GU FY22 DryDock Spec May_12.pdf

NOAA Ship Gordon Gunter FY 22 DRY DOCK Repair

May 2021

NOAA SHIP GORDON GUNTER

FY 22 DRY DOCK REPAIR SPECIFICATIONS

FY 2022 Dry Dock Repairs to NOAA Ship Gordon Gunter

Table of Contents

TABLE OF CONTENTS

1 SCOPE

2 GENERAL

REFERENCE

REQUIREMENTS

NOTES

3 BASE ITEMS

TEMPORARY SERVICES

DRYDOCKING AND ROUTINE DRYDOCK WORK

OVERHAUL AFT CAPSTANS

INSPECTION AND OVERHAUL OF MARKEY CTD (DESH-5) AND MARKEY BONGO (COM-7X) WINCHES

SEA VALVE OVERHAULS

BOW THRUSTER INSPECTION AND SERVICE

ABS SPECIAL PERIODICAL SURVEY – HULL 7

ANNUAL LIFE RAFT INSPECTION

ANNUAL SURVIVAL SUIT CERTIFICATIONS

WEIGHT TESTS OF LIFTING GEAR

ANNUAL FIRE INSPECTION AND CERTIFICATIONS

ANNUAL MIRANDA DAVIT INSPECTION, VALVE REPLACEMENTS AND FAST RESCUE BOAT (FRB) MAINTENANCE

MAIN MOTOR SERVICE

MARINE SANITATION DEVICE (MSD)

OILY WATER SEPARATOR

PUMP/MOTOR REPLACEMENT

GALLEY EXHAUST DUCT AND FAN CLEANING

GENERATOR ROOM STEEL REPLACE AND PRESERVATION

PRESERVATION – PROPULSION MOTOR ROOM BILGES

PRESERVATION – HPU ROOM

01 LEVEL DECK INSERT AND BOSUN WORKSHOP UPGRADE

FUEL TANKS 4-72-1-, 4-72-2, 4-72-3 AND 4-72-4 (ABS)

UNDERWATER HULL PRESERVATION AND COATING (MAINTENANCE COAT)

BALLAST TANK VENT REPLACEMENT

FAN AND MOTOR OVERHAULS

BULWARK REPAIRS

MAIN DECK REPAIRS

ANCHOR WINDLASS

EFFER CRANE (02 LEVEL DECK CRANE) OVERHAUL

GENERAL REPAIRS – TOP SIDE

GENERAL REPAIRS – BRIDGE DECK AND ABOVE

GENERAL REPAIRS – UPPER DECK

DOOR MODIFICATIONS

FREEBOARD COATING

HVAC SYSTEM CLEANING

SWITCHBOARD CLEANING

STABILITY TEST (AKA INCLINING EXPERIMENT)

DOCK AND SEA TRIALS

4 ADDITIONAL WORK

5 OPTION ITEMS

ELECTRICAL MODIFICATIONS

SHIP-WIDE FIRE DETECTION SYSTEM REPLACEMENT

SELF-CONTAINED AIR CONDITIONING UNIT INSTALLATION

LOUNGE MODIFICATIONS

SSDG RESILIENT MOUNTS REPLACEMENT

VALVE MODIFICATIONS AND REPLACEMENTS (ABS)

AIR CONDITIONING CHILLER AND REFRIGERATION REPLACEMENT (ABS)

REFRIGERATION (REEFER) SYSTEM REPLACEMENT (ABS)

MARINE GROWTH PREVENTION SYSTEM INSTALLATION

GYM OVERHEAD INSULATION REPLACE

MISSION SYSTEM MODS

MAIN DECK FAN ROOM 1-67-3-Q

PRESERVATION – TANKS AND VOIDS

PRESERVATION – STEERING GEAR ROOM, TUNNELS AND BOSUN WORKSHOP LADDER WELL

PRESERVATION – SEWAGE TANK

FUEL VALVE INSTALL

BALLAST TANK CONVERSION (UNDERDEVELOPMENT)

1 SCOPE

These Detail Specifications contain the requirements for five (5) year Dry Dock repairs and modifications to the NOAA Ship Gordon Gunter.

The National Oceanic and Atmospheric Administration (NOAA) operates a fleet of research vessels that supports research and mapping for the National Fisheries Service, National Ocean Service, Office of Atmospheric Research and the National Weather Service, as well as provides support to other Federal agencies.

These research missions are time sensitive and therefore the data must be collected at specific times during the sailing season to be meaningful. At the end of each sailing season the vessels enter a repair period (dry-dock or dockside) to address repairs that have been previously identified, perform upgrades to mission systems or ship systems that either extend the life of the ship or provide new data collection capabilities or for safer operations of ships systems as well as address any emergent work that would adversely affect the ships ability to safely perform its mission on schedule, while meeting all regulatory body requirements (American Bureau of Shipping and United States Coast Guard) and all habitability requirements, including any that may be required as a result of contracts for personnel to augment ship staff.

The work items in the repair specification are identified well in advance of the performance period in order meet the contracting lead times. Additional work items (emergent work) may arise during the period between the work package submittal, contract award, or even prior to the start of or during the contract performance period. In accordance with Commerce Acquisition Regulation (CAR) clause 1352.271-72, the Contracting Officer may order additional changes during the contract period of performance to address any additional work items identified as necessary to ensure the intent of the dry-dock or dockside repair contract is met; that is, that the vessel shall be able to safely perform its mission, that it will meet all habitability requirements and regulatory body requirements, and that such repairs will be timely performed to ensure to the maximum extent practicable that the ship's schedule is not adversely impacted.

2 GENERAL

Reference

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

NOAA Standard Specification S1600, “Structural Access Cuts.”

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

Drawing. No. 085-6233560, “General Arrangement Main Deck and Below.”

Drawing. No. 085-6233567, “General Arrangement Fcsle Dk & Above.”

NOAA Ship Gordon Gunter Drawing Index List

NOAA Weight Report Form, Microsoft XL Format, “Weight Report.xls”

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

“ABS Rules for Building and Classing Steel Vessels”

Requirements

Reference 2.1.1 forms a part of these Detail Specifications. All provisions and requirements contained therein are applicable to all work items, including all additional work items that are authorized by the Contracting Officer.

References 2.1.2 and 2.1.3 are amplifications of the requirements contained in reference 2.1.1 sections

4.17 and 4.21.

References 2.1.4 through 2.1.8 will be available for review during scheduled pre- bid inspection and during the performance period of the contract. The general arrangement drawings are the original Ocean Surveillance Ship T-AGOS 13 class drawings produced when the ship was built. Modifications to the ship after re-activation in 1998 for NOAA’s operations, and conversion in 1999 to meet National Marine Fisheries Service (NMFS) requirements, are not reflected in these arrangements. Some of the drawings and information provided in references 2.1.6 through 2.1.7 reflect some of the ship’s arrangements and construction changes since reactivation as a NOAA vessel. Contractor shall be responsible for verifying all current configuration, construction, and arrangement changes, as necessary, to comply with and perform the work requirements of these specifications. Contractors are encouraged to review ship’s drawings and to perform a field inspection of the ship and her equipment prior to submitting a bid proposal.

Ship’s drawings and technical publications may be borrowed during the performance period. All reference materials borrowed by the Contractor shall be signed for, and then returned to the COR after no further use of the reference materials is required.

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

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

Provide revised and updated copies of the production schedule to the COR as required to reflect actual work progress.

All new equipment and furnishings purchased by the Contractor for installation on the vessel shall be provided with factory supplied technical manuals, or data sheets, complete with parts listings. Faxed copies of this information are not acceptable. This documentation shall be turned over to the COR after installation is completed. Equipment technical manuals shall provide detailed information necessary to operate, maintain, troubleshoot, and repair the equipment. The manuals shall include detailed procedures for disassembly of equipment, parts lists, drawings, inspection criteria, troubleshooting, and test procedures. Provide four paper copies of each manual, plus one electronic copy in Abode Acrobat .pdf format.

All inspection, test, and quality reports shall be submitted to the COR in Microsoft Word electronic software formats, in addition to providing hard paper copies.

Reports –

Reports are called out in the specification under various titles, Condition Report or CR, Condition Found Reports or CFR, reports or findings.

Report are to be classified as follows:

Deficiency and classified as CFR, CR or as defined by the Contractor. Action is expected from the Government.

Findings or Condition are provided for information only ICFR or ICR. No action is expected from the Government.

Testing, Service Report or Certifications are provide as a deliverable of DCFR or DCR. No action required unless deliverable is deficient or questions about content or information.

Weigh all materials and items removed, installed, or relocated on the ship. Provide by-weekly updates in the Contractors Performance and Progress Report. Provide a summary report to the COR indicating the total weight in pounds of items and a breakdown of their locations by space, deck, frame, distance from centerline, and height above the deck. Reference 2.1.7 will be provided by the COR for the Contractor to identify, record, and document all weight changes for submitting the summary reports. Contractor may use their own weight report form for documenting weight changes. All the information required must be tracked and documented on any form provided.

Unless otherwise stated in the individual work items, prepare and coat all new steel, all existing steel surfaces identified to be cleaned and painted, and all paint systems disturbed while accomplishing work items, in accordance with reference 2.1.1. Finish coat colors shall match those of the surrounding, unmodified area.

Ship’s force will maintain a minimal presence during accomplishment of work to these specifications.

Their availability to operate ship’s equipment will be limited. Unless otherwise specified, provide a minimum of two working days’ prior notice for any equipment operations or lockout/tagout.

Ship’s Force standard workday is 8 hours (0700-1530). The ship in conjunction with the above paragraph can support work on an extended workday (0700-1900). The Contractor can request up to the extended workday from the COR, but NOAA cannot guarantee they have the work force to support.

All new and disturbed machinery and services shall be operated for a period sufficient to indicate satisfactory performance, but not less than one hour, after all adjustments and deficiency corrective actions have been made, without further adjustment.

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

All new installed equipment, GFM and/or Contractor Furnished, whether stated or not in the individual work items shall be commissioned by a factory authorized technical agent in order to maintain equipment warranty.

The Contractor shall provide the services to the ship to dispose of hazardous waste. This is waste generated by the ship and is outside waste stored in ship’s tanks. Waste will consist of but not limited to;

expended batteries from UPS and battery back-up systems, paint in containers up to 5 gallons, oily rags, etc.

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

All installations shall comply with the references in section 2.1 and the contractor shall consult Reference 2.1.9 for proper material, installation standards, and connections to ship systems, where one installation method for one system is not authorized for another system. Such as treaded connections verses welded connections or any other safety driven ABS requirements (ex. spray shields).

Frame numbers and space names are derived from ship’s drawings. All equipment changes and space modifications over the ship’s life span may not all be reflected in the referenced drawings. Contractors are encouraged to review all referenced drawings and to perform a field inspection of the ship prior to submitting a bid. Copies of drawings and technical manuals not included herein may be made available for review during any scheduled pre-bid inspection and during the performance period. Contractors my review available drawings and technical manuals on board ship or at the Port Engineer’s office at NOAA’s Gulf Marine Support Facility, 151 Watts Ave., Pascagoula, MS.

Care and protection of the ship shall be strictly adhered to while work is being performed and properly secured/protected at the end of each shift which includes, but not limited to, providing proper protection for existing equipment, removed equipment (spares), new equipment being installed, wire-ways, piping, electronics, ductwork, passageways, decks, bulkheads, handrails, doorways and floorings. Items damaged shall be reported to the COR and documented via CFR within 24 hours, and they shall be replaced or repaired by the contractor.

Kick-off/Pre-dockside Meeting Unless previously completed after Contract award, on the first day of the Period of Performance and before commencing work on the ship the Contractor shall host a kick-off meeting in the Ship’s Mess at 0800. At a minimum, the meeting shall be attended by the COR, Contracting Officer (in-person or via phone), and a Contractor's management official having authority to make binding commitments. Other interested parties may attend the meetings as appropriate.

The Contractor’s baseline Schedule, including start dates for each work item, and QA Test and Inspection Plan shall be submitted for approval by the COR at, or before, the Kick-off/Pre-dockside Meeting. Any potential impacts to schedule, habitability, and material delivery delays, or complex work shall be identified.

On the first day of the Period of Performance, the Contractor shall document existing ship conditions with a Ship’s Representative designated by the CO. Contractor shall document the pre-work as-found conditions of all spaces the contractor will work in or transit through.

Contractor shall complete and save a video recording of the existing ship conditions for documentation purposes. A copy of video shall be provided via CFR, to the COR, broken down by work item before work is started. Included in the video effort the Contractor is responsible to accomplish the following as applicable.

Contractor shall also develop sketches with dimensions for individual work items to ensure interferences are replaced as originally found and in the same or better condition/matter.

Contractor shall ensure all equipment is in operating condition prior to disassembly or interference removal.

Document placards, labels and stencils in way of the work and interferences.

Personal and Contractor Safety

The Contractor shall implement a written medical safety plan. The medical safety plan shall designate one key person and 2 alternates that will oversee the plan and ensure proper daily screening with proper documentation. The plan shall go beyond just medical screening.

The plan shall include the minimum:

• Contractor is responsible for providing all PPE, personal cleaning agents, and personal cleaning stations.

• Unless precluded by task related PPE (such as welding), all Contractor personnel are required to wear face coverings that cover the nose and mouth while on the ship at all times. Face coverings are required for both all interior and exterior areas of the vessel.

• To the maximum extent practical, and not to interfere with production work, Contractor shall practice social distancing while on the vessel.

• Contractor shall set up, maintain, and daily clean sanitary hand-washing stations in the following locations. Handwashing stations shall include running water (ship’s water may be utilized on the ship), soap/sanitizer, hand towels, and trash receptacles.

• Contractor break area (off the ship)

• Daily log of personnel on the vessel and status of testing

• Contact tracing and quarantine as per current Federal/State/Local guideline.

• Daily Medical Safety meeting by Contractor to all Contractor personnel prior to each workday

• Contractor shall take daily temperature readings of all contractor personnel onsite prior to the start of work. Any personnel reading 100.4 °F or higher shall not be permitted to work on any NOAA facility until three (QTY 3) consecutive daily readings below 100.4 °F are obtained.

Notes

The following descriptive data of the ship is provided for information:

Length, Overall 224’ 0”

Length, BP 194’ 0” Beam, Molded 43’ 0”

Mean Draft, Load Line 15’ 1” Displacement, Load Line 2328 LT Displacement, Lightship 1557.2 LT

Cruising Speed 11 Knots Officers & Crew Size 19

Electric Service 450VAC, 60Hz, 3PH, 800A Service (2X400A) Propulsion Diesel electric, twin screw

NOAA Ship Gordon Gunter is identified with ABS ID Number 9000291, IMO Number 8835255, Official Number 023674, Hull Number 1128, and is classed +A1, E, +AMS, and +ACCU.

(R-336)

GOVERNMENT FURNISHED MATERIAL/EQUIPMENT

ITEM QTY DESCRIPTION EST COST

See individual Items

3 BASE ITEMS

TEMPORARY SERVICES

References

NOAA Standard Specification MOC-000-1G, "Temporary Services at Contractor Facilities"

Government-Furnished Material: None additional

Requirements

Provide all temporary services required in accordance with Reference 3.1.1.1.

The following additional information and requirements apply:

(a) Electric power: Provide two 450 VAC, 3 Phase, 60 Hertz, 400 Amp circuits [800 amps total].

Properly rated shore power cables shall be the Contractor’s responsibility.

All power supplied to the ship shall be clean, with no indications of ground faults on the ship’s main switchboard. All ground fault deficiencies associated with the Contractor’s power supplied to the ship, shall be corrected at the Contractor’s expense. Such expense shall include housing allowance for ship’s crew, if the ship is still habitable at the time the deficiency is noted.

(b) Telephone lines: Provide up to four (4) telephone lines. Connect two voice lines to the shore offices (one in the COR's office and one in the ship's office). Connect one to the conference area. The fourth (4th) line will be determined based on the shore support facilities set up.

(c) Fax machines: Provide access to FAX machine.

(d) High-Speed Internet Service: Provide high-speed, broadband internet connectivity via a local

Internet Service Provider (ISP), or privately owned, internal internet connection. High-speed, broadband internet is defined as Digital Subscriber Service (DSL), Cable Network, or Fiber Optic Network services. The Port Office shall have Internet meeting a minimum speed of 1 Mbps Up and 10 Mbps down per user. The Ship shall have Internet with a minimum of 5 Mbps up and 25 Mbps down, speeds based on up to 10 users. The service provided shall be a business-type account that supports Virtual Private Network (VPN) connections, if available. Provide the proper number of connections necessary to satisfy the ship’s wet berth and dry dock locations, as well as the ship and COR’s dockside office space(s). All necessary cabling, DSL or cable modem(s), or fiber translators shall be provided for an RJ-45 network connection to the ship and office(s) routers. Provide a minimum of one Internet Protocol (IP) address with Directory Name Server (DNS) service for each of the ship and dockside office(s) locations. The ship’s electronic technician (ET) will provide the necessary routers and switches needed.

(e) Security Service. In addition to Reference 3.1.1.1 requirements, increase security round frequency from two-hour intervals to one-hour intervals. Security Service shall be provided for 2-shifts, Monday – Friday (1530- 0730) and 3-shifts Saturday, Sunday and Federal/Contractor Holidays.

(f) Air: Provide 125 psi dry, filtered, compressed air to a manifold on deck. Connection to the ship’s compressed air distribution system is not allowed.

(g) Cooling Water: Provide 300 gpm @ 80 psig capacity, for ship’s auxiliary sea water system which supports all refrigeration plant cooling water, air conditioning plant cooling water, and sanitary system toilet flushing needs (NOTE, the ship’s sea water system provides 600 gpm for full load).

In the event, the sea water or cooling water provided to these systems is disrupted or disabled, an alternate means of providing water service to these systems shall be the Contractor’s responsibility. Provide a pressure regulator on the discharge side of the Contractors cooling water supply to the ship’s systems capable of regulating pressure between 25 psig and 80 psig.

Contractor may provide separate cooling water service connections to meet the ship’s cooling water systems needs at designated hook-up locations. Note: A 4-inch pipe connection was installed on the auxiliary seawater cooling system branch line to the ship’s forward AC machinery space in 2003. Cooling water may be supplied at this location in the forward port side main generator room, just outboard of the port distilling plant. See ship’s Chief Engineer for individual cooling water service hook-up locations and pressure requirements for the separate systems. Contractor shall make-up temporary by-pass hose and/or piping arrangements to support the ship’s AC and refrigeration plant cooling water needs, in conjunction with the work requirements of other items in these specifications.

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

(i) Parking Spaces: Provide seven reserved vehicle parking spaces within 50 feet of the dry dock office spaces. Identify additional parking spaces for up to 15 vehicles, within or outside the shipyard, which may be available for parking by ship’s personnel and other NOAA representatives.

(j) Office Spaces: Provide two secure locked office spaces (one office space for the COR and one for ship’s office space). Increase office size to 12-feet x 20-feet. Provide three sets of keys to each space to the COR. COR’s office shall be made available 3 days prior to the ship’s arrival at the Contractor’s facility and shall remain so until 3 days after the ship has departed.

(1) Ship’s dockside office shall contain three desks along with six chairs. Provide voice phone lines with speaker in each office and at the Conference/meeting area(s). Provide high speed internet service as required in paragraph 3.1.3(2)(d) above. Provide access to one fax machine. Provide one 4-drawer file cabinet with lockset. Add one fire proof safe for ship’s security documents.

The minimum interior size of the safe shall be 14-inches long by 18-inches deep by 12-inches high. One (1) refrigerator/freezer (15-18 Cu Ft), one (1) Microwave Oven and one (1) coffee maker or access to a coffee maker.

(2) COR's dockside office space shall contain one desk, one 48-inch high by 36-inch wide bookshelf, and three chairs. Provide two phone lines [described above]: one voice and one fax. Provide high speed internet service as required in paragraph 3.1.3(2)(d) above. Provide one fax machine. Provide one 4-drawer file cabinet with lockset and one 3 foot wide x 4 feet high x 12 inches deep bookcase. Provide one copy machine capable of multiple copying, sorting, and paper size conversion (enlarging/reducing) of documents, in paper size ranges from letter (8.5 x 11 inches), legal (8.5 x 14 inches), and “D“ size drawings (11 x 17 inches). Provide six (6) new hard hats in the Port Office for NOAA ship visitors. Provide six (6) LED tactical type flashlights with a minimum of 1000 lumens, battery or rechargeable type, belt clip or belt case, adjustable lens for focusing light beam, no penlight type flashlights and a between 4-6 inches long.

(k) Oily Waste Disposal: Pump the bilge oily water holding tank 4-60-1-F (estimate 500 gallons on board, up to 1500 gallons maximum), the dirty oil tank 4-6-2-F ( estimate 500 gallons on board, up to 1500 gallons maximum), the sludge tank 3-50-2-F (estimate 50 gallons on board, up to 100 gallons maximum). Pumping of the bilge oily water holding tank, the dirty oil tank, and the sludge tank shall be done at the beginning of the contract performance period. Additional pumping will be required whenever liquid is added to these tanks or spaces because of contractor washing down in order to maintain gas-free certification, or other incidental liquid drainage into these spaces because of the performance of work. After pumping the Contractor shall provide receipts of the amount of oily waste disposed for ship’s records.

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

(m) Crane Service: Provide crane operator and riggers for ship's force equipment and material lifts needed during normal working hours. Adequate pier space and vehicle access for staging mission equipment and loading provisions shall be provided during the last two weeks of the contract period. Provide crane lifts with a 5-ton minimum capacity. The COR will provide a minimum of four hours-notice prior to any lifting required for ship’s force needs. For bidding, assume 160 hours of crane use by ship’s force.

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

While the Ship’s Grey water is in use, the Contractor shall pump the sewage tank once every 4 days. Contractor is not required to pump on weekends but the sewage tank shall not be more than 50% full at 0900 on the working day before the start of a weekend. For weekends longer than 2 days (Federal Holiday) the contractor shall pump the sewage tank on the last working day before the long weekend.

(o) Provide a connection for the ship’s grey water overboard discharges, located on the starboard hull side, just forward of the Plimsoll mark. Collect and properly dispose of all grey water overboard discharges, which shall meet the same requirements for sewage and turbid water disposal, in accordance with paragraph 3.10 of NOAA Standard Specification AMC-000-2C.

(p) The contractor shall provide a containment boom around the entire vessel while vessel is waterborne.

End of Item

DRYDOCKING AND ROUTINE DRYDOCK WORK

References

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

NOAA DWG GU-085-01 – Docking Plan

NOAA Standard Specification S1205. Zinc Protectors

MSC DWG 633-6233582 – Zincs Arr & Detail

ClearFlo Growth Prevention and Corrosion Mitigation System – Installation and Operation Manual

Technical Manual No. T9244-AQ-MMC-010/07332, “Stern Tube Bearings and Seals” – Hard copy available if needed

Ship’s Stern Tube Bearing Wear Down Record

Drawing 243-6233870, “Main Propulsion Shaft Installation Arrangement and Details”

Drawing 543-6233930, “System Tube/Shaft Bearing L.O. System”

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

MSC DWG 243-6233870 – Main Propeller Shaft Installation Arrangement and Detail

Government Furnished Material (GFM): None additional

Requirements

Provide drydocking and routine dry dock work in accordance with References 3.2.1.1 and 3.2.1.2.

The vessel shall dry dock with the first seven (7) calendar days of the contract performance period.

The following information and requirements apply –

Dry dock the vessel with a minimum of four feet clearance under the keel in the Docking Position No. 1. Provide two (2) additional keel blocks, one between frames 86 and 91, and one below the bow thruster between frames 9 and 11.

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

Clean the exposed surface of all rubber faced transducers immediately after drydocking. Provide protective coverings for all transducers and transducer openings as applicable.

Clean the propellers and bow thruster blade to bright metal by power brushing. The ships propellers are an anti-singing design. The leading and trailing edges of these propellers are finely finished, and care must be taken not to damage these areas. Exercise caution when polishing the propeller surfaces to minimize removal of metal.

Tail Shaft Inspection

General – All work on the tail shafts, stern tube seals, liners and bearings shall be accomplished under the guidance of a manufacturer’s technical representative from Wärtsilä Defense, INC. The Wärtsilä technical representative shall be on the work site at all times the stern tube seals, liners and bearing work is being performed. It is imperative that the manufacturer’s Representative provided have experience inspecting and servicing the stern tube bearing assemblies installed aboard the NOAA Ship Gordon Gunter, in order to properly obtain bearing wear down measurements and evaluate the condition of the bearings.

Provide the Services of an American Bureau of Shipping (ABS) surveyor to the extent necessary, to accomplish any required inspections or technical reviews to maintain compliance with ABS Class Requirements.

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

All disassembly, inspections, tests, and reassembly shall be accomplished in accordance with References 3.2.1.7 through 3.2.1.11.

Prior to drydocking the ship, check with the manufacturer on the availability of new propulsion shaft bearings. Provide this information to the COR, in the event inspection results reveal the need to replace any of these components for either tail shaft.

Preform all propeller and tail shaft inspections, shop inspections, and quality assurance in accordance with Reference 3.2.1.11, paragraphs 3.1, 3.2, 3.3, and 4, in addition to the following, unless otherwise specified.

Remove and dispose of all oil and water, if any, from both port and starboard stern tube lube oil systems, including stern tube and forward seal head tank and sumps. Open port and starboard sumps and head tank. Clean each tank of all dirt, rust, sludge and sediments using lint free rags and solvent. COR and/or CME will inspect the tanks and sumps prior to closing. Stern tube oil shall be replenished with new oil after reassembly and reinstallation. Perform a system flush in accordance with the manufacturer’s instructions prior to replenishing with new oil.

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

Under the guidance of the Wärtsilä technical representative, take-bearing wear down readings on both tail shafts, using a bearing wear down gage provided by the ship’s Chief Engineer. All readings taken shall be witnessed by the ABS surveyor, COR, Chief Engineer, and the Wärtsilä technical representative. In addition to providing recorded readings in an inspection report, readings shall also be entered in the ship’s wear down record, and be retained with the wear down gage. Return the wear down gage to Chief Engineer after recording all measurements taken.

Remove the port and starboard propellers from their tail shafts and inspect the threads for damage.

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

Disconnect the tail shaft couplings from the port and starboard propulsion motor output flanges.

Remove the couplings from the tail shafts. Slip the tail shafts aft approximately two feet or as needed to permit removal of the couplings. Remove couplings

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

Remove the forward seal liners, clamp rings, and liner O-rings from both tail shafts. Install new forward liners, clamp rings, and liner O-rings. Install new seal ring kits in the forward and after stern tube seal assemblies. See Note 3.2.5.8 for part numbers of mandatory replacement parts. Provide a report to the COR for any additional parts or repairs needed, if any.

Perform additional liquid penetrant or magnetic particle inspection of the tail shafts as required, for compliance with ABS rules.

After all inspections and repair work are completed, reassemble and reinstall all components of the port and starboard tail shafts, propellers, stern tube seals and lube oil systems. Reinstall couplings and secure them to the propulsion motor output flanges.

Upon completion of reassembly, fill the stern tube, lube oil head and sump tanks with new Vickers Hydrox 68, biodegradable stern tube oil See Note 3.2.5.4 for one such approved oil. New oil shall be filtered through a filter cart with a 3-micron filter and gravity fed, not pumped, into the stern tube lube oil systems. Capacity of each stern tube lube system is approximately 200 gallons.

Renew hull, sea chest, bow thruster tunnel, and shaft strut zinc anodes as designated by the COR in accordance with References 3.2.1.3 and 3.2.1.4. See Note 3.2.5.7.

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

(b) Install 84 new bolt-on zinc anodes type ZHC-23 conforming to MIL-A-18001K, same size and type, and in the same location as those removed. The new finished zinc plates shall weigh twenty three (23) pounds each. Provide certification to the COR that the new zinc anodes are in conformance with MIL-A-18001K. Assume 16 individual zinc hull mounted studs will be replaced. Studs damaged, corroded beyond re-use or direction of the COR. If more than 16 fail, the Contractor shall submit Condition Found Report (CFR) or Condition Report (CR) with findings and recommendation.

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

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

Perform the following work on the ClearFlo system in accordance with Reference 3.2.1.5, and under the guidance of an on-site manufacturer’s field engineer (see Note 3.2.5.6):

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

(b) Each sea chest also has a 316 stainless steel cathode approximately 10 inches long by 1 inch diameter welded perpendicular to and about 3-4 inches from each anode (2 per sea chest). In the case of the Main Generator Room cathodes, they are welded to the inside of the sea chest grating. Remove these cathodes from the gratings and weld them to the side of upper walls of the sea chests, still keeping them perpendicular and about 3-4 inches from their respective anodes. Clean each cathode of all foreign material (growth, paint, etc.), paying particular attention to the side facing the anodes.

(c) After refloating of the ship, test the ClearFlo system’s control cabinet for proper voltage adjustments to the anodes.

Rudder and Steering Repairs – In addition to the periodic checks on the rudder, rudder stock and associated support component, NOAA would like to investigate additional work on the rudder and steering system to address two criteria concerns; Verification of the structural of the rudder stock and Functionality and reliability of the steerage system. Below is an outline of the work to address these two areas.

Background – NOAA wishes to prioritize the structural integrity aspect, because of the fact we have a “spade” rudder system, where the stock is exposed to much higher bending stress than a design that has a pintle bearing.

This bending stress can lead to fatigue cracking, particularly in the areas where corrosion pitting can occur.

The greatest bending stress level is in way of the lower stock bearing and then diminishes as you go up toward the upper spherical bearing. Hence, the reason behind the increased shaft diameter in way of the lower water bearing.

The gravity load of the entire rudder system is carried by the upper spherical bearing, which sees that gravity load by transmitting that force through the radial key at the top, down through the quadrant, into the inner race of the spherical bearing, across the bearing and into the foundation.

If the stock cracks (especially in the keyway of the radial key), you can possibly lose your rudder and stock.

Of course, added safety is accomplished through the clamping of the quadrant. But, this just keeps the stock in the hole….the blade can still be lost, because there is no pintle to catch it.

Structural and steerage system checks. Using the service of Sound Propeller for in person and technical and procedural guidance preform the following:

1- Remove the rudder blade from the stock and lower to the dock floor, noting body bolt positions.

2- Remove the various connections to the steering controls, such as feedback system, steering cylinders, etc.

Secure these in place and make note of position on removal so proper repositioning can be made on reassembly.

3- Support the stock from underneath and remove remaining equipment from up above, such as radial key, quadrant, Bearing top plate, bearing ring nut, bearing and bearing carrier and compression ring/rudder trunk seal.

4- Lower the stock to the dock floor by installing a lifting eye and adequate chain fall to the threaded hole in the top of the stock.

5- Take the stocks into the shop and determine if lower liner removal will be needed to adequately NDT inspect the stocks.

If so, and, depending on liner/bearing condition, the lower liner may be removed destructively or by rapid heating to expand it away from the shaft. There is likely 1 to 1.5 thousandths per inch of diameter of interference (perhaps 0.010 to 0.015).

This interference must be expanded to allow the liner to drop free from the stock.

This process is best done with the shaft inverted, hanging plumb from a crane and with a wood landing surface.

6- Verify lower bearing clearances and conditions to determine suitability for continued use over existing liners.

7- Verify condition of upper spherical bearings to determine suitability for continued use.

8- NDT inspect the stocks using MT (mag-particle) and NDT the liners using PT (dye-penetrant) and provide CFR to the vessel representative. Certified NDT inspector

9- Discuss any corrective actions needed following the stock/liner inspection and carry out by CFR/CR process per the vessel representatives.

10- Remove the quadrants to the machine shop, along with all keys for inspection and corrective actions.

11- Measure the complete stack of bearing carrier, bearing, quadrant and radial key to determine the amount necessary for the requires spacing spigot un the underside of the quadrant.

12- Clamp the quadrant together and face the top for even contact with the radial key.

13- Add weld material to the spigot area at the bottom of the quadrant to allow the spigot to be machined as needed.

NOTE: keep heat low during this process to minimize distortion of the quadrant bore.

14- Machine the built up spigot, per the measurements/calculations performed in step 9, in order to restore the assembly to roughly the dimensions noted in the original drawing attached. 1 machinist

The critical measurement of this step is that we end with substantial clearance (perhaps 0.040) between the bottom of the quadrant and top of the bearing carrier (with the spherical bearing loaded).

15- Blue fit the repaired quadrant to the stock to ensure proper fit after weld repair.

16- Reassembly in reverse order with proper preservation on all relevant surfaces and using new soft goods wherever applicable.

17- Reset compression on trunk seal per manufactures specification.

18- Test swing the system while in dock with attendance of vessel representatives.

19- Test while under way in aggressive sea state of while undergoing aggressive maneuvers, to verify smooth operation in all operating conditions.

While ship is dry-docked, disassemble and remove rudderstocks and bearings from ship to shop.

Prior to disassembly, conduct an operational test of steering gear. Cycle rudders and observe existing conditions. Measure the time from the after control station of the full swing cycles of the rudders, hard port to hard STBD and hard STBD to hard Port. Repeat three (3) times and record the average of the 3 readings. Provide results as a CFR. Prepare and preserve trunks in conjunction with paragraph 3.2.3.5. Clean all grease passages.

In the presence of the COR or CME, conduct the following inspections on both sets of rudders stock assemblies:

(a) Complete visual inspection for mechanical defects.

(b) Measure bearing liners diameters. Three measurements, equidistant apart, shall be taken at each bearing surface of the shaft.

(c) Measure the runout of the shaft at the taper ends, couplings, and each bearing surface.

(d) Measure bearing housing inner diameters.

(e) Measure all keys and keyways.

(f) Conduct a liquid penetrant inspection of all surfaces of shaft liners.

(g) Conduct a magnetic particle or liquid penetrant inspection of tapers and keyways.

(h) While not depicted on Reference 3.2.1.7, a fiberglass reinforced plastic (FRP) covering was added to each rudderstock between the upper and lower bearing surfaces. Inspect the FRP covering for pinholes, porosity, and other defects by using a high frequency spark tester. Use 250-300 volts per mil of glass reinforcement (approximately 15,000 volts for a 4-ply covering). Pinholes will be evidenced by bright sparks as distinguished form the normal purplish corona.

(i) Inspect the FRP covering for proper adhesion to the shaft by tapping, at regular intervals of about 18 inches along the length of the covering, with a light hammer while holding the palm of one hand against the covering on the opposite side.

Discernible vibration, movement of the covering, or audible hollow sound is evidence of probable loose bond.

Reassemble the rudderstocks

Measure, and record new rudder stock clearance readings, conduct operational tests dockside and underway in conjunction with sea trials identified in other items in this specification. Ensure that rudders can be cycled a minimum of five times under way in less than 30 seconds with no wobble or binding. Measure the actual times and compare to the reading in paragraph 3.2.3.6 above.

After all modifications and repairs to the underwater hull are completed, including all underwater hull modifications required in other items of these specifications, provide COR with a final mark-up of the ship’s docking plan in accordance with Reference 3.2.2.2, section 3.5.6. Contractor shall also document repairs and alterations made on the final docking report form and submit the report with the marked-up copy of the ship’s docking plan.

Quality Assurance

As required by References 3.2.1.1, 3.2.1.2, 3.2.1.3, and 3.2.1.5. Provide certification documents for the ClearFlo field engineer’s service reports with test results.

Conduct an operating test of the stern tube lube oil system for each tail shaft to the extent practicable, under the guidance of the Wärtsilä representative, to check the system for leaks prior to undocking the ship.

Conduct a dock trial, once the ship is waterborne, to prove both propulsion shafts and propellers are operating within design parameters, and the shaft seal systems are functioning properly without any leaks. Ship's engineers will be available to assist contractor by operating ship's machinery.

Coordinate trials with the COR, providing a minimum of three work days’ advance notice. Correct all discrepancies found as a result of the work performed. This shall include re-docking the ship if necessary, if the discrepancy discovered is as a result of the work performed by the contractor, and cannot be corrected unless the ship is re-docked.

Conduct an underway sea trial. The Wärtsilä technical representative shall make all final shaft seal and liner adjustments required to ensure seals are seating properly on the shaft seal liners.

Provide the COR with two copies of the Wärtsilä technical representative’s service reports, and the ABS surveyor’s field inspection reports.

Check the stern tube lube oil seal systems for leaks at normal system operating pressures prior to undocking and at undocking to ensure no oil leaks when getting underway for sea trials.

Notes

The technical manual and referenced drawings can be reviewed on board the ship or in the port office during a scheduled pre-bid inspection, and aboard ship during the performance period.

Contact information for Sound Propeller Systems

SP Systems LLC – Technical Services

9130 15th Pl S # A, Seattle, WA 98108 206-392-0021 – Office 425-508-4233 – Cell Attn: Mike Wiegand President

The following information is provided for ordering new replacement parts from Wärtsilä Defense, Inc.:

2 ea SS-14845 #3 Clamp Ring MK2 #200 FC300

2 ea SS-14845 #1 Fwd Liner MK2M 200 Finish HDF 2 ea SS-14845 #8 O-Ring NBR 2 ea SS-14845 #6 Seal Ring MK2 200 NBR Fwd Kit 16 ea SS-14845 #11 Hex Socket Head Bolt SCM 16 ea SS-14845 #15 Spring Washer M10 SWRH 24 ea SS-14845 #17 Toothed Washer M6 2 ea A16400044998 Aft Seal Overhaul Kit

Parts ordering information and manufacturer’s service representative arrangements for the tailshaft stern tube seals, liners, and associated parts can be obtained from the following source:

Wärtsilä Defense, Inc.

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

The following is one environmentally friendly stern tube oil approved for use on Gordon Gunter by

Wärtsilä, the stern tube seal manufacturer:

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

References 3.2.1.6 is provided for information on arrangements and details of the main propeller shafts bearings.

The manufacturer’s representative for the ClearFlo system is Wilson Walton. The following address and telephone numbers are provided to purchase parts and to arrange for field engineer service:

Wilson Walton International, Inc 3349 Rt. 138, Bldg C, Suite E Wall, New Jersey 07719 Tel: (732) 681-0707 Fax: (732) 681-6118 Email: cassie@wilsonwlaton.com

Reference 3.2.1.4 shows type ZHS-23 (weld-on strap type) zincs. These were subsequently replaced by type ZHC-23 (bolt-on) zincs as specified in paragraph 3.2.3.9 (b).

mailto:cassie@wilsonwlaton.com

Overhaul Aft Capstans

Technical Manual GU-582-02 – 10 HP Deck Capstan – Hardcopy available on the ship

NOAA Standard Specifications, AMC-300-1, Overhaul of Electrical Rotating Machinery

Government Furnished Material: None additional

Requirements

Electrically and mechanically disconnect the capstans and provide crane services to lift the capstans off the ship for transport to an experienced contractor’s facility for overhaul of the capstans.

Properly protect all shipboard connections, cables, hoses, and fittings from damage and foreign debris from entering.

Disassemble and inspected the capstans and provide Condition Found Report (CFR) to include the conditions, wear and/or other visual conditions

Overhaul the existing electric motors in accordance with 3.3.1.2. Reassemble the motors with new components.

Reassemble the capstans using new components to include but not limited to: washers, fasteners, bushing, bearings, chain, gaskets, and seals.

Prepare, prime and paint the foundations of each capstan foundation using SP-11.

Transport back and reinstall capstans.

Quality Assurance

Bench test the electric motor – provide test results

Conduct an operational test of the capstan witnessed by the COR. Test shall be under load.

Notes: None additional

Inspection and Overhaul of Markey CTD (DESH-5) and Markey Bongo (COM-7X) Winches

Technical Manual GU-575-01 – Markey Type DESH-5 CTD Research Winch

NOAA Standard Specification,…