J.1_NOAA_SHIP_THOMAS_JEFFERSON_FY_18_DOCKSIDE_REPAIR_SPECIFICATION.pdf

Marine Engineering Branch - MOA2 Marine Operation Center, Atlantic

439 West York Street Norfolk, VA 23510

NOAA Ship Thomas Jefferson

FY18 DOCKSIDE REPAIRS

DETAIL SPECIFICATIONS

MOA2-09(17)

DATE: September 27, 2017

Written by:

Reviewed by:

September 27, 2017

TABLE OF CONTENTS

Table of Contents

1. SCOPE 2

2. GENERAL 2

3. BASIC ITEMS 6

3.1 ITEM NO. 301: Forward Crane Repairs and Testing 6

3.2 ITEM NO. 302: Aft Crane Repairs and Testing 10

3.3 ITEM NO. 303: FRB Davit Cylinder Repairs 14

3.4 ITEM NO. 304: Piping Repairs 18

3.5 ITEM NO. 305: Steel Replacements 22

3.6 ITEM NO. 306: Forecastle and Upper Deck Preservation 25

3.7 ITEM NO. 307: Ventilation Systems Cleaning 27

3.8 ITEM NO. 308: Galley Exhaust System Cleaning 30

4. OPTIONAL ITEM 400: ADDITIONAL ITEM REQUESTS 33

5. OPTIONAL ITEMS 34

5.1 ITEM NO. 501: Reduction Gear and Clutch Inspection 34

5.2 ITEM NO. 502: Plumbing and Drain System Flushing 36

5.3 ITEM NO. 503: Engine Room Louver Dampers Replacement 38

REFERENCES 41

GOVERNMENT FURNISHED MATERIAL 42

DELIVERABLES 43

LIST OF ATTACHMENTS 44

September 27, 2017

1. SCOPE

1.1 These Detail Specifications contain the requirements for

dockside repairs on the NOAA Ship Thomas Jefferson (formerly USNS Littlehales T-AGS 52).

1.2 The National Oceanic and Atmospheric Administration (NOAA) operates a fleet of research vessels that support research and hydrographic mapping for the National Marine Fisheries Service, National Ocean Service, Office of Ocean and Atmospheric Research, and National Weather Service, as well as provide maritime support to other Federal agencies. These research missions are time sensitive and therefore the data must be collected at specific times during the year to be meaningful. At the end of each vessel’s sailing season, the vessel enters a repair period (drydock or dockside) to address previously identified repairs, perform upgrades to mission or vessel systems that will provide new data collection capabilities, extend the life of the vessel, or provide for safer operation of the vessel’s systems as well as address any emergent work that would adversely affect the vessel’s ability to safely perform its mission on schedule, while complying to all regulatory body requirements (American Bureau of Shipping and United States Coast Guard) and habitability requirements, including any requirement that may arise as a result of contracts for personnel to augment ship staff.

1.3 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 TJ-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. Update QA TEST AND INSPECTION PLAN weekly and provide a copy to the COTR 24-hours prior to the scheduled weekly progress meeting. 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. Update the Test

Schedule weekly and provide a copy to the COTR 24-hours prior to the scheduled weekly progress meeting.

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 COTR.

2.2.7 Weigh all materials and items removed, installed, or

relocated on the ship. Provide a summary report to the COTR indicating the total weight in pounds of 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 There are several items that may affect habitability on the ship. Schedule work on these items into a 14 day contiguous window. During habitability related work, the Government will lodge and board the crew off the ship.

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

E 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, ,✠AMS,✠ACCU

3. BASIC ITEMS

3.1 ITEM NO. 301: Forward Crane Repairs and Testing

3.1.1 Abstract – This item provides the requirements for

repairing and load testing of the forward crane.

3.1.2 References

(a) NOAA Ship Thomas Jefferson Technical Manual TJ-573-01, “Operation & Maintenance Manual for Cranes, Deck and Boom”

(b) NOAA Standard Specification MOC-573-2, “Overhaul/Repair of Hydraulic Cylinders”

(c) NOAA Standard Specification MOC-573-1, “Testing of Davits and Weight Handling Gear”

(d) NOAA Ship Thomas Jefferson drawing TJ-573-6634807, “Fwd Crane Hydr Sys Arrngmnt”

(d) NOAA Ship Thomas Jefferson drawing TJ-573-6634887, “Fwd Crane Arrngmnts”

3.1.3 Government-Furnished Material

a. None

3.1.4 Requirements

a. Perform all work on the forward crane using reference (a) as a guide.

b. Disassemble, perform the following work, and assemble the crane to the extent necessary to accomplish the required work:

1. Renew all system hoses.

2. Renew all grease fittings.

3. Renew the sheaves thrust washers and bushings.

4. Renew the holding valve.

5. Renew the shuttle valve.

6. Perform the following work on the crane's wire rope winch:

a) Completely disassemble and clean all parts of dirt, debris, and foreign material.

b) Inspect the winch components for excessive wear, deterioration, and damage that may affect proper operation.

c) Assemble the winch using new bearings, seals, o-rings, gaskets, disc-friction, and springs.

7. Perform the following work on the crane’s wire rope winch hydraulic motor:

a) Completely disassemble and clean all parts of dirt, debris, and foreign material.

b) Inspect the motor components for excessive wear, deterioration, and damage that may affect proper operation.

c) Assemble the motor using new bearings, races, seals, o-rings, and gaskets.

8. Perform the following work on the boom extension cylinder and lufting cylinder:

a) Overhaul in accordance with reference (b).

b) Renew the counterbalance valve.

c) Remove, visual inspect for evidence of damage or excessive wear, and install the stainless steel cylinder pins.

d) Renew the boom pivot bushings and the cylinder bushings.

c. Renew the crane’s wire rope and attachment pin.

d. Adjust all the control valves to ensure smooth operation of the crane during normal operational conditions.

e. Flush and clean the hydraulic system to remove all dirt, water and other foreign debris. Fill the hydraulic system to capacity using fresh clean filtered hydraulic oil. Renew all oil filters and strainers.

1. Flush the hydraulic system with 140°F - 160°F hydraulic oil. Flushing shall be as follows:

a) Piping shall be flushed by installing temporary jumpers around each component.

b) A temporary pump and temporary strainer shall be installed in the system.

c) The strainer shall be of a 10 micron mesh replaceable element type with a pressure drop not to exceed the tolerances of the manufacturer at the flow and temperature for the type fluid used. Hydraulic fluid of the same type to be installed in the system shall be circulated until no appreciable quantity of soil is deposited on the strainers. The filter element shall be checked and replaced whenever the pressure drop reaches the limits specified.

d) The system shall be drained to the extent necessary to remove the jumpers, temporary strainers, and pump.

e) Assemble the hydraulic system and top off with filtered hydraulic oil.

f. Perform load tests on the crane in accordance with reference (d) and the following:

1. Perform a socket pull test to 40% of the breaking strength of the wire rope.

2. The 125-percent proof load is 8,375 pounds with one layer of wire rope on the winch drum at point of load take up. Measure wire size and length.

3. Stamp the test data on the existing stainless steel test plate on the crane. Test data shall include the name of contractor who performed the test and date of test.

g. After all testing is completed satisfactory; wrap all weather deck hose fittings with a petroleum wax tape similar to “Denso tape”.

3.1.5 Quality Assurance

a. Perform a hydrostatic pressure test on the new hoses to 150% system pressure. Install metal labels on the hoses containing the following minimum information: the hose type, manufacturer, test pressure, test date, and test facility.

3.1.6 Deliverables

a. Develop drawing TJ-573-6634807 in ACAD format and update to an “As-Built.”

1. Provide four full size and four half size hard copies of “approved” drawings on bond paper.

2. All drawings shall be in AutoCAD Version 2012 with electronic copies provided on CD-ROM.

b. Forward Crane Hose Inventory - Provide an inventory of all the hoses on the forward crane in Excel format. The inventory includes the service, fitting manufacturer, fitting part number, adaptors, hose manufacturer, hose size, hose rating and hose length.

c. Forward Crane Hose hydrostatic pressure test certificate

d. Forward Crane Wire Rope socket pull test Certificate

e. Forward Crane Inspection reports

f. Forward Crane Load test report

3.1.7 Notes

a. Crane information:

Manufacturer........Utility Steel Fabrication, Inc Model #.............15-2-50

b. The forward crane is currently tagged out of service because of undetermined operational issues with the boom extension cylinder.

c. The crane's HPU is located starboard side 2nd Deck, between frames 8 to 10, in Passageway (2-8-0).

d. Wire rope data: 250 feet of ⅝ inch non-rotating with closed swage socket one end. WLL = 7,240 lbs.

e. Ship’s force will be available to operate ship’s equipment. Provide one week prior notice to running equipment.

END OF ITEM

3.2 ITEM NO. 302: Aft Crane Repairs and Testing

3.2.1 Abstract – This item provides the requirements for

repairing and load testing of the aft crane.

3.2.2 References

(a) NOAA Ship Thomas Jefferson Technical Manual TJ-573-01, “Operation & Maintenance Manual for Cranes, Deck and Boom”

(b) NOAA Standard Specification MOC-573-2, “Overhaul/Repair of Hydraulic Cylinders”

(c) NOAA Standard Specification MOC-573-1, “Testing of Davits and Weight Handling Gear”

(d) NOAA Ship Thomas Jefferson drawing TJ-573-6634808, “Aft Crane Hydr Sys Arrngmnt”

(d) NOAA Ship Thomas Jefferson drawing TJ-573-6634888, “Aft Crane Arrngmnts”

3.2.3 Government-Furnished Material

a. None

3.2.4 Requirements

a. Perform all work on the aft crane using reference (a) as a guide.

b. Disassemble, perform the following work, and assemble the crane to the extent necessary to accomplish the required work:

1. Renew all system hoses.

2. Renew all grease fittings.

3. Renew the sheaves thrust washers and bushings.

4. Renew the holding valve.

5. Renew the shuttle valve.

6. Perform the following work on the crane's wire rope winch:

a) Completely disassemble and clean all parts of dirt, debris, and foreign material.

b) Inspect the winch components for excessive wear, deterioration, and damage that may affect proper operation.

c) Assemble the winch using new bearings, seals, o-rings, gaskets, disc-friction, and springs.

7. Perform the following work on the crane’s wire rope winch hydraulic motor:

a) Completely disassemble and clean all parts of dirt, debris, and foreign material.

b) Inspect the motor components for excessive wear, deterioration, and damage that may affect proper operation.

c) Assemble the motor using new bearings, races, seals, o-rings, and gaskets.

8. Perform the following work on the boom extension cylinder and lufting cylinder:

a) Overhaul in accordance with reference (b).

b) Renew the counterbalance valve.

c) Remove, visual inspect for evidence of damage or excessive wear, and install the stainless steel cylinder pins.

d) Renew the boom pivot bushings and the cylinder bushings.

c. Renew the crane’s wire rope and attachment pin.

d. Adjust all the control valves to ensure smooth operation of the crane during normal operational conditions.

e. Flush and clean the hydraulic system to remove all dirt, water and other foreign debris. Fill the hydraulic system to capacity using fresh clean filtered hydraulic oil. Renew all oil filters and strainers.

1. Flush the hydraulic system with 140°F - 160°F hydraulic oil. Flushing shall be as follows:

a) Piping shall be flushed by installing temporary jumpers around each component.

b) A temporary pump and temporary strainer shall be installed in the system.

c) The strainer shall be of a 10 micron mesh replaceable element type with a pressure drop not to exceed the tolerances of the manufacturer at the flow and temperature for the type fluid used. Hydraulic fluid of the same type to be installed in the system shall be circulated until no appreciable quantity of soil is deposited on the strainers. The filter element shall be checked and replaced whenever the pressure drop reaches the limits specified.

d) The system shall be drained to the extent necessary to remove the jumpers, temporary strainers, and pump.

e) Assemble the hydraulic system and top off with filtered hydraulic oil.

f. Perform load tests on the crane in accordance with reference (d) and the following:

1. Perform a socket pull test to 40% of the breaking strength of the wire rope.

2. The 125-percent proof load is 8,375 pounds with one layer of wire rope on the winch drum at point of load take up. Measure wire size and length.

3. Stamp the test data on the existing stainless steel test plate on the crane. Test data shall include the name of contractor who performed the test and date of test.

g. After all testing is completed satisfactory; wrap all weather deck hose fittings with a petroleum wax tape similar to “Denso tape”.

3.2.5 Quality Assurance

a. Perform an operational test of the crane prior to performing any work on the system.

b. Perform a hydrostatic pressure test on the new hoses to 150% system pressure. Install metal labels on the hoses containing the following minimum information: the hose type, manufacturer, test pressure, test date, and test facility.

1.

3.2.6 Deliverables

a. Develop drawing TJ-573-6634808 in ACAD format and update to an “As-Built.”

1. Provide four full size and four half size hard copies of “approved” drawings on bond paper.

2. All drawings shall be in AutoCAD Version 2012 with electronic copies provided on CD-ROM.

b. Aft Crane Hose Inventory - Provide an inventory of all the hoses on the aft crane in Excel format. The inventory includes the service, fitting manufacturer, fitting part number, adaptors, hose manufacturer, hose size, hose rating and hose length.

c. Aft Crane Hose hydrostatic pressure test certificate

d. Aft Crane Wire Rope socket pull test Certificate

e. Aft Crane Inspection reports

f. Aft Crane Load test report

3.2.7 Notes

a. Crane information

Manufacturer........Utility Steel Fabrication, Inc Model #.............15-2-50

b. The crane's HPU is located starboard side, between frames 85 to 87, in Engineer Stores (2-75-1).

c. Wire rope data: 155 feet of ⅝ inch non-rotating with closed swage socket one end. WLL = 7,240 lbs.

d. Ship’s force will be available to operate ship’s equipment. Provide one week prior notice to running equipment.

3.3 ITEM NO. 303: FRB Davit Cylinder Repairs

3.3.1 Abstract – This item contains the requirements for

overhauling and repairing the extension cylinder on the FRB Davit.

3.3.2 References

(a) NOAA Ship Thomas Jefferson manual TJ-583-03, “Davit, Rescue Boat”

(b) NOAA Standard Specification MOC-573-2, “Overhaul/Repair of Hydraulic Cylinders”

(c) NOAA Standard Specification MOC-573-1, “Testing of Davits and Weight Handling Gear”

(d) NOAA Ship Thomas Jefferson drawing TJ-583-6634804, “Rescue Boat Davit Hydr Sys”

(e) NOAA Ship Thomas Jefferson drawing TJ-583-6634886, “Boat Handling and Stowage”

3.3.3 Government-Furnished Material

a. None

3.3.4 Requirements

a. Perform all work on the Fast Rescue Boat (FRB) davit using reference (a) as a guide.

b. Renew all system hoses.

c. Disassemble, perform the following work, and assemble the crane to the extent necessary to accomplish the required work:

1. Perform the following work on the hydraulic extension cylinder:

a) Overhaul in accordance with reference (b) and the following:

1) Grind the rod to remove existing chrome.

2) Thermal spray the rod with tungsten and grind smooth.

3) Hone the barrels.

4) Renew the counterbalance valve.

5) Renew the valve blocks attached to the exterior of the cylinder.

6) Thermal spray the rods with tungsten and grind smooth.

7) Hone the barrels.

8) Prepare and preserve the exterior of the cylinder housing and control valves in accordance with GENERAL Section reference

2.1.2. Apply paint system STL-2 to the

prepared surfaces. The top coat color shall be white

d. After all testing is completed satisfactory; wrap the permanently exposed section of the hydraulic extension cylinder ram and all weatherdeck hose fittings with a petroleum wax tape similar to “Denso tape”.

3.3.5 Quality Assurance

a. Perform an operational test of the FRB Davit prior to performing any work on the system.

b. Perform a hydrostatic pressure test on the new hoses to 150% system pressure. Install metal labels on the hoses containing the following minimum information: the hose type, manufacturer, test pressure, test date, and test facility.

c. After completion of repairs and renewals, perform all inspections and load tests on the rescue boat davit and the rescue boat in accordance with the applicable sections of reference (b) and the following.

1. Weigh the FRB with all normal gear aboard.

2. Add the test weights to the boat davits to achieve the safe working load of 7700 pounds.

3. After completing the safe working load test, add an additional 770 pounds of test weights to the boat davits to achieve the dynamic and operational 110 percent proof load of 8470 pounds.

Hoist the test load to the fully stowed position and return to the waterline again. This test cycle shall be performed a minimum of five times.

4. During each test cycle check limits and make adjustments as needed.

5. During the lowering of each test cycle test the brake on the winch. It must be able to stop and hold the load instantly in any position.

6. After completing the dynamic and operational 110 percent proof load tests, add an additional 2,695 pounds of test weights to the boat davits to achieve the static 150 percent proof load test of 11,550 pounds and hold for ten minutes.

7. Stamp the test data on the existing stainless steel test plate on the crane. Test data shall include the name of contractor who performed the test and date of test.

3.3.6 Deliverables

a. Develop drawing TJ-583-6634804 in ACAD format and update to an “As-Built.”

1. Provide four full size and four half size hard copies of “approved” drawings on bond paper.

2. All drawings shall be in AutoCAD Version 2012 with electronic copies provided on CD-ROM.

b. FRB Hose Inventory - Provide an inventory of all the hoses on the FRB Davit in Excel format. The inventory includes the service, fitting manufacturer, fitting part number, adaptors, hose manufacturer, hose size, hose rating and hose length.

c. Hose hydrostatic pressure test certificate

3.3.7 Notes

a. FRB Davit support data:

PALFINGER MARINE USA Inc. (formerly Harding Safety) 705 Mt. Vernon Avenue Portsmouth, VA23707

Office: 757-399-1633 Cell: 757-395-9099

FAX: 757-399-6003

E-mail: Lawrence.omara@palfingermarine.com Web www.palfingermarine.com

b. The FBR Davit is located starboard side Main Deck between frames 76 to 80.

c. The FBR Davit HPU is located starboard side 2nd Deck between frames 76 to 80, in Engineer Stores (2-75-1).

d. Reference (e) is provided as a source for obtaining information about the FRB Davit only.

e. Ship’s force will remove the FRB prior to performance of any associated work and install the FRB after completion of all associated work.

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

Provide one week prior notice to running equipment.

End of Item mailto:Lawrence.omara@palfingermarine.com

3.4 ITEM NO. 304: Piping Repairs

3.4.1 Abstract – This item contains requirements for

installation of a new Remote Operated Valve (ROV), overhaul of check valve, replacement of motor operated valves and various piping repairs.

3.4.2 References

(a) NOAA Ship Thomas Jefferson drawing TJ-505-6634825, “Standard Piping Details”

(b) NOAA Standard Specification AMC-635-1, “Thermal Insulation of Piping”

(c) NOAA Standard Specification AMC-505-1B, “Valve Overhaul and Test”

(d) NOAA Ship Thomas Jefferson drawing TJ-528-007A, “Plumbing and Deck Drains”

(e) NOAA Ship Thomas Jefferson drawing TJ-529-002A, “Bilge & Ballast System Modification”

3.4.3 Government-Furnished Material

a. None

3.4.4 Requirements

a. General:

1. Accomplish all piping repairs using reference (a) for guidance.

2. Clean the 4-43-0 Sewage holding tank and make safe for entry.

b. Install a remote operated valve on the starboard side of the cross over piping system between the 4-43-1 and 4-43-2 voids.

The valve and remote operator to match the existing valve and remote operator on the port side of the cross over piping.

c. Replace the steel fire main bleed off piping from the tee upstream of the existing fire main check valve at frame 86 stbd 2nd deck to and including the steel to CUNI flange.

1. Upgrade the material to 90-10 CUNI with welded fittings.

2. Connect to the tee using a dielectric isolation kit.

d. Remove, overhaul, test and reinstall the valves listed in Table 307-1 in accordance with reference (c). The term “overhaul” used in reference (c) shall be redefined for this work item to be the same as “rebuild” is defined in GENERAL section reference 2.1.1.

Table 307-1: Overhaul Valves NO. Service Location

Space/Frm Size/type

1 Fire Main Check Valve 2nd Deck/86s 4" check, flanged 2 Ballast Pump Check Valve Lower Level

ER/68p 4" check, flanged

e. Replace the piping for the Fire Pump Seachest Vent from and including the isolation valve to and including the termination on the main deck:

1. Upgrade the vent piping to 90-10 CUNI with welded fittings.

2. Upgrade the isolation valve to a bronze body, Monel trim globe valve.

3. Upgrade the air blow down valve to a stainless steel ¼ turn ball valve with stainless steel ball and Teflon trim. Orient the valve so that the shut position does not extend into the walkway.

Connect to the tee using a dielectric isolation kit.

4. Connect to the retained vent pipe using a dielectric isolation kit.

f. Replace the Engine Room discharge piping from the Grey Water Lift Station to the “Y” connection at the 4 inch stand pipe located in the Main Deck Passageway.

1. Upgrade the vent piping to 90-10 CUNI with silver brazed fittings.

2. Install two cleanouts in the new piping. Locate the first cleanout in the upper level Engine Room in the vicinity of the landing and the second in the Main Deck Passageway in the longitudinal run. Cleanouts shall have similar construction as Detail 27A of reference (a) except materials shall be compatible with new piping.

3. Install a steel flange on the retained “Y” connection and connect the new piping to the flange using a dielectric isolation kit.

g. Perform the following work on the Sea Surface Sound Velocity and Thermosalinograph (TSG) piping systems:

1. Remove the existing boss Tee for the TSG discharge tubing located between the SSSV Tank and the SSSV pump. Install a straight section of pipe to reconnect the retained Tee to the SSSV pump.

2. Install a 2 inch stainless steel Liquid Operated Maintenance-Free Jet Pump in the athwartship section of the discharge from the SSSV pump. Replace or modify the route of the TSG discharge tubing to the suction port of the new jet pump through stainless steel reducers. Reuse the existing TSG tubing isolation valve.

h. Replace the valves and electric motor actuators listed in Table 307-2.

Table 307-2: Replace Valves NO. Service Location

Space/Frm Size/type

1 Fire/Ballast Cross Over valve

Main Deck/86s 4" butterfly, wafer

2 Independent Bilge Suction Valve

Lower Level ER/68p

4" butterfly, wafer

3 Bilge Ballast Overboard Valve

Lower Level ER/61p

4" butterfly, wafer

4 Ballast Sea Suction

(Provide – Do Not Install)

4" butterfly, wafer

5 Spare (Provide – Do Not Install)

4" butterfly, wafer

3.4.5 Quality Assurance

a. Perform a hydrostatic pressure test on all new fluid system piping to the greater of 150% system working pressure or city water system pressure.

b. Perform an operational test of the motor controlled cut out valves prior to and following all associated work on the system.

c. Prior to preservation, perform an air test on all new penetrations and inserts.

3.4.6 Deliverables

a. Update drawings TJ-528-007A and TJ-529-002A to “as-built” drawings to incorporate removals, new installations and modifications.

1. Provide four full size and four half size hard copies of “approved” drawings on bond paper.

2. All drawings shall be in AutoCAD Version 2012 with electronic copies provided on CD-ROM.

b. Hydrostatic pressure test on all new fluid system piping

c. Motor Controlled Cut Out Valves operational test reports

d. Air Test Reports of all new penetrations and inserts

3.4.7 Notes

a. Portions of this item will affect habitability.

b. Reference (e) is identified as a source for obtaining information.

3.5 ITEM NO. 305: Steel Replacements

3.5.1 Abstract – This item contains the requirements for steel repairs at various locations on the ship.

3.5.2 References

(a) NOAA Standard Specification AMC-533-1, “Potable Water Tank Disinfection”

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

(c) NOAA Ship Thomas Jefferson drawing TJ-512-6634856, “HVAC Arr & Details FCSLE Deck Fr 19-50”

(d) NOAA Ship Thomas Jefferson drawing TJ-512-6634853, “HVAC Arr details Main Deck bow-50"

3.5.3 Government-Furnished Material

a. None

3.5.4 Requirements

a. Perform the following work on the Potable water tanks 3-30-1 and 3-30-2

1. Crop out and insert the forward bulkhead in way of the penetrations for the tank level indicator petcocks. The crop out is to include previously blanked petcock penetrations.

2. Crop off and grind smooth all disused supports mounted inside the tanks.

3. Crop off and grind smooth the disused sounding tubes.

4. Install two 304 stainless steel couplings through the forward bulkhead of each tank. Located one coupling six inches from the bottom of the tank and the other six inches from the top of the tank. Double fillet weld the couplings in place; interior and exterior. Thread the coupling for a ¼” petcock.

5. Install a new stainless steel ¼” petcock in each of the top couplings.

6. Install two new stainless steel ¼” petcocks in each of the bottom couplings with stainless steel tees. Align one petcock with the top petcock for the same tank. Align the second petcock for use to take samples.

7. Install a new clear hose between the top and bottom petcocks for the same tanks using stainless steel hose clamps to secure the tubing to the petcock.

8. Spot-blast prepare all new steel plus an additional 100 ft2 in each tank in accordance with General Section reference

2.1.2. Apply a coating system compatible with the existing coating system to all prepared surfaces.

9. Disinfect the potable water tanks in accordance with reference (a)

b. Perform the following work on the forward tempered air supply trunk:

1. Crop out the existing trunk.

2. Manufacture new trunk using 304 stainless steel materials. Use the existing trunk as a template.

c. Perform the following work on the tempered air fan:

1. Electrically disconnect and remove the fan from the ship to a shop and perform the following work:

a) Disassemble the fan and clean all parts.

1) Inspect the fan parts for excessive wear, damage, and deterioration that may affect the operation of the fan.

2) Overhaul the electric motor in accordance with reference (b).

b) Reassemble the fan using new coupling, sealed bearings, gaskets, seals, and o-rings.

c) Dynamically balance the fan at the fan's normal RPM speeds.

2. Install the fan in its original location using new gaskets and fasteners with an anti-seize lubricant applied to the threads.

3.5.5 Quality Assurance

a. Perform an operational test of the tempered air fan prior to and following all associated work.

3.5.6 Deliverables

a. Safe Drinking Water Report

1. Provide to the COTR adequate documentation that the water fully complies with the Safe Drinking Water Act (SDWA). As a minimum, the documentation must include:

a) A report from a local health authority or an independent testing lab attesting that the water supply meets safe bacteriological levels.

b) Additional data, attainable from the water supplier, which verifies compliance with physical, chemical, and aesthetic standards of the SDWA.

b. Tempered Air Fan operational reports

c. Tempered Air Fan vibration balancing report

3.5.7 Notes

a. This is a habitability Item.

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

c. The coating in the tanks is PPG Protective and Marine Coatings Amercoat 333.

d. References (c) and (d) are provided as sources for obtaining information.

e. Fan and Motor Info:

Manufacturer: Hartzell Motor H.P.: 7.5 Motor Frame: 213T Motor RPM: 1800

CFM: 6855

Motor Power: 460V, 3 ph, 60 hz Motor SN: 70544-12 Fan Model: 50-26 VM3

3.6 ITEM NO. 306: Forecastle and Upper Deck Preservation

3.6.1 Abstract – This item provided requirement to replacing the nonskid deck coating on the Forecastle and Upper weather decks.

3.6.2 References

(a) None

3.6.3 Government-Furnished Material

a. None

3.6.4 Requirements

a. General:

1. Coating contractor to have current and active QP1 certification.

2. Maintain environmental records for days when the coating system is applied. Obtain environmental readings prior to application of any coating and at maximum of 1 hour intervals during application of the coating.

b. Prepare and preserve the forward 01 Level (Forecastle Deck) and entire 02 Level (Upper Deck) in accordance with GENERAL Section reference 2.1.2 and apply a rolled polysiloxane nonskid coating system that meets MIL-PRF-24667. Profile to match existing profile on the exterior Main Deck.

c. Prepare and preserve the lower 4 inches of the house bulkheads, bulwarks and other structures in accordance with GENERAL Section reference 2.1.2 and apply coating system STL-2. The top coat color to be black.

3.6.5 Quality Assurance

a. No additional requirements.

3.6.6 Deliverables

a. QP1 Certification

b. Coating Environmental Reports

3.6.7 Notes

a. NCP’s SILOXOGRIP N-9020 use Sherwin-Williams’ SeaGuard 5000 HS is known nonskid system that qualifies to MIL-PRF-24667.

Substitution of two prime coats Interbond 998 at 4-7 mils each is acceptable.

3.7 ITEM NO. 307: Ventilation Systems Cleaning

3.7.1 Abstract – This item contains the requirements for

cleaning, modification, and balancing the ship’s HVAC system.

3.7.2 References

(a) NOAA Standard Specification AMC-510-1B, “HVAC Cleaning”

(b) NOAA Ship Thomas Jefferson drawing TJ-512-6634841, “H.V.A.C. Diagram”

(c) NOAA Ship Thomas Jefferson drawing TJ-512-6634853, “HVAC Arr details Main Deck bow-50"

(d) NOAA Ship Thomas Jefferson drawing TJ-512-001, “HVAC Arr & Dets Fan Room 1-8-4"

(e) NOAA Ship Thomas Jefferson drawing TJ-512-002, “HVAC ARR & Details Upper Deck & Above”

(f) NOAA Ship Thomas Jefferson drawing TJ-512-6634844, “HVAC air handling unit list”

(g) NOAA Ship Thomas Jefferson drawing TJ-512-6634843, “Electric Heater List”

(h) NOAA Ship Thomas Jefferson drawing TJ-512-6634854 HVAC Arr & Details Main Deck 50-Stern Lower Level Frs 70-92

(i) NOAA Ship Thomas Jefferson drawing TJ-512-6634848, “HVAC Arr & Details Flat Level Fr22 – 30”

(j) NOAA Ship Thomas Jefferson drawing TJ-512-6634849D, “HVAC Arr & Details Lower Deck FR 0-55”

(k) NOAA Ship Thomas Jefferson drawing TJ-512-6634856, “HVAC Arr & Details FCSLE Deck Fr 19-50”

(l) NOAA Ship Thomas Jefferson drawing 89-5465-A1, “Bathroom Module Type B”

(m) NOAA Ship Thomas Jefferson drawing TJ-101-6634845 HVAC, “Gen Construction Details”

3.7.3 Government-Furnished Material

a. None.

3.7.4 Requirements

a. Perform the following modifications to the exhausts for the Bathroom Modules:

1. Replace the Broan Model 162 one bulb heater/fan with the fan omitted.

2. Upgrade the 4 inch rubber flexible duct to 4 inch Aluminum single wall spiral pipe and fittings.

3. Rivet and Aluminum tape seal the Spiral pipe to the existing exhaust duct and the exhaust connection on the new heater/fan unit.

b. Replace the damper inside the makeup air duct for the #3 Air Handler located in Fan Room 1-8-4.

c. Clean the entire HVAC system, exhaust systems, and ventilation supply systems in accordance with reference (a). Exclude the Machinery Space exhaust and Gaylord Hood exhaust systems from this part of this item.

d. After cleaning and with all equipment in normal underway operations and doors in normal underway position, balance the HVAC supply and exhaust ducts within all the conditioned spaces, to include the Galley exhaust and passageways using the existing duct dampers with references (b) and (c) as guides for minimum air flow through the vents. Mark and lock the damper handles in the balanced position.

3.7.5 Quality Assurance

a. Perform an operational test of the HVAC system, exhaust systems, and ventilation supply systems prior to and after cleaning.

b. Inspect the operation of all heaters, preheaters, and reheaters.

3.7.6 Deliverables

a. HVAC System Operational test reports

b. Heater inspection reports

c. HVAC System balancing Reports

3.7.7 Notes

a. This is a habitability item.

b. Schedule accomplishment of this item in the last 50% of the contract period to avoid contamination of systems after cleaning.

c. Ship’s force will be available to operate ship’s equipment.

d. References (b) through (m) are identified as sources for obtaining information.

3.8 ITEM NO. 308: Galley Exhaust System Cleaning

3.8.1 Abstract – This item contains the requirements for

cleaning the ship’s Galley Exhaust System.

3.8.2 References

(a) NOAA Standard Specification AMC-510-1B, “HVAC Cleaning”

(b) NOAA Ship Thomas Jefferson drawing TJ-512-6634841, “H.V.A.C. Diagram”

(c) NOAA Ship Thomas Jefferson drawing TJ-512-6634856, “HVAC Arr & Details FCSLE Deck Fr 19-50”

3.8.3 Government-Furnished Material

a. None.

3.8.4 Requirements

a. Perform the following work on the ship’s Gaylord Hood System:

1. Disassemble, clean, inspect, and reassemble the internal nozzles, baffles, ducts, and wash down systems.

2. Mechanically route out the interior of the hood drains and attached deck drains from the drain to the header located on the 2nd deck.

3. Operational test of the wash down system.

4. Clean the hood exhaust system duct from the hood to and including the exhaust goose neck in accordance with reference

(a) except the interior of all ducts shall also include cleaning using a solvent.

5. Electrically and mechanically disconnect the exhaust fan.

6. Remove the exhaust fan from the ship to a shop and perform the following work:

a) Disassemble the fan and clean all parts.

1) Inspect the fan parts for excessive wear, damage, and deterioration that may affect the operation of the fan.

2) Overhaul the electric motor in accordance with reference (b).

3) Reassemble the fan using new coupling, sealed bearings, gaskets, seals, and o-rings.

b) Dynamically balance the fan at the fan's slow and fast RPM speeds.

7. Install the exhaust fan on the ship in its original location using new vibration mounts, gaskets, flex joint and fasteners with an anti-seize lubricant applied to the threads.

3.8.5 Quality Assurance

a. Perform an operational test of the Galley exhaust system prior to and after all associate work.

b. Verify the dynamic balancing of the assembled exhaust fan in the fan's installed orientation.

c. Measure the air speed through the Gaylord Hood system and the Scullery exhaust vent prior to and after all associated work.

3.8.6 Deliverables

a. Galley Exhaust Fan vibration balancing report

b. Gaylord Hood system and the Scullery Air Speed report

3.8.7 Notes

a. This is a habitability item.

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

c. References (b) and (c) are identified as sources for obtaining information.

d. Fan and Motor Info:

Manufacturer: Hartzell Motor H.P.: 3.5 Motor Frame: 182T Motor RPM: 3600 Motor Power: 460V, 3 ph, 60 hz Motor SN: 70544-3

Fan Model: 44-16-DK2 MDA

4. OPTIONAL ITEM 400: ADDITIONAL ITEM REQUESTS

4.1 Abstract – This item is a place holder for growth work.

4.2 References

None

4.3 Government-Furnished Material

4.3.1 None

4.4 Requirements

4.4.1 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.

4.4.2 Schedule B provides an estimate of 1000 labor hours and $80,000 material growth for emergent work anticipated for this contract.

4.5 Quality Assurance

4.5.1 No additional requirements.

4.6 Deliverables

4.6.1 As required by the individual AIR.

4.7 Notes

4.8 None.

5. OPTIONAL ITEMS

5.1 ITEM NO. 501: Reduction Gear and Clutch Inspection

5.1.1 Abstract – This item contains requirements for annual

servicing of the reduction gear clutches.

5.1.2 References

(a) NOAA Ship Thomas Jefferson manual 241-01, “Reduction Gear, Main Propulsion

RS2719S”

5.1.3 Government-Furnished Material

a. None

5.1.4 Requirements

a. Perform the following work on the ship Propulsion Reduction Gear's forward and reverse clutch assemblies in accordance with reference (a) and the on-site guidance of a manufacturer's technical representative.

1. Disconnect the air, disassemble, and clean.

2. Inspect all clutch parts for deterioration, damage, or excessive wear that may affect operation of the units.

3. Assemble using new pilot bearings (P/N SKF 6215/C3 W64), rubber washers and clutch assembly stop nuts.

4. Connect the air.

b. Perform the following work on the auxiliary engine clutch assembly:

1. Disassemble the auxiliary propulsion engine and marine gear to the extent necessary to allow removal of the auxiliary drive shaft.

2. Remove the auxiliary drive shaft and inspect for damage and measure Total Indicated Runout.

3. Install the auxiliary drive shaft using new seals (P/N AP038652 and Midshaft seal P/N AP033450) and input bearing (P/N

AP015500).

4. Replace the auxiliary stub shaft (P/N AM149392) and pilot bearing (P/N SKF 6215-2RS1-C3W64). Install the bearing on the auxiliary stub shaft prior to installing the stub shaft on the auxiliary shaft using new fastener.

5. Replace the entire auxiliary clutch assembly (P/N 82916951) using new o-rings, fasteners and “J” bolts (P/N AM093002).

c. Provide assist to the on-site Original Equipment Manufacturer’s (OEM) technical representative to perform a visual inspection of the gear contact of the reduction gear and spray pattern for the nozzles.

5.1.5 Quality Assurance

a. Perform an operational test of the system prior to and after completion of all other work.

5.1.6 Deliverables

a. Reduction Gear Operational Test Reports

b. Reduction Gear OEM Inspection Report

5.1.7 Notes

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

Provide 2 weeks prior notice to running equipment.

b. Part numbers are provided for critical components. These and additional part numbers are available in reference (a) or from the OEM.

c. OEM Information:

Lufkin Gear Repair – Field Service 711 Industrial Blvd, Lufkin TX 75904

TEL: (936) 637-5307

FAX: (936) 633-3926

E-MAIL: LufkinGR.FieldService@ge.com

d. Reduction Gear Information:

REVERSING

RATIO: 4.026

MANUFACTURER: LUFKIN INDUSTRIES INC

APL: M698880258

LOCATION: 4-55-0

MODEL: RS2719S

SERIAL NUMBER: 7122

OIL PUMP DATA: Size - 5RCSA, 61 gpm STANDBY PUMP DATA: IMO Delaval, size - 143, 18.5 gpm STANDBY PUMP ELECTRIC MOTOR: Frame 184TC, 5 HP, TEFC mailto:LufkinGR.FieldService@ge.com

5.2 ITEM NO. 502: Plumbing and Drain System Flushing

5.2.1 Abstract – This item provided the requirements for

flushing the drain systems onboard the ship

5.2.2 References

(a) NOAA Ship Thomas Jefferson drawing TJ-528-6634785, “Plumbing and Deck Drains Diagram”

5.2.3 Government-Furnished Material

a. None

5.2.4 Requirements

a. Chemically flush the entire plumbing and drain piping system using “Blow Out” or equal.

1. The chemicals shall be of a type and concentration capable of dissolving all nonmetallic deposits without damaging the piping.

2. Readily biodegradable per OECD 301D.

3. Environmentally safe, people safe, and piping safe.

4. Neutralize instantly with ambient temperature fresh water after flushing.

b. Flushing shall be conducted through a closed loop system.

5.2.5 Quality Assurance

a. Prior to and after work on the plumbing and drain system piping perform a TV/Video inspection of the interior of the piping.

This inspection should include 10% of the piping system.

b. Perform an operational test of all piping systems identified in this item for repairs prior to and after completion of said repairs.

c. Prior to filling the piping system for chemical cleaning, provide technical documentation of product efficacy and Safety Approvals.

5.2.6 Deliverables

a. Plumbing and Drain piping TV/Video inspection

b. Plumbing and Drain piping operational test reports

5.2.7 Notes

a. This item is a habitability item.

b. Reference (a) is listed as a source for obtaining information.

c. “Blow Out” is a trade name synthetic acid flush that will not harm the piping system. Contact for this product is through Environmental Manufacturing Solutions, 2241 Barraud Ave, Norfolk, VA 23504.

September 27, 2017

5.3 ITEM NO. 503: Engine Room Louver Dampers Replacement

5.3.1 Abstract - This item contains the requirements for

replacement of the motor operated metal louver dampers for the supply ventilation in the Engine Room.

5.3.2 References

(a) NOAA Standard Specification MOC-300-3, “General Requirements for Electrical/Electronic Items”

(b) NOAA Ship Thomas Jefferson drawing TJ-512-6634850, “HVAC Arrngt & Detls Engine Room”

(c) Spiral Metal drawing “Engine Room Louver Dampers”

5.3.3 Government-Furnished Material

a. None

5.3.4 Requirements

a. General

1. Protect the ship interior spaces when closures are removed.

2. Template all installations on the ship and new equipment.

3. Perform all electrical work in accordance with reference (a).

b. Remove and scrap the existing motor operated metal louver dampers for the Engine Room combustion air intake and ventilation intake. Turn the motors over to ship’s force. Retain the electrical supply cabling for reuse.

c. Crop out and install new angle steel foundations for the new dampers.

d. Provide and install new modular louvered dampers.

1. The new louvered damper shall meet the following basic characteristics:

a) Framing, louvers, rods, supports, wire mess, fasteners – all stainless steel construction.

September 27, 2017

b) Bushings - bronze

c) Linkage – stainless steel

d) Combustion Air Intake – two module construction, each module ≈4’x2’-9”x6”

e) Ventilation Intake – two module construction, ≈4’x5’-1”x6”

f) Motor – Spring loaded closed with no power. 120 volts 60 hertz. Either watertight or contained within stainless steel watertight enclosure mounted on the frame. One motor per module mounted outboard.

2. Mounting Gasket – Fire retardant rated

3. Mounting fasteners – stainless steel with an anti-seize lubricant applied to the threads.

e. Spot blast prepare and preserve up to 100 ft2 of noncontagious areas for the Engine Room supply ventilation system supply plenum in accordance with GENERAL Section reference 2.1.2.

Apply paint system STL-11.

5.3.5 Quality Assurance

a. Perform an operational test of the existing dampers prior to removal to prove the circuit.

b. Perform an operational test of the new dampers to prove the system.

5.3.6 Deliverables

a. Louver Damper Operational test reports

b. Develop TJ-512-6634850 in an AutoCAD 12 format and update to “As-Built”. Provide four full size and four half size hard copies of “approved” drawings on bond paper and electronic copies provided on CD-ROM.

5.3.7 Notes

a. The Engine Room louver dampers are located in the weather on the 01-Deck, forward side of the Stack. There is a bolted access to the ventilation intake plenum locate upper level, port side, frame 57 Engine Room (4-55-0).

September 27, 2017

b. The coating on the exterior of the Stack is Sherwin-Williams’ Sher-Loxane 800, epoxy polysiloxane coating system.

c. Existing louver dampers manufacturer’s information:

Spiral Metals 4145 North Flannery Rd.

Baton Rouge, LA 70814 Phone: (225) 272-6635

FAX: (225) 272-6652

jlking@spiralmetals.com mailto:jlking@spiralmetals.com

REFERENCES

NOAA Standard Specifications

AMC 300-1, “Overhaul of Electrical Rotating Machinery” AMC-000-1G, “General Requirements for Ship Repair Contract Work on NOAA Ships”

AMC-505-1B, “Valve Overhaul and Test” AMC-510-1B, “HVAC Cleaning”............................................ 27, 30 AMC-533-1, “Potable Water Tank Disinfection” AMC-631-2D, “Coating Systems for Steel Surfaces” AMC-635-1, “Thermal Insulation of Piping” MOC-300-3, “General Requirements for Electrical/Electronic Items” MOC-573-1, “Testing of Davits and Weight Handling Gear”............. 6, 10, 14 MOC-573-2, “Overhaul/Repair of Hydraulic Cylinders”................. 6, 10, 14

Ship's Drawings

89-5465-A1, “Bathroom Module Type B” TJ-085-002F, “Booklet of General Plans” TJ-101-6634845 HVAC, “Gen Construction Details” TJ-505-6634825, “Standard Piping Details” TJ-512-001, “HVAC Arr & Dets Fan Room 1-8-4" TJ-512-002, “HVAC ARR & Details Upper Deck & Above” TJ-512-6634841, “H.V.A.C. Diagram”..................................... 27, 30 TJ-512-6634843, “Electric Heater List” TJ-512-6634844, “HVAC air handling unit list” TJ-512-6634848, “HVAC Arr & Details Flat Level Fr22 – 30” TJ-512-6634849D, “HVAC Arr & Details Lower Deck FR 0-55” TJ-512-6634850, “HVAC Arrngt & Detls Engine Room” TJ-512-6634853, “HVAC Arr details Main Deck bow-50"....................