Gordon Gunter.

(h) Re-install the bearings and assemble the housings, renewing gaskets. Fill the bearing lube oil systems with approximately 85 gal (per side) of Mobil DTE Heavy Medium oil at 100 degrees Fahrenheit, through a new 5 micron filter, as directed by the Chief Engineer.

(i) Measure and record bearing wear down readings. If the bearing wear down gage is not available a micrometer may be used.

(j) Re-measure the air gap as in paragraph (b) above, to verify that the alignment has not changed.

3.3.3.15 Disconnect the tailshaft couplings from the port and starboard propulsion motor output flanges. Remove the couplings from the tailshafts. Slip the tailshafts aft approximately 18 inches or as needed to permit removal of the couplings. Remove couplings. See Note 3.3.5.2.

3.3.3.16 Disassemble and clean the forward and aft stern tube seal assemblies. Perform an inspection of the tail shafts’ forward and aft stern tube seal assemblies under the guidance of the Wärtsilä technical representative. Provide a condition report to the COR including recommendations for any additional repairs or parts needed.

3.3.3.17 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 COR for any additional parts or repairs needed, if any.

3.3.3.18 After all inspections and repair work are completed, fill the entire stern tube, including lube oil head and sump tanks, with Government-furnished Castrol BioStat 100 oil. New oil shall be filtered through a filter cart with a 3 micron filter and gravity fed, not pumped, into the stern tube lube oil systems. Capacity of each stern tube lube oil system is approximately 150 gallons.

3.3.3.19 Conduct an operational test of the stern tube lube oil system for each tail shaft and inspect for leaks for 72 hours prior to undocking the ship.

3.3.4 Quality Assurance

3.3.4.1 After completion of all work, perform operational tests of the port and starboard propellers and shaft assemblies, first at the dock during dock trials, and then during the sea trial. Measure and record the vibrations, lube oil pressures, and water temperatures throughout their full speed range.

3.3.5 Notes

3.3.5.1 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 Attn: Scott Miller Tel: (757) 485-5275 Fax: (757) 558-3627

3.3.5.2 Recommended source for removing and reinstalling tailshaft couplings and for performing the propulsion motor aft bearing inspection and cleaning:

Williams Machine Works, Inc.

5624 Main Street Moss Point, MS 39562 Attn: David Hicks

Tel: (228) 475-7651 Cell: (228) 219-9044 Fax: (228) 474-1679 e-mail: DCH_WMW@bellsouth.net

3.4 ABS SPECIAL PERIODICAL SURVEY – HULL 6

3.4.1 References

3.4.1.1 NOAA Standard Specification MOC-100-1A, "ABS Load Line Survey"

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

3.4.1.3 Drawing No. OE-123-01, “Tank Sounding Tables.”

3.4.1.4 Drawing No. OE-601-101, "General Arrangement"

3.4.1.5 Drawing No. 101-6233544, “Scantlings Main Deck and Below”

3.4.1.6 Drawing No. 101-6233545, “Scantlings Focsle Deck and Above”

3.4.1.7 Drawing No. 101-6233546, “Scantlings Inboard Profile”

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

3.4.1.9 Drawing No. 581-6233594, “Anchor Handling Arrangement & Details”

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

3.4.1.11 American Bureau of Shipping (ABS), “Rules for Survey After Construction 2005", Part 7.

3.4.1.12 American Bureau of Shipping (ABS) Rules for Building and Classing Steel Vessels, Section 2/1.13, “Anchor Chains”

3.4.1.13 NAVSEA Standard Item 009-32, “Cleaning and Painting

Requirements; accomplish,” date: 01 AUG 2008, CATEGORY: II.

3.4.1.14 NOAA Standard Specification AMC-533-1, “Potable Water Tank Disinfection.”

3.4.1.15 Ultrasonic Thickness readings from ABS Special Survey – Hull 5, dated December 2010.

3.4.1.16 Drawing No. 437-6233672, “Tank Level Indicator System & Elementary Wiring Diagram.”

3.4.2 Government-Furnished Material

3.4.2.1 None.

3.4.3 Requirements

3.4.3.1 All work shall be conducted in accordance with References

3.4.1.1 and 3.4.1.2.

3.4.3.2 Schedule services of an American Bureau of Shipping (ABS) surveyor to accomplish all inspections required under Special Periodical Survey – Hull 6. All inspections shall be accomplished with COR, or other designated 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.

3.4.3.3 Assist ship’s 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.

Existing water in ballast tanks, or fresh water provided by Contractor, shall be used for ballast tank boundary inspections.

3.4.3.4 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.

3.4.3.5 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.

3.4.3.6 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 3.4.1.1.

3.4.3.7 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 10 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 COR.

3.4.3.8 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:

3.4.3.9 Open and prepare the following tanks and voids for inspection.

Information on tank locations, capacities, and structure is available on References 3.4.1.3 through 3.4.1.8. 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), 4-72-1-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.

(c) Ballast tanks:

4-B-0-W (fore peak tank), 4-23-0-W 4-23-2-W, 4-23-3-W, 4-40-0-W (anti-roll dump tank), 4-52-0-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)

3.4.3.10 While Fuel Oil Tank 4-14-1-F is open and gas-free, renew the following components of the Tank Level Indicator (TLI) system in the tank, using Government-furnished parts (see Detail 11-A on Sheet 3 of Reference 3.4.1.16 for details). Following installation, test the TLI to demonstrate proper operation.

a) Transmitter XM-36485-81-0510-0-L, (piece no. 46 in the drawing parts list), quantity 1;

b) Transmitter XM-36465-78-0510-0-L, (piece no. 50 in the drawing parts list), quantity 1;

c) Transmitter XM-36460-75-0510-0-L, (piece no. 51 in the drawing parts list), quantity 1;

d) “T” Cable Assy36890-A-F5-J/B-F5-J/C-F20-J-LP (piece no. 17 in the drawing parts list) , quantity 1;

e) Jumper Cable Assembly (piece no. 16 in the parts list), quantity 1

3.4.3.11 Prepare and accomplish ultrasonic testing (UT) on the following areas, in accordance with Reference 3.4.1.2, 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:

(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 (stiffeners 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.

3.4.3.12 Perform routine service of the anchor chains and both anchors in accordance with the requirements of References 3.4.1.2 and 3.4.1.12.

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.

3.4.3.13 Remove, prepare, inspect, and test the anchors and anchor chain (eight shots port and seven shots starboard) in accordance with Reference 3.4.1.2. In accordance with Reference 3.4.1.2, the anchor chain shall be cleaned via abrasive blasting and painted with a primer coat prior to testing.

3.4.3.14 After all anchor chain inspections have been completed, provide a condition report to the COR 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.

3.4.3.15 Prepare and paint anchors in accordance with Table 5, line 14 of Reference 3.4.1.13.; color: black.

3.4.3.16 Prepare and paint the retained and new anchor chain, if any, in accordance with Table 5, line 15, 16, 17, or 18 of Reference 3.4.1.13; color: in accordance with Reference 3.4.1.2.

3.4.3.17 Accomplish the following work on the hawse pipes and spill pipes while the anchor chains have been removed for inspection and preservation:

3.4.3.17.1 Prepare the interior of the hawse pipes and spill pipes (port and starboard) by machining and/or grit blasting using 16 grit virgin aluminum oxide to achieve SSPC-SP5 finish and a 2-3 mil profile.

3.4.3.17.2 Degrease with Zep solvent to remove all dust and other contaminants.

3.4.3.17.3 Coating system shall be applied by a certified applicator of thermal spray coatings of austenitic stainless steel with bond coat using twin electrical arc process. See note 3.4.5.7 for a recommended source.

(a) Pre-heat steel locally in hawse pipe and spill pipe interiors to approximately 150F using open flame.

(b) Apply a bond coat of Ni/Al (80/20) alloy, followed by a top coat of 316 stainless steel; coating thickness shall be 10 mils.

3.4.3.18 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 COR. Note: chain locker drain piping runs in common with bow thruster cooling water discharge piping.

3.4.3.19 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.

3.4.3.20 Reassemble the chain, marking it in accordance with Reference

3.4.1.2. Reinstall on the ship.

3.4.4. Quality Assurance

3.4.4.1 Per Reference 3.4.1.1, 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.

3.4.4.2 Submit a written report containing the results of inspection and testing required by Reference 3.4.1.2. The report shall contain the test date, time, results, and names of witnesses.

3.4.4.3 Submit documentation for new anchor chain shots provided, if any, certified ABS Grade 2 in accordance with Reference 3.3.1.12.

3.4.4.4 COR will witness cleaned and painted chain lockers prior to reinstalling the preserved and new anchor chain.

3.4.4.5 Provide COTR…