A0002 - Spec. Rev 1.doc

American Aero Oceanmaster CG300 Marine Crane

SPECIFICATION FOR OVERHAUL AND REPAIR

Developed By: CWO4 Bryan Wright (Rev-1, 30 July 2010)

TABLE OF CONTENTS

Work Item Title Page iiRevisions Record

Consolidate List of References iii Consolidated List of Government-furnished Property v Consolidated List of Critical Inspection Items vi Principal Characteristics vii General Requirements WORK ITEM 1: Oceanmaster CG300 Marine Crane Upperworks, Overhaul WORK ITEM 2: GFE Box and Components, Overhaul WORK ITEM 3: Hydraulic System Components, Inspect and Renew WORK ITEM 4: Boom, Overhaul

Revisions Record

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

Consolidate List of References

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors, by the Coast Guard at an appropriate time, or upon request, free or charge.

· Other Government documents may be accessed – free of charge – as follows:

· MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

· Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

· Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws:: www.gpoaccess.gov The Government is aware of the following internet web links where contractors may procure commercial specifications:

· American Welding Society (AWS) http://www.awspubs.com/index.php

· ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

· NFPA: http://www.nfpa.org

· SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace Coast Guard Drawings

Coast Guard Drawing FL 9210-1, Rev -, Weatherford Marine CG 300 Crane

Coast Guard Publications

Caterpillar/Perkins, Series 1106 Engine Service Manual, 8 April 2003

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual

Coast Guard Technical Publication (TP) 1952B, Section A, Construction Crane, Oceanmaster CG300

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC STD SPEC 0740), Jan 2009, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 5000 (SFLC STD SPEC 5000), Jan 2009, Auxiliary Machine Systems

Other References American Society for Testing and Materials (ASTM) E114, 2010, Standard Practice for Ultrasonic Pulse-Echo Straight-Beam Examination by the Contact Method

American Society for Testing and Materials (ASTM) E165, 2009, Standard Test Method for Liquid Penetrant Examination

American Society for Testing and Materials (ASTM) E587, Reapproved 2005, Standard Practice for Ultrasonic Angle-Beam Examination by the Contact Method

American Society for Testing and Materials (ASTM) E709, 2008, Standard Guide for Magnetic Particle Examination

American Society for Testing and Materials (ASTM) E1003, 2005, Standard Test Method for Hydrostatic Leak Testing

American Society for Testing and Materials (ASTM) E1417, 2005, Standard Practice for Liquid Penetrant Examination

American Society for Testing and Materials (ASTM) E1444, 2005, Standard Practice for Magnetic Particle Examination

Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters

Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency

Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation MIL-C-81309, May 2005, Corrosion Preventive Compounds, Water Displacing, Ultra-Thin Film

MIL-PRF-16173, Sep 2006, Corrosion Prevention Compound, Solvent Cut-back, Cold-Application

Consolidated List of Government-furnished Property

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

($/Unit)

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center

Consolidated List of Critical Inspection Items

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000_STD, paragraph 3.2.6.5 (Inspection report particulars)):

This section is not applicable to this package.

Principal Characteristics

American Aero Oceanmaster CG300 Marine Crane

CRANE

PRIME MOVER

PUMPS

00000_0310_FLT

REC_0000_FLT_ Commercial Project @ Contractor’ Facility (0110) General Requirements

1. SCOPE

1.1 Intent. This item describes the general requirements to be followed by the Contractor while conducting this availability.

2. REFERENCES

Coast Guard Drawings

None.

Coast Guard Publications

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes

Other References

Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters

Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency

Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and also to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.2 Contractor-provided fire watch personnel. The Contractor shall provide fire watch personnel and equipment.

3.3 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740.

3.4 HW disposal. The Contractor is considered as the generator of all contract-generated hazardous wastes and shall use its facility’s EPA generator ID number for management, transportation, and disposal of said hazardous wastes. Ensure the following:

3.4.1 Contractor’s hazardous waste handlers shall comply with applicable requirements of 40 CFR 262.

3.4.2 All contract generated hazardous wastes shall be packaged in 49 CFR-compliant containers.

3.4.3 The designated wastes shall be disposed of at a state or Federally-approved and permitted HW TSDF.

3.4.4 Name of destination TSDF shall be submitted to the KO at the Arrival Conference.

4. NOTES

4.1 Access to COMDTINST M10360.3. The COMDTINST M10360.3 may be accessed at the following URL address: http://www.uscg.mil/directives/cim.asp

4.2 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 0000 to be completed and submitted during preservation of “critical-coated surfaces”, are provided at the end of this document.

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

Vessel Name: _______________________ Hull Number: ______________

CLIN No.: _____________

Work Item Title: ________________________________________________

Specific Area Being Preserved: ___________________________________________________________

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

Ensure all coatings are in compliance with COMDTINST M10360.3, Appendix C.

CHECKPOINT 2 - PAINT STORAGE

Ensure all coatings are kept at a temperature of 65 to 85°F at all times, unless otherwise specified by the coating manufacturer(s).

CHECKPOINT 3 - AMBIENT CONDITIONS

Ensure surface and surrounding temperatures are each between 50 and 90°F for water-based coatings, and 35 and 95°F for other coatings, unless otherwise specified by the coating manufacturer(s).

Ensure maximum relative humidity (RH) is as follows, from surface preparations through final curing of topcoat: 50% for tanks, voids, and vent plenum; and 85% for all other areas, unless otherwise specified by manufacturer(s).

Ensure surface temperature is at least 5°F above the dew point, unless otherwise specified by the coating manufacturer(s).

CHECKPOINT 4 - PRE-SURFACE PREPARATION

Remove surface contaminants (soluble salts, loose rust, mud, and marine growth) with low pressure fresh water wash down (maximum 5,000 psi). If oil and grease are present, perform solvent cleaning, as per SSPC SP-1.

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure cleanliness of prepared surface is as per specification (i.e.: SSPC SP-12, SP-11, SP-10…).

Verify surface anchor profile (1.5-3.5 mils for abrasive-blasted steel surfaces; 1.0 mil (minimum) for power-tool cleaned surfaces; 1.0-1.5 mils for abrasive-blasted aluminum surfaces); and 1.5 –2.5 for surfaces to be coated w/single coat of inorganic zinc). Conduct 5 sets of 3 readings for the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area.

Measure soluble salt conductivity (5 measurements per 1000 sqft) – maximum threshold: 70 microsiemens/cm for non-submerged surfaces and 30 microsiemens/cm for submerged surfaces.

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Verify proper mixing and stand-in (induction) times.

Ensure no paint is applied when the temperature is expected to drop to freezing before the paint has dried.

Ensure surfaces are completely dry, unless otherwise allowed by the coating manufacturer(s).

Verify wet film thickness (WFT) at random, to prevent under or over application. Verify final DFT.

Brush out all runs, sags, drips, and puddles.

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

After primer coat (mist coat after inorganic zinc), brush-apply un-thinned coat of same primer paint over edges, weld seams, cut-outs, and areas of complex geometries @ 3-4 mils wet film thickness (WFT).

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

Verify proper mixing and stand-in (induction) times, as applicable.

Verify wet film thickness at random, to prevent under or over application.

Brush out all runs, sags, drips, and puddles.

CHECKPOINT 9 – FINAL INSPECTION

Verify final system dry film thickness.

Ensure that system cure is in accordance with manufacturer's recommendation for intended service.

Ensure potable water tank exhaust ventilation is maintained continuously from and during coating application through final system cure, to exhaust all solvent to the atmosphere and to prevent solvent entrapment.

For immersion coatings (including tank U/W body), record date and time of the following events:

Final coat application:_________/_________; Return to service or removal from environment controls: _______/_______

CHECKPOINT 10 – RECORD KEEPING

Complete, sign, and submit all provided QA Inspection Forms.

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________

Signature of Inspector: _______________________________________ Date:_______________ Time: _________

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

Vessel Name: _______________________

(Use one sheet for each activity. Record conditions every four hours from before surface preparation to application of final coating system coat)

| DP - Surface |

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________

Signature of Inspector: _______________________________________ Date:_______________ Time: _________

QA-3 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG)

Vessel Name: _______________________

Location of Surface Profile Measurements: ___________________________________________________________

(mils)

Abrasive Manufacturer and Sieve Size: _________________________________

Place Surface Profile Replica Tapes In The Spaces Provided Below, To Serve As Permanent QA record. Maintain separate log for each area/location. When an Area Is Divided Into Separate Sections, Maintain A Separate Log for Each Section.

Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils Place Surface Profile Replica Tape Here

Reading:__________ mils

Average Mil Reading (IAW ASTM D4417-Method C) for above 15 readings: ______________

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________

Signature of Inspector: _______________________________________ Date:_______________ Time: _________

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

Vessel Name: _______________________

Location of Work (including frame numbers): _______________________________________

Area (square feet): ____________

(microsiemens/cm)

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________

Signature of Inspector: _______________________________________ Date:_______________ Time: _________

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

Vessel Name: _______________________

Coating Manufacturer: ___________________Product Name: _______________________Batch Number: ____________

Induction Time: _______________________________________________________________

Coating System Sequence (Indicate Whether: Primer, Touch-Up Primer, Barrier Coat, 3rd Coat…): __________________

Dry Film Thickness (DFT) Measurements IAW SSPC PA-2

*BASE METAL READING (BMR)

*Required, If Magnetic Pull-Of (Type I/Banana) Gauge Is Used.

Location (Frame Reference): ___________________

Avg.

Avg.

Avg.

Application Method (Airless, Conventional Spray, Rolled):____________________

Average DFT: __________________________________________________________

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________

Signature of Inspector: _______________________________________ Date:_______________ Time: _________ WORK ITEM 1: Oceanmaster CG300 Marine Crane Upperworks, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to overhaul the Upperworks for the Oceanmaster CG300 Marine crane.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing FL 9210-1, Rev -, Weatherford Marine CG 300 Crane

Coast Guard Publications

Caterpillar/Perkins, Series 1106 Engine Service Manual, 8 April 2003

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Coatings and Color Manual

Coast Guard Technical Publication (TP) 1952B, Section A, Construction Crane, Oceanmaster CG300

Surface Forces Logistics Center Standard Specification 0740 (SFLC STD SPEC 0740), Jan 2009, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 5000 (SFLC STD SPEC 5000), Jan 2009, Auxiliary Machine Systems

Other References

American Society for Testing and Materials (ASTM) E114, 2010, Standard Practice for Ultrasonic Pulse-Echo Straight-Beam Examination by the Contact Method

American Society for Testing and Materials (ASTM) E165, 2009, Standard Test Method for Liquid Penetrant Examination

American Society for Testing and Materials (ASTM) E587, Reapproved 2005, Standard Practice for Ultrasonic Angle-Beam Examination by the Contact Method

American Society for Testing and Materials (ASTM) E709, 2008, Standard Guide for Magnetic Particle Examination

American Society for Testing and Materials (ASTM) E1417, 2005, Standard Practice for Liquid Penetrant Examination

American Society for Testing and Materials (ASTM) E1444, 2005, Standard Practice for Magnetic Particle Examination

3. REQUIREMENTS

3.1 General. The Contractor shall overhaul the cab equipment for the Oceanmaster CG300 Crane (by American Aero), in accordance with TP 1952-A, and as specified herein.

3.2 Rip-outs and removals. The Contractor shall:

3.2.1 Rip-outs. Remove and dispose of the following cab assembly components shown on Coast Guard Fleet Drawing FL-9210-1 and the drawings in TP 1952-A:

· Fluid filters, strainers, and associated mounting hardware.

· Flex hoses.

· Cab controls: operators console assembly, meters and gauges, associated wiring, breaker panels, cabling, battery charger (if applicable), and mounting brackets/harnesses.

· Diesel engine and associated components, including the hot starts, flanged exhaust flex pipe (3-inch stainless steel), muffler, engine mounts, and associated mounting hardware.

· Seat assembly and associated mounting hardware.

3.2.2 Removal, cleaning , and inspection. Remove, disassemble, clean, and inspect all other cab assembly components shown on Coast Guard Fleet Drawing FL-9210-1 and the drawings in TP 1952-A and submit a written condition found report to COTR within 24 hours after the inspection. These components include but are not limited to:

· Navigation Light Mast (if applicable).

· All slewing gear, gear-box, and associated components.

· All hydraulic winches, pumps, heat exchanger, associated piping, valves, and fittings.

· AC unit (include any repair recommendation in CFR).

· Electric swivel assembly

· Load cell, load cell gauge, and associated components.

NOTICE!

For cranes with load cell gauge mounted outside of the crew cab, remove gauge from mounting bracket on boom base post. Crop gauge mounting bracket from boom and grind flush all welds.

· All doors (operator cab & access spaces), cab windows, and associated mounting hardware.

· Cab deck plates

· Ball ring and associated components.

· All pins, sheaves, keepers, shafts, plates, spacers, rollers, and associated mounting hardware.

3.3 Nondestructive inspection. The Contractor shall nondestructively inspect the following components and surfaces using either the ultrasonic (UT), magnetic particle (MT), or liquid penetrant (PT) inspection method. UT inspect in accordance with ASTM E114 and ASTM E587. MT inspect in accordance with ASTM E709 and ASTM E1444. PT inspect in accordance with ASTM E165 and ASTM E1417. Submit a written condition found report, including any recommended repairs, to the COTR within 24 hours of completing the inspection.

· All winch foundations.

· All boom pins and pin-holes.

· Ratchet and pawl assembly foundation and pins.

· Lifting eyes of crane upper works.

· All sheave foundations.

· Boom foot mount.

3.4 Navigation light mast bracket modification. Fabricate and fit three stuffing tubes, stanchion brackets and supports so that the cab will be suitable for either cutter class application (WLIC 75 or WLIC 160). Perform all welding and non-destructive testing (NDT) in accordance with SFLC Std Spec 0740.

3.5 Fuel and hydraulic tank cleaning. The Contractor shall clean the following tanks until all areas are free of grease, oil, flux, scale, dirt, loose particles or loose Corrosion products, and any other contamination foreign to the base material.

Type of tank Capacity

Cleaning (gallons)

(Method)

Fuel Oil Supply

Hot Water Hydraulic

Steam

3.6 Component renewal and installations. Renew all tank internal filters, filler caps, drain, ball valve, 1½” fuel oil fill pipe, hydraulic tank sight glass, and fuel oil tank float, prior to closing the tanks. Renew all crane cab controls, operator’s seat, and insulate cab in accordance with ANSI and API standards.

3.7 Door overhaul. The Contractor shall overhaul the designated doors and associated door frames, as shown on Drawings CG3002B and CG3002B1 contained in TP 1952-A, in accordance with the door manufacturer’s instructions.

Part Number

Size (inches)

Description 80607

26” x 66”, Steel, Operator’s Access Door

2-dog, RH with renewed oval window

80609

24” x 30”, Steel, Engine Compartment Door

1-dog, LH

80608

20” x 30”, Steel, Hydraulic Machinery

2-dog, LH

Compartment Door

Hydraulic Machinery

1-dog, LH

Compartment Door

Heat Exchanger/Radiator

2-dog, LH

Access Door

3.8 Propulsion engine performance verification/inspection. The Engine shall be inspected and placed on dynamometer pass manufacturer performance requirements, provide CFR to the COTR.

3.9 Hydraulic Oil Heat Exchanger (P/N # 480058). The Contractor shall perform Backflushing, per subsection 3.4 (Backflushing) and as follows:

3.9.1 Reassembly. Reassemble the heat exchangers to their original configurations, with new gaskets, mounting hardware, and fasteners.

3.9.2 Fill jacket water cooling systems. For testing, refill the jacket water cooling systems with a mixture of distilled water, anti-freeze and/or Corrosion inhibitor, as specified by the Coast Guard Inspector.

3.10 Ball ring overhaul. The Contractor shall disassemble, clean, inspect, and reassemble the ball ring assembly, shown on Drawing CG300-6-80 (Assembly Bearing), in accordance with TP 1952-A, and as specified herein.

3.10.1 Nondestructive inspection. The Contractor shall nondestructively inspect on all other ball ring components, including the spacer ring, using either the ultrasonic (UT), magnetic particle (MT), or liquid penetrant (PT) inspection method. UT inspect in accordance with ASTM E114 and ASTM E587. MT inspect in accordance with ASTM E709 and ASTM E1444. PT inspect in accordance with ASTM E165 and ASTM E1417. Submit a written condition found report, including any recommended repairs, to the COTR within 24 hours of completing the inspection.

3.10.2 Reassembly. When authorized reassemble the ball ring assembly.

3.10.3 Final reinstallation. After final inspection, the Contractor shall reinstall the ball ring assembly with new bolts and Type 316L Stainless Steel washers, which must be “Sharpie Tested”, in accordance with TP 1952-A (Bolt Torque and Installation Procedure).

3.11 Boom stops. The Contractor shall overhaul and lubricate two boom stop assemblies, in accordance with TP 1952-A, and as specified herein. Cut a notch on both sides of the boom stop bases so that the boom stop clears the new operator cab when lowered to 0 degrees and the topping lift wire rope clears on the other side.

3.12 Calibrate meters and gages. The Contractor shall provide qualified technicians, portable instrument standards and all necessary equipment to calibrate all meters and gauges identified below, shown in TP 1952-A. The Contractor shall remove the meters and gauges from the crane to a shore-side calibration facility. If this is done the Contractor shall exercise extreme care in transporting and reinstalling the meters and gauges to ensure they remain in calibration.

NOTE

Meters and gauges may be portable or permanently mounted in control panels.

Meter/Gauge Servicing Range Pressure Main and Whip 0-3000 psig Pressure Boom Hoist 0-3000 psig Pressure Slewing(Swing) Drive 0-3000 psig Temperature Lube Oil 100-220 deg. F Level Fuel Oil (E)mpty - (F)ull Pressure Lube Oil 5-100 psig Temperature Engine Jacket Water 100-265 deg. F Ammeter Electrical -30 - +30 Amps Tachometer/Hour Engine RPM/Hours

0-4000 RPM/HR.

3.12.1 Post-calibration. After calibration, the instruments must perform within the manufacturer's original specifications for accuracy over the entire range for that instrument.

3.12.1.1 Failure. Those that fail to meet this requirement shall be disassembled, cleaned, adjusted, reassembled with new gaskets, and calibrated again at a shoreside calibration facility. At no additional cost to the Government, the Contractor may, renew and test gauges designated for repair.

3.12.2 Standards. The Contractor shall calibrate meters and gauges using standards whose calibration is certified as being traceable to the National Standards and as follows:

3.12.2.1 Derivation. These calibration standards must have been derived from accepted values of natural physical constants or by the ratio type of self-calibration techniques.

3.12.2.2 Support. Support all Contractor-used standards by certificates, reports, or data sheets attesting the date, accuracy, and environmental or other conditions under which the furnished results were obtained. Certificates or reports from other than the National Bureau of Standards shall attest the comparison of the standards used, to the National Standard, at planned intervals, either directly or through a controlled system using the above methods.

3.12.2.3 Accuracy level. Utilize standards which have an accuracy level at least four times that of the instrument being calibrated.

3.12.3 Labeling. Affix a calibration label to the face (over the calibration screw, if so equipped) of the instrument successfully calibrated. The label installed shall remain legible for the entire calibration period and shall indicate the calibration date, the re-calibration date (re-calibration due date shall be two years unless otherwise notified by the Coast Guard Inspector), and the code or initials of the calibrating individual.

3.12.4 Certificate. Provide a certificate of calibration for each instrument that includes the date, manufacturer, model and serial number, full name of the individual performing the calibration, and the traceability number of the standard used in the calibration.

3.12.5 Report. Provide a written report listing each instrument on the crane that was calibrated with its nomenclature, manufacturer, model and serial number, date of calibration, and specific location on the vessel.

3.13 Upper-works preparation. The Contractor shall:

3.13.1 Cab preparation. Prior to surface preparation, remove visible oil, grease, soil, soluble welding residues, and salts from the surfaces.

3.13.2 Surface preservation. After all authorized repairs and tests are completed, the Contractor shall prepare and coat all upper-works surfaces, using the system specified for "Machinery Exposed To Weather, Option I" in COMDTINST M10360.3, Appendix A (Cutters and Boats Exterior Painting Systems). Select spar (10371) as the top coating color.

3.14 Reassembly. After all authorized repairs, the Contractor shall reassemble the Upper-works assembly to the original configuration in accordance with TP 1952-A.

3.14.1 Renew all gaskets, O-rings, seals, plugs, cotter pins, and fasteners during reassembly.

WARNING!

ALL Winch Mounting Bolts are Grade 8 bolts.

3.14.2 Renew, tag, and test all flex hose assemblies.

3.14.3 Renew winch control assemblies.

3.14.4 Renew and label all electrical panels and their associated equipment as required, provide CFR to COTR.

3.14.5 Renew operator cab seat as needed, provide CFR to COTR.

3.14.6 Lubricate all moving components as required with manufacturer's recommended lubricants.

3.15 Failure responsibility. If any inspection or test fails to meet the requirements herein, the Contractor shall take corrective procedures and/or furnish materials to correct each deficiency.

4. NOTES

This section is not applicable to this work item.

WORK ITEM 2: GFE Box and Components, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to overhaul a designated GFE Box and associated components.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings

None Coast Guard Publications

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Coatings and Color Manual

Coast Guard Technical Publication (TP) 1952B, Section A, Construction Crane, Oceanmaster CG300

Surface Forces Logistics Center Standard Specification 0740 (SFLC STD SPEC 0740), Jan 2009, Welding and Allied Processes

Other References

American Society for Testing and Materials (ASTM) E1003, 2005, Standard Test Method for Hydrostatic Leak Testing

MIL-PRF-16173, Sep 2006, Corrosion Prevention Compound, Solvent Cut-back, Cold-Application

MIL-C-81309, May 2005, Corrosion Preventive Compounds, Water Displacing, Ultra-Thin Film

3. REQUIREMENTS

3.1 GFE Box. The Contractor shall remove GFE Box components, overhaul/renew components and box, and reinstall the components in the box as specified herein and the Contract Line Items (CLINs) specified in the SECTION B of this specification.

3.2 Disassembly. Upon receipt of the GFE Box at the Contractor’s facility, the Contractor shall do the following:

3.2.1 Open the GFE Box and compare contents to the “USCG CG-300 GFE Parts” listing provided with the GFE Box, in the presence of the Coast Guard Inspector.

3.2.2 Remove all components from the GFE Box.

3.3 Load cell gauge. When authorized, the Contractor overhaul the load cell assembly in accordance with TP 1952-A (Load Cell Maintenance), and the requirements herein.

3.3.1 Label. The Contractor shall affix a calibration label to the face of the load cell gauge. The label shall be able to remain legible for the entire calibration period and shall indicate the following:

3.3.1.1 The calibration date.

3.3.1.2 The re-calibration due date (one year unless otherwise notified by the Coast Guard Inspector).

3.3.1.3 Code or initial of the calibrating individual and name of company.

3.3.2 Certificate. The Contractor shall provide a certificate of calibration for the load cell gauge which shall include the date, manufacturer, model, serial number, and the full name of the individual & company performing the calibration.

3.4 Swing drive overhaul. The Contractor shall overhaul, lubricate, and test the swing drive assembly, shown in Figures 1 and 2 below, in accordance with the requirements herein.

Figure 1

Figure 2

3.5 Furnish swivel assembly. When authorized by the KO, the Contractor shall furnish a new, 10-conductor, 50 amp for 110VAC Swivel, similar to the one removed.

3.6 Winch overhaul. The Contractor shall overhaul and test the hydraulic winch assemblies, in accordance with TP 1952-A, (Winches) and as follows:

3.6.1 Type. Braden Winch, PD12C Series Planetary Winches. Three types:

Two (2) regular.

· One (1) counterbalance.

· One (1) ratchet & pawl.

· Winch Motor

· All steel discs

· Cam clutches

· All friction discs

· Needle valves

· Mounting bolts

· Two speed solenoid valve

3.6.2 Inspections and testing. Contractor shall perform a dynamic load test to rating (12,000 lbs) and provide tag.

3.6.3 Winch assembly non-working surface preservation. After all authorized repairs and tests are completed, the Contractor shall prepare and coat all upper-works surfaces, using the system specified for "Machinery Exposed To Weather, Option I" in COMDTINST M10360.3, Appendix A (Cutters and Boats Exterior Painting Systems). Select spar (10371) as the top coating color.

3.6.4 Winch assembly working surfaces preservation. Coat all working surfaces, which includes the winch drum, with Solvent Cutback Corrosion Preventative Compound, conforming to MIL-PRF-16173, Type II, Grade 3, or Thin Film Corrosion Preventative Compound, conforming to MIL-C-81309, Type II, Class I.

3.6.5 Label plate. The Contractor shall provide and install an anodized-hydrated aluminum label plate on the tested winch assembly. The label plate shall state the date of overhaul, date of operational and weight test, and name of the Contractor performing the overhaul and test.

3.7 Valve overhaul. The Contractor shall overhaul the below listed hydraulic control valves for the Oceanmaster CG300 Crane by American Aero, in accordance with TP 1952-A, and as specified herein. Each valve consists of a control valve portion and a relief valve portion.

Valve Part/Drawing No.

Two-Speed Control Valve 488289-001 Dual Main and Whip Line Control Valve

480585 Slewing Drive Control Valve 480917 Boom Hoist Control Valve 480432

3.7.1 Disassemble and inspect. Completely disassemble each valve, match and mark all components, and visually inspect all parts for defects and deterioration. Submit a written report of all findings and recommendations to the COTR within 24 hours after inspecting.

3.7.2 Component renewals. Renew the following components, per the valve manufacturer’s recommendations:

· O-Rings and backup rings.

3.7.3 Reassembly. Reassemble each valve.

3.7.4 Tests. The Contractor shall perform the following test:

3.7.4.1 Hydrostatic test. After all authorized repairs of welded joints, the Contractor shall hydrostatically test each relief valve to its rate test pressure in accordance with SFLC Std Spec 0740, Appendix C, “Hydrostatic Test”, using system fluid in accordance with ASTM E1003. Be aware that no leakage or permanent deformation of pressure-containing parts is permissible.

3.7.4.2 Lifting test. After a satisfactory hydrostatic test, perform a lifting test on each relief portion of the valve, listed in 3.1 herein. Each valve shall seat cleanly after pressure relief without simmering. The test shall be accomplished using the appropriate test media. The Contractor shall adjust the relief pressure as necessary to obtain the specified lifting pressure. After adjustment, the Contractor shall perform a final test to confirm each relief valve's lifting pressure.

3.7.5 Coating. After all authorized repairs and tests are completed, the Contractor shall prepare and coat the valve exterior surfaces in accordance with the manufacturer’s recommended procedures.

3.7.6 Documentation. The Contractor shall attach a copper tag (1-inch by 2-inches by 1/16-inch) with wire to each valve, engraved with 1/8-inch letters stating valve number, test pressure, flow rate, date of test, and name of testing facility. The Contractor shall certify in writing for each valve tested the date of the test, test pressure, and place of test; a separate letter shall be provided to the COTR for each valve tested within 72 hours of the completion of the test.

3.8 New hydraulic pump. The Contractor shall furnish a new three-stage hydraulic pump (P/N 483305-084) for the Oceanmaster CG300 Crane by American Aero, shown in TP 1952-A, with new mounting hardware.

3.9 Component reinstallation. After overhauling and/or renewing the components and GFE Box, the Contractor shall install the components, in their proper locations using new Type 316L Stainless Steel fasteners. Fill out and sign the “GFE Parts” listing and provide the original and one (1) copy to the COTR.

3.10 Pre-shipment inspection. The Contractor shall conduct a pre-shipment inspection of the GFE Box and installed components, in the presence of the COTR/Coast Guard Inspector, to verify all components are installed and in “A” Condition.

3.11 Secure GFE Box. The Contractor shall secure the GFE Box lid to the box, using new, Type 316L Stainless Steel Fasteners and rubber Tie-downs.

3.12 Winch operational and weight test. The Contractor shall install each hydraulic winch on a test rig and perform a dynamic load test of (12,000 pounds) prior to installing them in the GFE Box.

· Suspend the static load from a rope attached to the winch drum for 10 minutes and verify the brake holds without slipping.

· Raise and lower the dynamic load a minimum of 10 feet through 3 complete cycles using a rope attached to the winch drum.

· Raise and lower the working load a minimum of 10 feet through 10 complete cycles using a rope attached to the winch drum.

4. NOTES

This section is not applicable to this work item.

WORK ITEM 3: Hydraulic System Components, Inspect and Renew

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew designated components for the Oceanmaster CG300 Marine crane hydraulic system.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings

None Coast Guard Publications

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Coatings and Color Manual

Coast Guard Technical Publication (TP) 1952B, Section A, Construction Crane, Oceanmaster CG300

Surface Forces Logistics Center Standard Specification 5000 (SFLC STD SPEC 5000), Jan 2009, Auxiliary Machine Systems

Other References

None

3. REQUIREMENTS

3.1 Inspection. The Contractor shall inspect all system hydraulic components and submit a written condition found report to COTR within 24 hours after the inspection.

3.2 Renew hydraulic components. Once a change request has been released by the COTR, the Contractor shall renew the designated hydraulic components listed in TP 1952-A (pages 226 through 228 “Hydraulic Fittings, Adapters, Flanges, Etc.” and “U.S.C.G. Hose List”) in accordance with SFLC Std Spec 5000, Appendix C.

4. NOTES

This section is not applicable to this work item.

WORK ITEM 4: Boom, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to overhaul the boom.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings

None Coast Guard Publications

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Coatings and Color Manual

Coast Guard Technical Publication (TP) 1952B, Section A, Construction Crane, Oceanmaster CG300

Surface Forces Logistics Center Standard Specification 0740 (SFLC STD SPEC 0740), Jan 2009, Welding and Allied Processes

Other References

None

3. REQUIREMENTS

3.1 The Contractor shall perform American Aero Quality Control Procedure (QCP) #12.11 Rev 6 in Part 4 (Operations and Maintenance Addendum) of TP 1952-A and submit a written condition found report to the COTR within 24 hours after completing the inspection.

3.2 After a change request has been released by the COTR, the Contractor shall perform all designated weld repairs and non-destructive testing (NDT) in accordance with SFLC Std Spec 0740.

3.3 Surface preservation. After all authorized repairs and tests are completed, the Contractor shall prepare and coat the boom surfaces, using the system specified for "Machinery Exposed To Weather, Option I" in COMDTINST M10360.3, Appendix A (Cutters and Boats Exterior Painting Systems). Select spar (10371) as the top coating color.

4. NOTES

This section is not applicable to this work item.