J.1_TJ_Dry_Docking_and_Tunnel_Thruster_Servicing.pdf

NOAA Ship Thomas Jefferson

Dry Docking and Tunnel Thruster Servicing

MOA2-08(17)

DATE: December 14, 2017

Written by:

Reviewed by:

Marine Engineering Branch - MOA2 Marine Operation Center, Atlantic

439 West York Street Norfolk, VA 23510

December 14, 2017

TABLE OF CONTENTS

Table of Contents

1. SCOPE 1

2. GENERAL 1

3. BASIC ITEMS 5

3.1 ITEM NO. 301: Temporary Services 5

3.2 ITEM NO. 302: Dry Docking 7

3.3 ITEM NO. 303: Tunnel Thruster Servicing 9

4. OPTIONAL ITEM 400: ADDITIONAL ITEM REQUESTS 13

5. OPTIONAL ITEMS 14

5.1 ITEM NO. 501: Bow Sonar Dome Removal 14

REFERENCES 16

GOVERNMENT FURNISHED MATERIAL 17

DELIVERABLES 18

LIST OF ATTACHMENTS 19

i

1. SCOPE

1.1 These Detail Specifications contain the requirements for

dry-docking and servicing of the tunnel truster on the NOAA Ship Thomas Jefferson (formerly USNS Littlehales T-AGS 52).

1.2 The work items in this repair specification were identified well in advance of the performance period in order to meet contracting lead times. Additional work items (emergent work) may have arisen following submission of the original work package but prior to award of the contract, after award of the contract but prior to start of the performance period or even during the contract performance period. In accordance with Commerce Acquisition Regulation (CAR) clause 1352.271-72, the Contracting Officer may modify the contract during the Period of Performance to address any emergent work as necessary to ensure the intent of the drydock or dockside repair contract is met; that is, the vessel shall be able to safely perform its mission, the vessel will meet all habitability and regulatory body requirements, and such repairs will be performed timely to ensure, to the maximum extent practicable, that the vessel's schedule is not adversely impacted.

2. GENERAL

2.1 References

2.1.1 NOAA Standard Specification AMC-000-1G, “General

Requirements for Ship Repair Contract Work on NOAA Ships”

2.1.2 NOAA Standard Specification AMC-631-2D, “Coating Systems for Steel Surfaces”

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

Requirements: Accomplish”

2.1.4 NOAA Ship Thomas Jefferson drawing 085-002F, “Booklet of General Plans”

2.1.5 ABS Steel Vessels Under 90 Meters (295 Feet) in Length

2.2 Requirements

2.2.1 References 2.1.1 and 2.1.2 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.

2.2.2 Provide an electronic copy, in Adobe Portable Document

Format (PDF), and two hard copies of all Condition Reports.

2.2.3 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. The form shall 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. QA Inspection Report

2.2.4 Maintain a separate Test Schedule.

2.2.5 Develop, in consultation with the ABS Surveyor, a written survey schedule that lists the items to be inspected and the scheduled dates and times of the inspections.

2.2.6 Unless otherwise stated in these work items, prepare and coat all new steel, disturbed, or otherwise required painted surfaces in accordance with reference 2.1.2. If no paint system is identified in the item, apply the appropriate coating system to the area being coated as identified by paragraph 5.2 of this reference except that the topcoat color shall match the surrounding area. Reference 2.1.2 may be amended with reference 2.1.3 when approved by the COR.

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

2.2.8 The Contractor may reduce the ship's draft by offloading liquid loads and/or ballasting in order to provide the required clearances under the keel during transit to and from the contractor's facility. Oil Tanks shall not be ballasted. After all other work has been completed, reload and trim the ship to the as-found conditions.

In the event fuel is offloaded, the fuel shall be metered off and on the ship through a filter de-watering system. Store removed fuel in clean storage facilities. The minimum draft for transit which will be permitted is 12 feet - 6 inches.

2.2.9 The cleanliness of the ship at the time of redelivery to NOAA shall be equal to or better than the cleanliness of the ship at the time of delivery to the contractor.

2.2.10 NOAA Ship Thomas Jefferson is ABS Classed. All fabrication and materials are to be in accordance with reference 2.1.5. so as to retain her ABS Class.

2.3 Deliverables

2.3.1 Condition Reports (see requirement in reference 2.1.1)

2.3.2 Progress Reports (see requirement in reference 2.1.1)

2.3.3 List of Contractor’s Supervisors (see requirement in

reference 2.1.1)

2.3.4 Safety Plan (see requirement in reference 2.1.1)

2.3.5 Gas Free Certifications (see requirement in reference

2.1.1)

2.3.6 Hot Work Notices (see requirement in reference 2.1.1)

2.3.7 Hazardous Material List and MSDS (see requirement in

reference 2.1.1)

2.3.8 Quality Assurance (QA) Test and Inspection Plan

2.3.9 Test Schedule

2.3.10 ABS Approved Welding Procedure and Welder Certification

– Provide a copy of ABS approved welding procedures and welder certificates prior to starting any work. Maintain a list of currently qualified welders throughout the contract performance period.

2.3.11 ABS Survey Schedule - Submit the ABS survey schedule to the COR within 48 hours after the start of the contract performance period. The ABS survey schedule shall list all initial inspections required by the ABS Surveyor.

2.3.12 Weight Report

2.4 Notes

2.4.1 Hazardous Materials:

a. NOAA Ship Thomas Jefferson was constructed between 1988 and 1991. There was no asbestos used during the construction and any asbestos requirements contained in the referenced Standard Specifications do not apply.

b. 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 the costs of gas freeing where tank(s) are required to be gas freed to perform work in more than one item.

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

2.4.2 Reference 2.1.4 was used in the identification, location, and naming of spaces within these Detailed Specifications. Even though reference 2.1.4 has been modified since construction, differences still exist.

2.4.3 The following general characteristics of the ship are

provided for information:

ABS Class Number...9105067 Delivery Date..01 Dec 1991 Length Overall.........208 feet Beam (Molded)...........45 feet Propulsion.............Diesel, single screw Cruising Speed..........12 knots Electric Service.......345 KW, 225/450 volts AC Officer size Crew size ABS Class Notations....✠A1, E ,✠AMS,✠ACCU

2.4.4 Except as otherwise stated in this specification, NOAA

plans to deliver the ship to the contractor's facility with the following maximum drafts and displacement (approximately 62% liquid loading):

Forward Draft............14 feet - 0 inches Aft Draft................14 feet - 6 inches Displacement..........≈2200 long tons

3. BASIC ITEMS

3.1 ITEM NO. 301: Temporary Services

3.1.1 Abstract – This item covers the requirements for providing temporary service during repair of the ship’s tunnel thruster (bow thruster).

3.1.2 References

(a) NOAA Standard Specification AMC-000-2C, “Temporary Services at

Contractor Facilities”

3.1.3 Government-Furnished Material

a. None

3.1.4 Requirements

a. Provide all temporary services required in accordance with reference (a) for the entire performance period.

b. The following additional information and requirements apply:

1. Electric: Provide and maintain 400 amps, 60 hz, 460 volts ac, 3 phase electrical shore power services. Estimated demand load is 250 amps average. The ship’s two receptacles are for NATO (Joy type) plugs rated at 400 amps each. Ship’s force will identify which of the ship’s receptacles to connect to for this availability at the time of hookup.

2. Telephone Service: Not required

3. Steam: Not required.

4. Toilet Facilities: Not required.

5. Parking Spaces: Provide parking spaces for eight vehicles. Provide the follow labels for the parking spaces:

a) One each: “NOAA - COR”

b) One each: “NOAA - CO”

c) One each: “NOAA - CME”

d) Five each: “NOAA”

6. Dockside Office Space: Not required.

7. Security Services: Not required.

8. Air: Not required.

9. High Speed Internet Service: Not required.

10. ABS Surveyor: Schedule the services of an ABS Surveyor as required by ABS for performing inspections of all new installations, hull modifications, and tank inspections. NOAA will pay for all normal ABS surveys and surveys associated with the 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.

11. Additional Crane Services: Not required.

3.1.5 8 hours prior to completion of the contract repair period, remove temporary deck covering.

3.1.6 Quality Assurance

a. No additional requirements

3.1.7 Deliverables

a. Safe Drinking Water Report (see requirements of reference

(a))

3.1.8 Notes

End of Item

3.2 ITEM NO. 302: Dry Docking

3.2.1 Abstract – This item covers the requirements for hauling and refloating of the ship during repair of the ship’s tunnel thruster (bow thruster).

3.2.2 References

(a) NOAA Standard Specification AMC-997-1A, “Drydocking & Routine

Drydock Work”

(b) Transducer Face Coating Procedure

(c) NOAA Ship Thomas Jefferson drawing TJ-161-6634743, “Shaft Strut”

(d) NOAA Ship Thomas Jefferson drawing TJ-562-6634741, “Rudder

Arrangement and Details”

(e) NOAA Ship Thomas Jefferson drawing TJ-243-6634740, “Propeller Shafting, Arrangement and Details”

(f) NOAA Ship Thomas Jefferson drawing TJ-801-6634640, “Hull Lines”

(g) NOAA Ship Thomas Jefferson drawing TJ-801-6634641, “Table of

Offsets”

(h) NOAA Ship Thomas Jefferson drawing TJ-568-004, “NOAA Ship Thomas Jefferson Bow Thruster Installation”

(i) NOAA Ship Thomas Jefferson drawing TJ-245-6634744, “Propeller

Diagram”

(j) NOAA Ship Thomas Jefferson drawing TJ-079-03F, “Trim & Stability Booklet”

3.2.3 Government Furnished Material.

3.2.4 Requirements

a. Provide dry-docking in accordance with GENERAL Section reference 2.1.4 and reference (a).

b. The requirements of reference (a) paragraphs 3.5.1, 3.5.2, 3.5.6, 3.7, 3.8, 3.9 with its subparagraph(s) and 3.10 are waived.

c. The following additional requirements apply:

1. Modify the requirements of reference (a) paragraph

3.11.3 and 3.11.4 to prepare and coat the transducer faces in accordance with reference (b) using an approved coating system.

2. The ship shall be hauled within 24 hours of arrival at the contractor facility.

3. The minimum acceptable forward and after drafts and corresponding displacement tons permitted to dry-dock the ship consistent with safe stability and structural integrity are as follows:

a) Fwd = 10 feet - 3 inches

b) Aft = 10 feet - 9 inches

c) Displacement ≈ 1440 LT

4. Haul the ship in position 2 at a minimum keel block height of 5 feet.

5. After positioning and before hauling the ship, conduct a diver’s inspection of the underwater keel blocks positions relative to the dome to verify that the keel blocks will not come in contact with the centerline multi-beam dome.

6. Additional requirements for the propeller polishing:

a) Clean and polish forward and after surface of the propeller blade tips between 0.7 and 1.0 radius lines and the leading edges of the propeller blades over 0.2 of the blade width to a finish equal to the “B” specimen of the Rubert Comparator having a roughness average (RA) of

76.8 micro-inch.

b) Clean and polish the remainder of the propeller blades to a finish equal to the “C” specimen of the Rupert Comparator having an RA of 188.0 micro-inch.

7. Clean and polish tunnel thruster propeller to a finish equal to the “C” specimen of the Rupert Comparator having an RA of 188.0 micro-inch.

3.2.5 Quality Assurance

a. No additional requirements.

3.2.6 Deliverables

a. Drydock Certificate (see requirements of reference (a)

b. Record inspection results on the attached NOAA DOCKING REPORT S0700/SWB997 in lieu of Docking Report form 2410.

3.2.7 Notes

a. References (c) through (j) are listed as sources for obtaining information.

b. Intersleek 1100SR with a final coat FXA992-Blue is an approved coating system for the transducer faces.

END OF ITEM

3.3 ITEM NO. 303: Tunnel Thruster Servicing

3.3.1 Abstract – This item contains the requirements for the

removal, installation and testing of the ship’s tunnel thruster (bow thruster).

3.3.2 References

(a) NOAA Ship Thomas Jefferson manual TJ-568-02, “Mechanical Tunnel

Thruster Operator’s Manual”

(b) NOAA Standard Specification MOC-631-3B, “Underwater Body Ablative Coating System”

3.3.3 Government-Furnished Material

a. Tunnel Thruster Lower Housing (est value $100,000)

b. Oil – Mobilgard 600 XP150 (est value $500)

3.3.4 Requirements

a. General:

1. Obtain the services of an Original Equipment

Manufacture’s (OEM’s) authorized representative of the tunnel thruster to provide onsite guidance during removal, installation and testing of the tunnel thruster

2. Use reference (a) for guidance.

3. Install temporary guards on either side of the tunnel for the tunnel thruster to preclude materials entering the bilge.

4. Touch up sections of the underwater body coating system damage during accomplishment of this item in accordance with the maintenance coating section of reference (b).

b. Perform the following work on the ship’s tunnel thruster

1. Remove the electric motor and store for reuse.

Protect the electric motor from accidental damage and contamination.

2. Drain the system oil and pump all oil out of the lower housing unit.

3. Disconnect the oil head tank piping from the lower unit and cap to prevent contamination.

4. Remove the propeller from the lower unit and retain.

5. Remove the lower unit from the ship, crate for shipping and turn over to the Government.

6. Install the GFM lower unit using new gasket and fasteners with anti-seize lubricant applied to the threads.

7. Install the propeller on the lower unit.

8. Retrieve from storage and install the retained electric motor using new coupling and fasteners with anti-seize lubricant applied to the threads.

9. Modify the head tank piping as follows:

a) Install a quarter turn ball isolation valve at the top plate of the lower unit through the horizontal leg of a vertical tee. All material to match the existing piping material.

b) Install a second quarter turn ball sampling valve on the vertical leg of the new vertical tee with a threaded plug on the open end.

10. Prior to refloating the ship, fill the oil system to capacity with GFM oil.

3.3.5 Quality Assurance

a. After installation and refloating of the ship:

1. Perform an operational test of the tunnel thruster in accordance with OEM recommendations. At a minimum the bow thruster shall be cycled four times through all speeds for left and right thrust.

2. Perform a bollard pull test and measure the full thrust of the tunnel thruster.

3.3.6 Deliverables

a. Tunnel Thruster - operational test report

b. Tunnel thruster – Bollard Pull Test

3.3.7 Notes

a. Electric motor is previously disconnected both electrically from the controller and mechanically from the coupling with the lower housing.

b. Ship’s force will be available to run ship’s equipment.

c. Coordinate polishing of the tunnel thruster propeller with requirements of Basic Item “Dry Docking”.

d. Underwater Hull Data:

1. Complete system applied 02/2009. Last maintenance coat applied 12/2016

2. Epoxy anti-corrosive - Intertuf 262 (red and grey)

3. Controlled Depletion Polymer Antifouling -

Interclene 245NA (BRA572-Black and BRA570-Red)

e. Motor Information:

MFR: Marathon Electric Model: 900400-001

S/N: WAA017369

HP: 350

RPM 1780

Volt: 460

P/N: CVL 505USTDS29031AN W

Frame: 505USDV

f. Bow Thruster Manufacturer information:

Tyson Griffin | Field Service Manager, US Thrustmaster of Texas, Inc.

6900 Thrustmaster Drive | Houston, TX | 77041 T | +1 832 399 5137 M | +1 832 358 6396

PRODUCT SUPPORT CONTACT INFO

24 Hr. Service & Parts Hot Line T | 713-937-6295 Email | service@thrustmastertexas.com mailto:service@thrustmastertexas.com

4. OPTIONAL ITEM 400: ADDITIONAL ITEM REQUESTS

4.1 References

None

4.2 Government-Furnished Material

4.2.1 None

4.3 Requirements

4.3.1 This item is a place holder only. Refer to the contract clause “NOAA/ERAD ADDITIONAL ITEM REQUESTS LABOR RATE (MARCH 2005)” for all requirements dealing with emergent work and changes associated with this contract.

4.3.2 Schedule B provides an estimate of 100 labor hours and

$20,000.00 material growth for emergent work anticipated for this contract.

4.4 Quality Assurance

4.4.1 No additional requirements.

4.5 Notes

4.6 None.

5. OPTIONAL ITEMS

5.1 ITEM NO. 501: Bow Sonar Dome Removal

5.1.1 Abstract – This item provides the requirements for the

removal of the ship’s disused bow sonar dome.

5.1.2 References

(a) NOAA Ship Thomas Jefferson drawing TJ-165-6634882, “Sonar Dome

Strl Arrngmnts & Details”

(b) NOAA Standard Specification MOC-631-3B, “Underwater Body Ablative Coating System”

5.1.3 Government-Furnished Material

5.1.4 Requirements

a. Crop off and scrap the bow sonar dome shown in reference

(a)

b. Crop out the associated pipe conduit from the conduit origination in the sonar dome to the termination on the Main Deck.

c. Crop out and insert the disused hull and main deck penetrations.

d. Spot blast prepare and coat the damaged preservation system in the tank in accordance with GENERAL Section reference 2.1.2.

e. Spot blast prepare and coat the exposed hull in accordance with reference (b). Reduce the coats of anti-fouling from three to two coats for this item.

5.1.5 Quality Assurance

a. Perform a vacuum box test of the new hull inserts.

b. After complete of welding of the inserts and prior to preservation, perform a 2 psig air test of the 4-0-0 tank.

5.1.6 Deliverables

a. Condition report of vacuum box test results.

b. Condition report of air test results.

5.1.7 Notes

a. Ballast tank 4-0-0 was last coated in FY09 with International Paint Ultra High Solids Interline 624 series epoxies.

b. Ship’s force will pump Ballast tank 4-0-0 to low suction prior to hauling.

c. Underwater Hull Data:

1. Complete system installed FY09. Maintenance system applied FY17.

2. Epoxy anti-corrosive - Intertuf 262 (red and grey)

3. Controlled Depletion Polymer Antifouling -

Interclene 245NA (BRA572-Black and BRA570-Red)

REFERENCES

NOAA Standard Specifications

AMC-000-1G, “General Requirements for Ship Repair Contract Work on NOAA Ships”

AMC-000-2C, “Temporary Services at Contractor Facilities” AMC-631-2D, “Coating Systems for Steel Surfaces” AMC-997-1A, “Drydocking & Routine Drydock Work” MOC-631-3B, “Underwater Body Ablative Coating System”................... 9, 14

Ship's Drawings

085-002F, “Booklet of General Plans” TJ-079-03F, “Trim & Stability Booklet” TJ-161-6634743, “Shaft Strut” TJ-165-6634882, “Sonar Dome Strl Arrngmnts & Details” TJ-243-6634740, “Propeller Shafting, Arrangement and Details” TJ-245-6634744, “Propeller Diagram” TJ-562-6634741, “Rudder Arrangement and Details” TJ-568-004, “NOAA Ship Thomas Jefferson Bow Thruster Installation” TJ-801-6634640, “Hull Lines” TJ-801-6634641, “Table of Offsets”

Technical Manuals

TJ-568-02, “Mechanical Tunnel Thruster Operator’s Manual”

Other

NAVSEA Standard Item 009-32, “Cleaning and Painting Requirements: Accomplish”

Transducer Face Coating Procedure

Regulations

ABS Steel Vessels Under 90 Meters (295 Feet) in Length

GOVERNMENT FURNISHED MATERIAL

Oil – Mobilgard 600 XP150 Tunnel Thruster Lower Housing

DELIVERABLES

ABS Approved Welding Procedure and Welder Certification ABS Survey Schedule Condition report of air test results Condition report of vacuum box test results Condition Reports Gas Free Certifications Hazardous Material List and MSDS Hot Work Notices List of Contractor’s Supervisors Progress Reports Quality Assurance (QA) Test and Inspection Plan Safe Drinking Water Report Safety Plan Test Schedule Tunnel thruster – Bollard Pull Test Tunnel Thruster - operational test report Weight Report

LIST OF ATTACHMENTS

* NOAA Docking Report

* Weight Reporting Spreadsheet

NOAA DOCKING REPORT

S0700/SWBS997 (06/01)

Contract No: Contractor: Ship’s Name: Date:

Type of Dock: Docking Plan No.: Docking Position: Docking Date: Time:

Remarks:

Hull: □ Steel Wood

WL

Condition as Found:

PORT SIDE

STARBOARD SIDE

Indicated Conditions: D = Structural Damage R = Loose/Leaking Rivits Z = Deteriorated/Missing Zinc P = Areas of Pitting F = Loose Fasteners C = Damaged Coating System W = Deteriorated Welding S = Leaking Seams

Brief Description:

Recommended Repairs: Cost Estimate:

Repairs/Alterations Made:

PORT SIDE

STARBOARD SIDE

Brief Description:

PAINTING Boot Top

Under Water

Recommendation Hand Scrape

Power Tool

Blast Clean

Primer Repaint Ft2

AC AF REMARKS

Ft 2 F ai le d Primer Boot Top

Anti-corrosive Underwater Body

Anti-fouling Cost Estimate:

PROPOSED PAINTING Manufacturer Formula No. of Coats @ DFT Specification COLOR

BO

O

T

TO

P Primer

Anti-corrosive

Anti-fouling

U

N D

ER

W

AT

ER

Primer

Anti-corrosive

Anti-fouling

REMARKS:

NOAA DOCKING REPORT

S0700/SWBS997 (06/01) Page 2 of 2

Contract No: Contractor: Ship’s Name: Date:

Bearings: (Enter “AS FOUND” clearances as appropriate)

PORT SIDE STBD SIDE

LOCATION BEARING TOP BOTTOM INBOARD OUTB'D FWD AFT TOP BOTTOM INBOARD OUTB'D FWD AFT

STERN FWD

TUBE AFT

INTER'MD FWD

STRUT AFT

AFT FWD

STRUT AFT

RUDDER

PINTEL

Recommendations: Cost Estimate:

Bearings: (Enter “AS LEFT” clearances as appropriate)

PORT SIDE STBD SIDE

LOCATION BEARING TOP BOTTOM INBOARD OUTB'D FWD AFT TOP BOTTOM INBOARD OUTB'D FWD AFT

STERN FWD

TUBE AFT

INTER'MD FWD

STRUT AFT

AFT FWD

STRUT AFT

RUDDER

PINTEL

Brief Description of Repairs/Replacements:

Propellers: Condition: Recommendation:

Cost Estimate: Repairs Accomplished:

Shafting: Condition: Recommendation:

Cost Estimate: Repairs Accomplished:

Shaft Covering: Condition: Recommendation:

Cost Estimate: Repairs Accomplished:

Zinc Anodes: Condition: Recommendation:

Cost Estimate: Repairs Accomplished:

Cathodic Protection: Condition: Recommendation:

Cost Estimate: Repairs Accomplished:

Sea Chests: Condition: Recommendation:

Cost Estimate: Repairs Accomplished:

Signed: Typed/Printed Name: Title: Date:

WEIGHT REPORTING SPREADSHEET

Ship's Name: Date:

Page of

ITEM

DESCRIPTION

WEIGHT

COMPARTMENT

VERTICAL

LOCATION

LONGITUDINAL

LOCATION

TRANSVERSE

LOCATION

"+" ADD

"-" REMOVE

POUNDS

DECK

HEIGHT

ABOVE DECK

(FEET)

FRAME

NUMBER

DISTANCE OFF

FRAME

F (FWD) OR

A (AFT)

(FEET)

DISTANCE FROM

CENTERLINE

P (PORT) OR

S (STBD)

(FEET)