RFP_ATTACHMENT_J.1.pdf

NOAA SHIP HENRY B. BIGELOW (R225)

FY2017

DOCKSIDE REPAIRS

DETAIL SPECIFICATION

June 2016 (Revised 07/07/16)

NOAA - Port Office Northeast Marine Support Facility

166 Water Street Woods Hole, MA 02543

Marine Operations - Engineering

Marine Operation Center, Atlantic 439 West York Street

Norfolk, VA 23510

NOAA Ship Henry B. Bigelow FY17 Dockside Repairs

June 2016 (Revised 7/7/16)

Table of Contents

1. Scope 3

2. General Requirements 3

3. Basic Items

3.1 301: Telescoping Crane Repair 7

3.2 302: Shore Power Connection Box Replacement 9

3.3 303: Main Propulsion Motor Bearing Inspections 11

3.4 304: Generator Inspections, Cleanings and Bearing Replacements 12

3.5 305: SSDG Engines Major Overhauls – 3512 14

4. Additional Work Items

4.1 401: Additional Work [Labor and Materials] 22

5. Option Items

5.1 501: Mission Hydraulic HPU Hose Renewal 23

5.2 502: 02 Deck Covering Replacement 26

5.3 503: 01 Deck Covering Replacement 30

5.4 504: 2 Deck Covering Replacement 34

5.5 505: Mission Hydraulics Cooling Water Piping Modifications 38

Appendix A: Standard Specifications, References, and Drawings 41 Appendix B: Government Furnished Material 43

1. Scope - These detailed specifications contain requirements for NOAA Ship Henry B.

Bigelow (R225) FY17 Dockside Repairs.

2. General Requirements

2.1 References

2.1.1 NOAA Standard Specification AMC-000-1F, General Requirements for Contract

Repair Work on NOAA Ships

2.1.2 NOAA Standard Specification MOC-631-2D, Coating Systems for Steel Surfaces

2.1.3 Drawing HB-085 FA02, General Arrangements

2.1.4 Drawing HB-631 FF04, Painting Schedule

2.2 Requirements

2.2.1 References 2.1.1 through 2.1.3 form 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.

All work procedures and all materials shall meet the ABS Rules.

2.2.2 Unless otherwise stated in these work items, prepare and coat all new steel, disturbed steel, or otherwise required painted surfaces in accordance with References 2.1.2 and

2.1.4. If no paint system is identified in the item, then apply the appropriate coating system similar to the area being coated as identified in Paragraph 5.2 of Reference

2.1.2 except that the top coat shall match the surrounding area.

2.2.3 Provide an electronic copy of all Condition Reports in Adobe Portable Document

Format (.pdf).

2.2.4 Maintain a Quality Assurance (QA) TEST AND INSPECTION PLAN applicable to all work items, including all additional work items which are authorized by the Contracting Officer. Update QA TEST AND INSPECTION PLAN weekly and provide a copy to the COR 24-hours prior to the scheduled weekly progress meeting.

Include the following minimum information for each work item and additional work item:

a. Specification item and paragraph number

b. Component/Equipment name

c. Test or Inspection description

d. Acceptance Criteria

e. Quality Assurance Inspection Report

2.2.5 Maintain a separate Test Schedule. Update Test Schedule weekly and provide a copy to the COR 24-hours prior to the scheduled weekly progress meetings.

2.2.6 Develop, in consultation with the American Bureau of Shipping (ABS) Surveyor, a written survey schedule that lists the items to be inspected and the scheduled dates and times of the inspections. Submit the survey schedule to the COR within 48 hours after the start of the contract performance period. The survey schedule shall list all initial inspections required by the ABS Surveyor. In addition, the Contractor shall schedule the services of an ABS Surveyor as required by ABS for performing inspections of all new installations, hull modifications, tank inspections, gauging inspections, and load tests. NOAA will pay for all ABS surveys using a Blanket Purchase Agreement associated with work required by these specifications. The Contractor shall provide a credit for any additional ABS charges associated with rescheduling of surveys and rework surveys which are directly under the control of the Contractor.

2.2.7 Provide a copy of ABS approved welding procedures and maintain a list of currently ABS qualified welders.

2.2.8 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 the materials and items with a breakdown of their locations by space, deck, frame, distance from centerline, and height off of the deck. A sample Weight Report form is attached to these specifications.

2.2.9 Update Reference 2.1.3 to “as-built” drawing for modifications accomplished by these detail specifications.

2.2.10 Update all other referenced drawings in individual work items using AutoCAD or

AutoCAD LT programs for modifications accomplished by work items.

2.2.11 Electrical power distribution systems available aboard the ship for Contractor power tools include 480vac via three submersible pump receptacles and 120vac receptacles throughout the ship.

2.2.12 The Contractor shall minimize shipboard work and inspections requiring ship’s force and COR presence on December 24, 25 and 26, 2016 and January 1 and 2, 2017.

Shipboard work may include mechanical tools and light industrial work. The Contractor shall not schedule nor conduct any shipboard hot work during these periods.

2.2.13 Vehicle and personnel access to NOAA Ship Henry B. Bigleow for pre-bid inspections is restricted via gated security. All contractors, vendors, and visitors are required to make pre-arrival arrangements for access at a minimum of 14 days in advance by calling the Port Engineer at 508-495-4708 (office) or 508-642-3986 (cell).

2.3 Notes

2.3.1 Descriptive data of NOAA Ship Henry B. Bigelow is as follows:

Length Overall 208.6 feet Beam (Molded) 49.2 feet Displacement 1,840 metric tons Light Ship

2,479 metric tons Full Load Draft 20.35 feet Full Load Centerboard Retracted

29.7 feet Full Load Centerboard Extended Cruising Speed 12 knots [Max speed 14 knots] Propulsion Diesel Electric, Single Propeller, Fixed Pitch, with two in-line 1508 hp DC Motors Generators Caterpillar 3508B, 3512B (two each) 600 volts AC Bow Thruster Elliott 40T3S, 360 Degree Electric Service 480 volts AC Year Built Commissioned July 2006 Builder VT Halter Marine Inc, Moss Point, MS

ABS ID 06142681

IMO Number 9349057 Construction Welded Steel Hull, Aluminum Superstructure Crew size 22 Bunks 39 Homeport of Record Woods Hole, MA Drydock and Repair Contractors Facility

2.3.2 Reference 2.1.3 was used in the identification, location, and naming of spaces within these Detailed Specifications. As the government cannot guarantee the accuracy of this drawing, contractors are encouraged to verify information identified in reference

2.1.3 prior to starting any work or submitting a bid.

2.3.3 A copy of referenced drawings and technical manuals may be reviewed on board the ship during pre-bid inspection or in the Northeast Fisheries Science Center, 166 Water Street, Woods Hole, MA 02543 upon request.

2.4 Hazardous Materials

2.4.1 NOAA Ship Henry B. Bigelow was constructed between 2004 and 2006. There was no asbestos used during construction. Asbestos requirements contained in referenced Standard Specifications do not apply to this ship.

2.4.2 Several items in this specification require gas freeing of tanks in order to accomplish the required work. Prospective bidders should be careful not to duplicate costs of gas freeing where tank(s) are required to be gas freed to perform work in more than one item.

2.4.3 The Contractor is responsible for the control, handling, and disposal of any hazardous materials generated during accomplishment of this contract.

2.5 Metrication

2.5.1 A combination of Standard English units of measure (feet – pounds) and Metric

System International (SI) units of measure (millimeter - kilogram) were used in the builders' drawings, specifications and reference materials for construction, operation, maintenance and repair of this ship. In this specification for NOAA Ship Henry B.

Bigelow, there is a combination of Standard English units and metric units.

3. BASIC ITEMS

3.1 Item 301: Telescoping Crane Repairs

3.1.1 Work Description – Provide all labor, material and equipment to repair the port

(Telescoping) crane and provide and install new wireless controls for operating the port crane.

3.1.2 References

(a) Tech Manual HB-572-03 (FRV40-225-111-010) Telescoping Boom Crane, Model EB70-60-25S, Appleton

(b) NOAA Standard Specification AMC-573-1C, Testing of Davits and Weight

Handling Gear

3.1.3 Government Furnished Material

3.1.3.1 None

3.1.4 Requirements

3.1.4.1 In conjunction with Ship’s Force, follow ship’s Lockout and Tagout Procedures to secure the telescoping crane hydraulic and electrical systems.

3.1.4.2 Remove the telescope hydraulic cylinder from the 2nd extended boom (outer most) and renew all of the counterbalance valves in accordance Reference (a).

3.1.4.3 Reinstall the telescope hydraulic cylinder.

3.1.4.4 Provide wireless remote controls for the telescoping boom crane. The wireless remote controls shall consist of the following:

a. Chest Pak and associated batteries receiver unit.

b. Receiver Box

c. Amplifier and display box

3.1.4.5 Provide a certified Appleton tech rep to attend the ship and install and calibrate the new wireless remote control system. Provide all necessary assistance, i.e. welders, electricians, labors, to install the new wireless remote controls on the ship.

3.1.4.6 Clear all crane Tagouts / Lockouts with Ship’s Force.

3.1.4.7 Perform an operational test on the crane using the wireless controls to ensure that all of the equipment works properly. The operational test will consist of wirelessly controlling the crane’s swing, telescope, winch and luff functions.

3.1.4.8 Perform a load test on the crane in accordance with Reference (b). The contractor shall provide a dynamometer, certified within the past 3 months, to verify the accuracy of the test weights and all test weights. The test weights shall be as follows:

Equipment SWL (lbs) 125% of SWL (Test Weight)

Telescoping Boom Crane (Retracted) 8,000 10,000 Telescoping Boom Crane (Extended) 5,000 6,250

3.1.5 Quality Assurance

3.1.5.1 As required by references (a) and (b).

3.1.6 Notes

3.1.6.1 The manufacturer’s information for the crane is as follows:

Telescoping Crane Manufacturer: Appleton Marine Model Number: EB70-60-25S Serial Number: 12960

END OF ITEM

3.2 Item 302: Shore Power Connection Box Replacement

3.2.1 Work Description – Includes labor, material, and equipment to remove the existing shore power connection box and install a new stainless steel box with all associated components in the box.

3.2.2 References

(a) None

3.2.3 Government Furnished Material

3.2.3.1 Shore Power Connection Box

3.2.4 Work Requirements

3.2.4.1 In conjunction with Ship’s Force, follow ship’s Lockout and Tagout Procedures to secure existing shore power connection box.

3.2.4.2 Disconnect all electrical cables to the shore power connection box and remove the box from the ship. Provide the ship’s CME the opportunity to remove all parts that he wishes to retain as spares and then scrap the box and remaining parts.

3.2.4.3 Pull back all of the wires running into the shore power connection box back down through the existing kick pipes into the Scientist’s Ready Room (1-56-0). Crop out the existing kick pipes and scrap. Provide and install new 316 stainless steel kick pipes in place of the removed kick pipes.

3.2.4.4 Power tool clean and preserve the deck below the existing shore power connection box in accordance with Reference 2.1.4. The top coat shall match the surrounding color.

3.2.4.5 Install, securely mount and wire up the new shore power connection box.

3.2.4.6 Clear shore power Tagouts / Lockouts with Ship’s Force.

3.2.5 Quality Assurance

3.2.5.1 In conjunction with ship’s force, install the two (2) shore power cables into the new box and ensure that the shore power system is working properly. Repair all deficiencies, if any.

3.2.6 Notes

3.2.6.1 None.

3.3 Item 303: Main Propulsion Motor Bearing Inspections

3.3.1 Work Description – Includes labor, material and equipment required to inspect the main propulsion drive motor bearings.

3.3.2 References

(a) Tech Manual HB-235 01 (FRV40-225-058-010) Main Propulsion DC, ASI Robicon

3.3.3 Government Furnished Material

3.3.3.1 None

3.3.4 Work Requirements

3.3.4.1 In conjunction with Ship’s Force, follow ship’s Lockout and Tagout Procedures to secure/de-energize the two main propulsion motors.

3.3.4.2 Provide a Michell Bearing certified manufacturer’s service representative to perform the following work on the No. 1 and No 2 main propulsion motors bearings:

3.3.4.2.1 Open and inspect the bearings in accordance with Reference (a).

3.3.4.2.2 Remove the cooler on each bearing and clean the cooler in accordance with

Reference (a).

3.3.4.3 Provide the COR with a condition report stating the findings of the bearing journals and coolers.

3.3.5 Quality Assurance

3.3.5.1 COR inspection.

3.3.6 Notes

3.3.6.1 Below is the name plate data for the bearings:

Location Identity No. Drawing Number Order No.

#1 Forward 3 212847 11890 #1 Aft 4 212847 11890 #2 Forward 1 212848 11890 #2 Aft 2 212849 11890

3.4 Item 304: Generator Inspections, Cleanings and Bearing Replacements

3.4.1 Work Description – Includes labor, material and equipment required to inspect the ship’s service diesel generators (SSDG’s), clean the generators and replace the generator bearings.

3.4.2 References

(a) Tech Manual HB-235 01 (FRV40-225-041-010) Generator, 3 Phase Synchronous, Models GSN 560 X4 – 1700KVA & GSN 500 X4 – 1138KVA

(b) Standard Specification AMC-300-1, Overhaul of Electrical Rotating Machinery

3.4.3 Government Furnished Material

3.4.3.1 None

3.4.4 Work Requirements

3.4.4.1 In conjunction with Ship’s Force, follow ship’s Lockout and Tagout Procedures to secure/de-energize the SSDG’s 1, 2, 3 and 4.

3.4.4.2 Provide the services of a certified Ansaldo service rep prior to moving the generators to oversee all work on the generators.

3.4.4.3 Prior to removing any mounting bolts; check and record all parallel and angular alignments between the shaft couplings and perform and record shaft run out reading.

Provide the COR with a condition report stating all of the readings.

3.4.4.4 Measure and record the shim heights on all the generator mounting bolts. Provide the

COR with a condition report stating all of the measurements.

3.4.4.5 Provide additional supports in the overhead as necessary to allow each generator to be moved.

3.4.4.6 Install a locking bracket on each generator shaft to keep the rotor in place while moving the generator.

3.4.4.7 Renew the forward (drive end) and aft roller bearings on generators 1, 2, 3 and 4.

3.4.4.8 Inspect each generator in accordance with Reference (a) and under the guidance of the service rep.

3.4.4.9 Perform an in place cleaning of each generator under the guidance of the service rep and in accordance with Reference (b).

3.4.4.10 Reinstall each generator, shaft coupling and shroud to the engine and realign the generator to the engine. Install the removed stainless steel shims around the mounting bolts. The alignment of the shafts shall, at a minimum, equal all readings recorded prior to the removal of the generator but in no case exceed 12 thousandths of an inch.

3.4.5 Quality Assurance

3.4.5.1 In conjunction with ship’s force perform operational tests on each generator to the satisfaction of the OEM tech rep. At a minimum each test shall consist of a no load test and then a test with each generator put on the bus providing power to the ship.

3.4.6 Notes

3.4.6.1 Below is the name plate data for the generators:

Generator Manufacturer: ASI Robicon Model Number: GSN 500 X4 S/N’s: #1 – 8006279, 1700kVA #2 – 8006280, 1700kVA #3 – 8006281, 1138kVA #4 – 8006282, 1138kVA

3.4.6.2 There No. 1 and No. 2 SSDG engines will be overhauled during the same time as the dockside repairs. The rear main seals on each engine will be replaced during the engine overhauls and requires the removal of the respective generators of each engine. The contractor that gets the dockside repair package will be required to remove/reinstall the generators. The generators will not be reinstalled until the contractor performing the engine overhauls has completed all work required on each engine with the generators removed.

3.4.6.3 The Ansaldo contact information is as follows:

Pierluigi Barautta Tel: 832-214-4187 (Office) or 713-502-9552 (Cell) Email: pierluigi.barutta@nidec-asi.com

3.5 SSDG Engines Major Overhauls – 3512

3.5.1 Work Description – Includes labor, material and equipment to perform major overhauls on SSDG No. 1 and No. 2 diesel engines.

3.5.2 References

(a) Tech Manual HB-233 01 (FRV40-225-029-010) Diesel Engine Caterpillar 3512B

3.5.3 Government Furnished Equipment

3.5.3.1 None

3.5.4 Requirements

3.5.4.1 General – The following requirements apply to all work:

3.5.4.1.1 Except as otherwise specified, the contractor shall provide all labor, material, services, tools, supervision, and technical expertise needed to accomplish the work required by this specification.

3.5.4.1.2 All work shall be performed by an authorized repair facility of the engine manufacturer or under the direct on-site supervision of a factory-trained mechanic currently certified by the engine manufacturer. Upon request, the Contractor shall submit evidence that they are a current Caterpillar Authorized Marine Dealer (A.M.D.) or other Caterpillar authorized Repair Facility, or proof of current certification of the Caterpillar factory-trained mechanic that will supervise the work on-site.

3.5.4.1.3 Provide and install “mandatory-renewal” parts and components during the overhaul as required by this Detail Specification and other procurement documents. Renewal of other parts and components determined to be needed may be provided by the government and shall be installed by the contractor. Additional needed parts and components which are not provided by the government will be negotiated by the Contracting Officer as an additional cost to the purchase order or contract.

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

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

3.5.4.1.6 All work shall be in accordance with Reference (a) and the manufacturer's service, maintenance, and overhaul technical manuals, including all current and applicable amendments and service bulletins. Unless otherwise specified, the contractor shall provide a copy of the applicable manuals, amendments, and service manuals at the job site. All repairs shall be made according to the manufacturer's engine specifications, clearances, tolerances, and procedures.

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

3.5.4.1.8 Thoroughly clean and conduct a thorough visual inspection of all disassembled parts for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability of the engine.

3.5.4.1.9 After inspections and tests have been completed and prior to reassembling the components, submit a typed report of all inspection findings and test results, including a record of all measurements and readings taken, to the Contracting Officer's Representative (COR) or other NOAA representative named in the procurement document. Include in the report recommendations for all additional repairs, inspections, tests, and part renewals needed to insure continued reliable service of the engine. Do not proceed with any additional (not covered by scope of previously required work) repairs, inspections, tests, part renewal, or reassembly until authorized by the Contracting Officer or purchasing agent who issued the procurement document.

3.5.4.1.10 After removals are complete, inspect the block for external surface corrosion. Any areas found to have surface rust or coating breakdown perform spot preservation to bare metal and apply OEM specified paint matching the existing engine color.

Ensure that during any preservation and painting efforts that all areas where debris could enter the engine internals are completely covered.

3.5.4.1.11 After the report has been accepted and all additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed.

3.5.4.1.12 All replacement external components, new and/or remanufactured, such as heads, valve covers, spacer plates, piping, fasteners, etc. shall be painted to match the existing engine color using OEM paint PRIOR to installation on the engine.

3.5.4.1.13 Remove and reinstall interferences as required to accomplish the required work.

3.5.4.1.14 Daily clean up all debris incidental to the performance of the required work. Upon completion of all work, clean all work sites to their as-found condition.

3.5.4.1.15 Coordinate mechanical and electrical tagouts through ships force engineering department.

3.5.4.1.16 Interface with the engine electronic control module (ECM) prior to commencing work and record any active alarms or codes in the ECM. Provide a condition report to the COR with all codes that require corrective action or further investigation.

3.5.4.1.17 Verify the current ECM software version and verify with the engine manufacturer that this is the most up to date version. If the current version is not the most up to date update the engine ECM with the latest software version.

3.5.4.2 Major Overhauls – The following requirements apply:

3.5.4.2.1 Perform major overhauls of the Caterpillar 3512B SSDG diesel engines No. 1 and

No. 2 per the requirements of Caterpillar as defined in Reference (a) and as follows:

3.5.4.2.2 Drain and properly dispose of all liquids in the engines.

3.5.4.2.3 Replace the following components:

a. Camshaft Bearings

b. Crankshaft Seals

c. Crankshaft Thrust Washers

d. Electronic Unit Injectors

e. Gear Train Bushings

f. Gear Train Bearings

g. Piston Rings

NOTE: The main and connecting rod bearings were replaced on both engines in May

2016 and therefore will not be replaced during this overhaul.

3.5.4.2.4 Inspect the following components according to the instructions that are in the Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”.

Recondition the worn components or exchange:

a. Connecting Rods

b. Crankshaft Vibration Damper

c. Cylinder Head Assembly

d. Cylinder Liners

e. Fuel Priming Pump

f. Fuel Transfer Pump

g. Oil Cooler Core

h. Oil Pump

i. Pistons

j. Piston Pins

k. Turbocharger

Recondition the worn components or exchange, if necessary.

a. Camshaft Followers

b. Camshaft Thrust Washers

c. Engine Wiring Harness and perform “Wiggle Test”

d. Exhaust Manifold Bellows

e. Fuel Pressure Regulating Valve

f. Pushrods

g. Rocker Arms

h. Spacer Plate

i. Software Update

NOTE: Renew all gaskets and seals of all disturbed equipment and parts.

3.5.4.2.5 Inspect the following components according to the according to the instructions that are in the Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”.

a. Aftercooler Core

b. Camshaft

c. Crankshaft

d. Driven Equipment (alignment)

e. Engine Cylinder Block

f. Engine Control Module

g. Exhaust Bellows Shields

h. Flywheel

i. Front Gear Train (gears)

j. Oil Suction Screen

k. Rear Gear Train

3.5.4.2.6 Inspect the camshaft for damage to the journals and the lobes.

3.5.4.2.7 Replace the crankshaft vibration damper if any of the following conditions occur:

a. Excessive wear of the front bearing for the crankshaft.

b. Excessive wear of the gear train that is not caused by a lack of lubrication.

3.5.4.2.8 Inspect the gears of the gear train and inspect the gear train bushings for the following conditions:

a. Worn Gear Teeth

b. Unusual Fit

c. Unusual Wear

3.5.4.2.9 Clean the oil cooler core and the aftercooler core and the pressure test both of the cores.

3.5.4.2.10 Clean the oil sump.

3.5.4.2.11 In addition to the above work renew all of the following parts and components.

a. Seals, O-rings, and gaskets of all removed and disassembled components and parts

b. Thermostats, water and oil temperature regulators

c. All filter elements on the engine

d. Install OEM plastic clip on fuel spray guards on all pressurized fuel component connections. If plastic guards are not available install ABS approved fuel and oil line spray tape on pressure connections.

3.5.4.2.12 Replace the following sensors, if so equipped:

a. Crank Case Pressure

b. Oil Temperature

c. Oil Pressure

d. Jacket Water Temperature

e. Boost Pressure

f. Right and Left Bank Exhaust Temperature

g. Fuel Pressure

3.5.4.2.13 Replace the existing air starters with a TDI air starter, Model T109-P. Provide and install a 40 mesh air strainer and a TDI relay valve, part number RLVA.

3.5.4.2.14 Refill the coolant (ship will provide non-chromate corrosion inhibitor) system. The coolant system shall be refilled with fresh water and the same type of non-chromate corrosion inhibitor (ship will provide) as existing. Ship’s force will refill the lube oil crankcase with ship supplied oil.

3.5.4.2.15 Tests - Conduct the following tests of the engine after all components have been reassembled.

a. Test all alarm and shutdown systems prior to starting the engine. Conduct a preliminary tune-up of the engine.

b. Monitor engine operations as the ship's engineers start the engine. Check all joints for leaks.

3.5.4.2.16 Perform operational tests of the engine as follows:

a. Operate engines at no-load for one hour and until normal no-load operating temperatures are reached.

b. Increase the load on the engine to 25-percent of its normal operating full load and operate for one-half hour.

c. Increase the load on the engine to 50-percent of its normal operating full load and operate for one-half hour.

d. Increase the load on the engine to 75-percent of its normal operating full load and operate for one hour.

e. Increase the load on the engine to 100-percent of its normal operating full load and operate for two hours.

3.5.4.2.17 For electrical generators prime movers, the ship will install house loads onto the generators for the load tests. Loads tests up to approximately 50-percent capacity shall be performed pier side. All load tests over 50-percent capacity shall be performed during an underway testing. Test loads shall be based on the full load capacity of the generator.

3.5.4.2.18 During and following each operational test period, make adjustments, correct leaks, and monitor performance of the engine.

3.5.4.2.19 Near the end of each operational test period, take and record the following information using an external computer capable of communication with the OEM engine software via the ECM. Record any engine codes or alarms that occur during the testing period. Provide the COR and chief engineer with a digital copy of the recorded information for all engines:

a. crankcase pressure

b. cylinder exhaust temperatures

c. lube oil temperatures

d. water temperatures

e. fuel oil pressures

f. lube oil pressures

g. water pressures

h. electrical load on generator prime movers

i. exhaust back pressures

j. air box pressure

k. other operating parameters as permitted by installed instrumentation.

3.5.4.2.20 Prepare and submit to the COR or other NOAA representative named in the procurement document a report of all data taken in conjunction with the test periods.

Include in the report the manufacturer's recommended limits for the applicable parameter.

3.5.4.2.21 During the performance of the tests, continually monitor the temperatures and pressures and compare them to the manufacturer's recommended limits. If at any time a temperature or pressure exceeds or falls below the manufacturer's recommended upper or lower limits, the tests shall be stopped and the cause is to be determined. After the cause has been corrected, the tests shall be restarted from the beginning.

3.5.4.2.22 Final Adjustments and Tune-up - After satisfactory completion of the operational tests, perform the following:

a. Reset valves, reset injectors, and set governor speed.

b. Conduct final adjustments and tune-ups as required providing smooth, efficient, and reliable operation of the engine.

3.5.4.2.23 The contractor shall provide one (1) complete list in electronic form (Microsoft word or excel or PDF), including OEM part numbers, quantities and both the OEM description AND application name description of all OEM parts installed or used as part of any scope of work completed under this specification.

An example of the name specific requirement would be a Cat Sensor would be name "Sensor GP", Part No. 135-2336, Qty 1 Ea. Add the “plain name” to the description to read:

OEM Name: "Sensor GP", Application Name: Oil Pressure Sensor, Part No. 135-

2336, Qty 1 Ea

3.5.5 Quality Assurance

3.5.5.1 COR inspection.

3.5.6 Notes

3.5.6.1 The SSDG diesel engines use Shell Rotella 15w-40. Approximately 350 gallons total.

3.5.6.2 The following is the engine and generator information:

Engines No. 1 and No. 2 MFG: Caterpillar Inc.

Model: 3512 Serial: 8EM00516 and 8EM00517 SSDG No. 1 and No. 2 MFG: ASIRobicon Model: 500X4-1700 Serial: 8006280-2004 600 Volt, 1360 kW, 1700 kVA

4. ADDITIONAL WORK ITEMS

4.1 Item 401: Additional Work [Labor and Material]

4.1.1 Work Description – Additional Work - Labor and Material

4.1.2 References

4.1.3 Government Furnished Material

4.1.3.1 None

4.1.4 Requirements

4.1.4.1 This is a place holder only. Refer to the contract clause “1352.271-72

ADDITIONAL ITEM REQUIREMENTS (AIR) – GROWTH WORK (APR 2010)”

for all requirements dealing with emergent work and changes associated with this contract.

4.1.4.2 Schedule B provides an estimate of labor hours and material growth for emergent work anticipated for this contract.

4.1.5 Quality Assurance

4.1.5.1 COR Inspection.

4.1.6 Notes

4.1.6.1 None

5. OPTION ITEMS

5.1 Item 501: Mission Hydraulic HPU Hose Renewal

5.1.1 Work Description – Includes labor, material, and equipment to renew the hydraulic hoses on the mission hydraulics HPU.

5.1.2 References

(a) None

5.1.3 Government Furnished Material

5.1.3.1 None

5.1.4 Requirements

5.1.4.1 In conjunction with Ship’s force, follow ship’s lockout / tagout procedures to secure all electrical power and hydraulics serving the mission hydraulics HPU.

5.1.4.2 Renew all existing hydraulic flex hoses that are located on the mission hydraulics

HPU located in the Oceanographic Winch Room. The new flex hoses shall be the same length as the existing hoses and shall have the same fittings. New flex hoses shall be pressure tested and tagged with engraved or embossed aluminum tags indicating test pressure and date. Conduct hydrostatic pressure tests of all fittings and flex hoses to 150-pecrent of system operating pressure and check for leaks. Correct any leaks. Below is a list of hoses on the Mission Hydraulics HPU. Fill in the actual lengths on the table below and provide a copy to the COR.

NOTE: This list of hoses came from the Bigelow’s sister ship and the actual quantity, size and length of the hoses on the Bigelow may differ.

EQUIPMENT:

MISSION HYDRAULICS HPU

Item Hose Assembly Description Adapters if needed Length

(Estimate) Length (Actual)

1 F451TC0606-16-16 28.00

2 F451TC0603-8-8-8 22.00

3 F7110303-24-24-24 26.00 4 F4110303-24-24-24 24.50 5 F7110303-24-24-24 25.00

6 F451TC0603-16-16-16 23.00

7 F7110303-24-24-24 24.00 8 F7110303-24-24-24 28.25

9 F451TC0603-16-16-16 23.75

10 F7110303-24-24-24 25.50

11 F451TC0606-8-8-8 42.00

12 F451TC0606-8-8-8 42.00

13 F451TC0603-16-16-16 24.00

14 F451TC0603-16-16-16 24.00

15 F7110303-24-24-24 26.00 16 F7110303-24-24-24 25.50 17 F7110303-24-24-24 24.00 18 F7110303-24-24-24 24.50 19 F7110303-24-24-24 26.00 20 F7110303-24-24-24 26.00

21 F451TC0603-16-16-16 24.00

22 F451TC0603-16-16-16 24.25

23 F7110303-24-24-24 25.00 24 F7110303-24-24-24 25.00 25 F7110303-24-24-24 24.50 26 F7110303-24-24-24 26.00

27 F451TC0603-16-16-16 24.00

28 F451TC0606-16-16-16 37.00

29 F7111506-32-32-32 20.00 30 F7110606-32-32-32 18.50

31 F71106JS-24-24-24 19.50

32 F7111539-24-24-24 23.00

33 F451TC1503-20-20-20 20.25

34 F451TC3939-20-24-20 20-24 TETX-S 19.00

35 F71115J9-24-24-24 24.00

36 F71115JS-24-24-24 21.00

37 F71106J9-24-24-24 21.50

38 F71106JS-24-24-24 23.00

39 F71115JS-24-24-24 20.00

40 F71106J9-24-24-24 20.50 41 F7111506-24-24-24 20.00 42 F7113939-24-24-24 23.50

43 F451TC0603-16-16-16 19.50

44 F451TC0639-20-16-16 18.00

45 F71115JS-24-24-24 20.75

46 F71106J9-24-24-24 22.75 47 F71115J9-24-24-24 28.25

48 F71119JS-24-24-24 22.00

49 F71119JS-24-24-24 22.50

50 F71115J9-24-24-24 27.00

51 F451TC0606-8-8-8 24.00

52 F7113939-24-24-24 22.50 53 F7111506-24-24-24 20.25

54 F71119JS-24-24-24 22.00

55 F71115J9-24-24-24 28.00

56 F71119JS-24-24-24 22.50

57 F71115J9-24-24-24 28.00

5.1.5 Quality Assurance

5.1.5.1 Ship’s force will operate all equipment associated with the Mission Hydraulics HPU so that a check can be made to see if any of the hoses and/or fittings are leaking.

Repair all leaks, if any.

5.1.6 Notes

5.1.6.1 None

5.2 Item 502: 02 Deck Covering Replacement

5.2.1 Work Description – Includes labor, material, and equipment to remove the existing deck covering on the 02 deck.

5.2.2 References

(a) PPI NBR 63421-006H (Rev 04), Preservation Process Instruction (PPI) for

Cosmetic Polymeric Deck Coverings Type II, Classes 1 & 2 for Wet and Dry Interior Spaces

(b) Navy MIL-D-3134J, Deck Covering Materials

5.2.3 Government Furnished Material

5.2.3.1 None

5.2.4 Requirements

5.2.4.1 Replace the deck covering on the 02 deck interior spaces with poured rubber deck coverings and per the following requirements:

5.2.4.1.1 02 Level

- 02 Passageway (02-29-0): 211 Sq Ft

- Ladder (1-51-2): 16 Sq Ft

- Ladder (02-51-2): 18 Sq Ft

- Laundry (02-45-0): 20 Sq Ft

- Linen Locker (02-47-1): 8 Sq Ft

- Hospital (02-50-1): 155 Sq Ft

Total Sq Ft 02 Deck: 428

(NOTE: The total square feet noted may not be exact. The contractor is responsible for determining the exact square footage of the deck areas requiring replacement.)

5.2.4.2 Mark, remove, and properly store interferences including sinks, water fountains, temporary deck matting, desks, file cabinets, exam table, gun safe, lockers, etc. This includes all labor and equipment required to disconnect plumbing, remove fasteners, rivets and other fastening devices and any replacement fasteners, etc required upon reinstallation. Upon completion of the work required by this item, re-install interferences and prove operational.

5.2.4.3 Prove all deck drain(s) in the compartment(s) to be dealt with to be clear and free flowing. Plug the drain(s) to preclude introduction of debris resulting from this work item. Upon completion of the decking renewal, remove the plug(s) and again prove the drain(s) to be clear and free flowing. The COR shall witness testing of all drains.

5.2.4.4 Submit a condition report to the COR listing any drain(s) found to be obstructed.

Clearing such drains, if determined to be necessary by the COR, shall be the subject of a condition report.

5.2.4.5 Install protective covering to protect the vessel's equipment and to contain the dust generated by this work item to the affected compartment(s). All ladder wells and hatches shall be completely sealed with signs posted to prevent accidental access ruining the new deck covering while drying. In the hospital the racks are to be wrapped and sealed along with any other medical gear remaining in the space. The COR shall approve the protective covering prior to the start of productive work.

5.2.4.6 Chip-up and remove the existing tile deck covering and underlayment in its entirety, including coving. Debris shall be removed from the vessel and properly disposed of on a daily basis.

5.2.4.7 Remove any existing but un-used anchor clips from the deck and grind smooth in way of removals.

5.2.4.8 Power tool clean the entire deck, the bulkheads up to a line 4 inches above the deck, and all foundations, clips for equipment and retainer rings around deck drains, to bare metal in accordance with Reference (a). Blow down and/or vacuum the compartment to remove all dirt and dust generated by the surface preparation activities.

5.2.4.9 Inspect the surface preparation with the COR. Inspection shall include the condition of all permanently attached fixtures in way of the rolled deck covering installation.

Upon approval of the surface preparation by the COR, apply one (1) coat of Mil-P- 24441, Formula 150 zinc primer or equivalent product per flooring underlayment manufacturer’s recommendations to all prepared surfaces. The primer shall be 3-4 mils DFT.

5.2.4.10 Submit a condition report to the COR listing deteriorated foundations, deck drain retainer rings, etc., found during the inspection after all power tool cleaning has been completed. Additional repairs, if deemed necessary by the COR, shall be the subject of a change order.

5.2.4.11 Upon approval by the COR, wipe down the primed surfaces with solvent. When dry, install ultra lightweight underlayment similar to Epmar 1290. The underlayment shall be a minimum of thickness per manufacturer’s recommendations and shall fair-in irregularities in the deck including weld seams, depressions, etc. Total thickness of the underlayment shall be dependent upon, and adjusted upward as necessary, to conform to the rubber deck covering thickness requirements as set forth in paragraph

5.2.4.12.

5.2.4.12 Upon inspection and approval of the underlayment by the COR, install pre-colored navy blue rubber deck membrane material similar to American Safety MS1600 in accordance with References (a) and (b). The base coat shall be a minimum of ¼ inch thick but shall not exceed ½ inch thick. The thickness of the rubber basecoat shall be maintained within these limits with no allowable deviation. All flooring shall be sloped for positive drainage to the deck drains and shall be coved up the bulkheads 4 inches. The finished surface shall be even and free of pour marks or settling irregularities.

NOTE: Poured decking must be pre-colored, painting the rubber decking after being poured will not be acceptable.

5.2.4.13 When cured, prepare surface to a smooth and fair profile. Final surface shall be nonporous, smooth and free of pits, spalls, crevices and pour marks. Apply mixed white and gold colored flakes, uniformly distributed, firmly embedded and exposed at the surface. Apply low profile texture coat and 3 coats of sealer similar to American Safety SC100. Cracks or voids found in the urethane or sealant shall be rejected as defects. Such defects shall not be patched. Acceptable corrective action shall be removal and re-installation of the sealer and subsequent layers.

5.2.4.14 When surface preparation of the rubber deck is completed, blow-down and vacuum the entire compartment, including protective covering and equipment and fixtures in the compartment.

5.2.4.15 Clean and paint disturbed surfaces to match the surrounding areas.

5.2.4.16 Remove all protective covering. Clean the compartment(s) and leave in a condition ready for use. The COR shall inspect all areas after cleaning.

5.2.5 Quality Assurance

5.2.5.1 Test the drainage in the compartment. Prove that the drainage is positive and without low spots which would tend to collect water.

5.2.5.2 Navy blue deck color and white/gold flakes are to match the color of the main deck passageway. Contractor to verify deck rubber color match and flake color match prior to ordering materials and commencement of work.

5.2.5.3 Ultra lightweight underlayment, poured rubber membrane decking and sealer are to be intended for installation as a complete deck cover solution. Materials are to be intended or purposed for shipboard use on steel decking and are to be of suitable quality to stand up to heavy foot traffic.

5.2.6 Notes

5.2.6.1 None

5.3 Item 503: 01 Deck Covering Replacement

5.3.1 Work Description – Includes labor, material, and equipment to remove the existing deck covering on the 01 deck.

5.3.2 References

(a) PPI NBR 63421-006H (Rev 04), Preservation Process Instruction (PPI) for

5.3.3 Government Furnished Material

5.3.3.1 None

5.3.4 Requirements

5.3.4.1 Replace the deck covering in all of the following deck interior spaces with poured rubber deck coverings and per the following requirements:

5.3.4.1.1 01 Level

- 01 Deck Aft Ladder Landing (01-49-2): 76 Sq Ft

- ET Shop Entrance Way (01-47-2): 32 Sq Ft

- Ships Office (01-37-2): 92 Sq Ft

- 01 Deck Passageway (01-14-0): 205 Sq Ft

- 01 Level Fan Room (01-37-0/1): 210 Sq Ft

- 01 Level Gear Locker (01-26-1): 12 Sq Ft

- 01 Level Linen Locker (01-29-1): 8 Sq Ft

Total Sq Ft 01 Deck: 635

(NOTE: The total square feet noted may not be exact. The contractor is responsible for determining the exact square footage of the deck areas requiring replacement.)

5.3.4.2 Mark, remove, and properly store interferences including sinks, water fountains, temporary deck matting, desks, file cabinets, exam table, gun safe, lockers, etc. This includes all labor and equipment required to disconnect plumbing, remove fasteners, rivets and other fastening devices and any replacement fasteners, etc required upon

5.3.4.3 Prove all deck drain(s) in the compartment(s) to be dealt with to be clear and free

5.3.4.4 Submit a condition report to the COR listing any drain(s) found to be obstructed.

5.3.4.5 Install protective covering to protect the vessel's equipment and to contain the dust hatches shall be completely sealed with signs posted to prevent accidental access ruining the new deck covering while drying. In the hospital the racks are to be

5.3.4.6 Chip-up and remove the existing tile deck covering and underlayment in its entirety,

5.3.4.7 Remove any existing but un-used anchor clips from the deck and grind smooth in way

5.3.4.8 Power tool clean the entire deck, the bulkheads up to a line 4 inches above the deck, and all foundations, clips for equipment and retainer rings around deck drains, to bare

5.3.4.9 Inspect the surface preparation with the COR. Inspection shall include the condition

Upon approval of the surface preparation by the COR, apply one (1) coat of Mil-P- 24441, Formula 150 zinc primer or equivalent product per flooring underlayment

5.3.4.10 Submit a condition report to the COR listing deteriorated foundations, deck drain

5.3.4.11 Upon approval by the COR, wipe down the primed surfaces with solvent. When dry, install ultra-lightweight underlayment similar to Epmar 1290. The underlayment shall be a minimum of thickness per manufacturer’s recommendations and shall fair-in irregularities in the deck including weld seams, depressions, etc. Total thickness of

5.3.4.12.

5.3.4.12 Upon inspection and approval of the underlayment by the COR, install pre-colored navy blue rubber deck membrane material similar to American Safety MS1600 in accordance with References (a) and (b). The base coat shall be a minimum of ¼ inch thick but shall not exceed ½ inch thick. The thickness of the rubber basecoat shall be maintained within these limits with no allowable deviation. All flooring shall be sloped for positive drainage to the deck drains and shall be coved up the bulkheads 4

5.3.4.13 When cured, prepare surface to a smooth and fair profile. Final surface shall be nonporous, smooth and free of pits, spalls, crevices and pour marks. Apply mixed white and gold colored flakes, uniformly distributed, firmly embedded and exposed at the surface. Apply low profile texture coat and 3 coats of sealer similar to American Safety SC100. Cracks or voids found in the urethane or sealant shall be rejected as

5.3.4.14 When surface preparation of the rubber deck is completed, blow-down and vacuum

5.3.4.15 Clean and paint disturbed surfaces to match the surrounding areas.

5.3.4.16 Remove all protective covering. Clean the compartment(s) and leave in a condition ready for use. The COR shall inspect all areas after cleaning.

5.3.5 Quality Assurance

5.3.5.1 Test the drainage in the compartment. Prove that the drainage is positive and without low spots which would tend to collect water.

5.3.5.2 Navy blue deck color and white/gold flakes are to match the color of the main deck

5.3.5.3 Ultra lightweight underlayment, poured rubber membrane decking and sealer are to

5.3.6 Notes

5.3.6.1 None

5.4 Item 504: 2 Deck Covering Replacement

5.4.1 Work Description – Includes labor, material, and equipment to remove the existing deck covering on the 2 deck.

5.4.2 References

(a) PPI NBR 63421-006H (Rev 04), Preservation Process Instruction (PPI) for

5.4.3 Government Furnished Material

5.4.3.1 None

5.4.4 Requirements

5.4.4.1 Replace the deck covering in all of the following deck interior spaces with poured rubber deck coverings and per the following requirements:

5.4.4.1.1 2nd Deck

- Passageway (2-14-0): 332 Sq Ft

- Aft Ladder 2nd Deck (3-47-0): 38 Sq Ft

- Aft Ladder 3rd Deck (3-47-0): 16 Sq Ft

- Linen Locker (2-39-1): 15 Sq Ft

- Gear Locker (2-21-2): 30 Sq Ft

- Fwd Ladder 2nd Deck (3-31-0): 34 Sq Ft

- Fwd Ladder 3rd Deck (3-31-0): 42 Sq Ft

Total Sq Ft 2nd Deck: 507

(NOTE: The total square feet noted may not be exact. The contractor is responsible for determining the exact square footage of the deck areas requiring replacement.)

5.4.4.2 Mark, remove, and properly store interferences including sinks, water fountains, temporary deck matting, desks, file cabinets, exam table, gun safe, lockers, etc. This includes all labor and equipment required to disconnect plumbing, remove fasteners, rivets and other fastening devices and any replacement fasteners, etc required upon

5.4.4.3 Prove all deck drain(s) in the compartment(s) to be dealt with to be clear and free

5.4.4.4 Submit a condition report to the COR listing any drain(s) found to be obstructed.

5.4.4.5 Install protective covering to protect the vessel's equipment and to contain the dust hatches shall be completely sealed with signs posted to prevent accidental access ruining the new deck covering while drying. In the hospital the racks are to be

5.4.4.6 Chip-up and remove the existing tile deck covering and underlayment in its entirety,

5.4.4.7 Remove any existing but un-used anchor clips from the deck and grind smooth in way

5.4.4.8 Power tool clean the entire deck, the bulkheads up to a line 4 inches above the deck, and all foundations, clips for equipment and retainer rings around deck drains, to bare

5.4.4.9 Inspect the surface preparation with the COR. Inspection shall include the condition

Upon approval of the surface preparation by the COR, apply one (1) coat of Mil-P- 24441, Formula 150 zinc primer or equivalent product per flooring underlayment

5.4.4.10 Submit a condition report to the COR listing deteriorated foundations, deck drain

5.4.4.11 Upon approval by the COR, wipe down the primed surfaces with solvent. When dry, install ultra-lightweight underlayment similar to Epmar 1290. The underlayment shall be a minimum of thickness per manufacturer’s recommendations and shall fair-in irregularities in the deck including weld seams, depressions, etc. Total thickness of

5.4.4.12.

5.4.4.12 Upon inspection and approval of the underlayment by the COR, install pre-colored navy blue rubber deck membrane material similar to American Safety MS1600 in accordance with References (a) and (b). The base coat shall be a minimum of ¼ inch thick but shall not exceed ½ inch thick. The thickness of the rubber basecoat shall be maintained within these limits with no allowable deviation. All flooring shall be sloped for positive drainage to the deck drains and shall be coved up the bulkheads 4

5.4.4.13 When cured, prepare surface to a smooth and fair profile. Final surface shall be nonporous, smooth and free of pits, spalls, crevices and pour marks. Apply mixed white and gold colored flakes, uniformly distributed, firmly embedded and exposed at the surface. Apply low profile texture coat and 3 coats of sealer similar to American Safety SC100. Cracks or voids found in the urethane or sealant shall be rejected as

5.4.4.14 When surface preparation of the rubber deck is completed, blow-down and vacuum

5.4.4.15 Clean and paint disturbed surfaces to match the surrounding areas.

5.4.4.16 Remove all protective covering. Clean the compartment(s) and leave in a condition ready for use. The COR shall inspect all areas after cleaning.

5.4.5 Quality Assurance

5.4.5.1 Test the drainage in the compartment. Prove that the drainage is positive and without low spots which would tend to collect water.

5.4.5.2 Navy blue deck color and white/gold flakes are to match the color of the main deck

5.4.5.3 Ultra lightweight underlayment, poured rubber membrane decking and sealer are to

5.4.6 Notes

5.4.6.1 None

5.5 Item 505: Mission Hydraulics Cooling Water Piping Modifications

5.5.1 Work Description – Includes labor, material and equipment required to modify the mission hydraulics cooling water piping.

5.5.2 References

5.5.3 Government Furnished Material

5.5.3.1 None

5.5.4 Work Requirements

5.5.4.1 In conjunction with Ship’s Force secure…