4CHENA_75409_SPEC_DD_P08R0.Doc

USCGC CHENA (WLR-75409)

75 FOOT RIVER BUOY TENDER

SPECIFICATION FOR DRYDOCK REPAIRS

Developed By:

MKC Hiller(EPO) CWO4 Hellmers(PE) CWO2 Carl Boothe(TDM) Ki Pak (Specification)

Commander (v) Maintenance and Logistics Command, Atlantic 300 E. Main Street, Suite (600) Norfolk, VA 23510-9102

TABLE OF CONTENTS

Work Item Title Page iiiList of Sketches

Revisions Record iv List of Applicable References v List of Government-furnished Property x List of Critical Inspection Items xi Specification Feedback xii Principal Characteristics xiii General Requirements Welding Repairs Remove, Inspect, and Reinstall Propeller Shafts Remove, Inspect, and Reinstall Intermediate Shaft Straighten Shaft Renew Water-Lubricated Shaft Bearings Renew Propeller Shaft Sleeve(s) Remove, Inspect, and Reinstall Propellers Perform Minor Repairs and Reconditioning of Propeller Clean, Inspect, and Test Grid Coolers Overhaul and Renew Valves Remove, Inspect, and Reinstall Rudder Assemblies for Steering and Flanking Systems Rebuild Rudder Stock and Rudder Renew Rudder Lower Bearing Trunk Preserve Spud and Spud Well Surfaces and Renew Spud Well Liners Shrink Wrap Crane and Boat Davit Inspect Various Deck Fittings Preserve Barge Buoy Deck Preserve Complete Underwater Body Routine Drydocking Provide Temporary Logistics Inspect and Overhaul Strainers Preserve Shaft Alley, Sewage Hold, and Bridge Surfaces Ultrasonic Testing

List of Sketches

Work

Item Sketch Number Page This section is not applicable to this package.

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.

List of Applicable 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. Electronic copies of the latest Editions of MLCA Standard Specifications are available on the Internet and may be accessed at the following Internet Uniform Resource Locator (URL) address: http://www.uscg.mil/mlclant/vdiv/specs/default.htm. Guidance for obtaining copies of all other documents referenced herein is provided in the solicitation.

Order of precedence. In the event of conflicts between text of this specification and the applicable references specified herein, order of precedence shall be in accordance with MLCA Standard Specification 0000_STD, paragraph 3.2 (Order of precedence), unless otherwise specified by the Contracting Officer (KO). The Contractor shall immediately notify the KO in writing of any perceived conflicts contained herein. Nothing in these documents, however, supersedes applicable laws and regulations, unless a specific exemption has been obtained.

FEDERAL AND MILITARY SPECIFICATIONS AND STANDARDS

MIL-A-18001, Sept 1993, Anodes, Sacrificial Zinc Alloy (Commercially Accepted - ASTM B418)

MIL-G-21164D Notice 1, 24 OCT 1991, Grease, Molybdenum Disulfide, For Low and High Temperatures

MIL-G-23549C(I1), Rev C, Amend 1, 30 Apr 1997, Grease, General Purpose

MIL-PRF-16173, Jan 1993, Corrosive Preventive Compound, Solvent Cutback, Cold Application

MIL-PRF-18458, May 2003, Grease, Wire Rope-Exposed Gear

MIL-PRF-24647, Feb 2005, Paint System, Anticorrosive And Antifouling, Ship Hull

MIL-PRF-83483, Feb 1998, Thread Compound, Antiseize, Molybdenum Disulfide Petrolatum

MIL-STD-167-1, Nov 2005, Mechanical Vibrations of Shipboard Equipment (Type I - Environmental and Type II - Internally Excited)

MIL-STD-2191, Nov 1992, Repair Welding, Weld Cladding, Straightening, and Cold Rolling of Main Propulsion Shafting

OTHER GOVERNMENT DOCUMENTS, DRAWINGS, AND PUBLICATIONS

DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0000_STD, 2006 Edition, General Requirements

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 8634_STD, 2004 Edition, Drydocking

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 8635_STD, 2004 Edition, Provide Temporary Logistics

DRAWINGS

Coast Guard Drawing 130 CGB 085-004, Rev 1, Barge Docking Plan Coast Guard Drawing 130 CGB 111-002, Rev 9, Hull Details, Side Shell Plating and Framing Sections and Details

Coast Guard Drawing 130 CGB 530-002, Rev 3, Cooling Water Piping Schematic

Coast Guard Drawing 75E WLR 0700-1, Rev 1, Docking Plan (Classic)

Coast Guard Drawing 75E WLR 0700-3, Rev A, Docking Block Arrangement

Coast Guard Drawing 75E WLR-2200-1, Rev 5, Rudder Trunk Details

Coast Guard Drawing 75E WLR 2200-2, Rev 4, Backing Rudder Details

Coast Guard Drawing 75E WLR 2200-3, Rev 4, Steering Rudder Details Coast Guard Drawing 75E WLR-2200-4, Rev-2, Steering Arrangement and Details

Coast Guard Drawing 75E WLR 2602-1, Rev 2, Towing Knee and Spud Well

Coast Guard Drawing 75E WLR 2602-2, Rev 1, Spud Hoist and Spud

Coast Guard Drawing 75E WLR 4103-002, Rev 1, Piping Arrangement Eng Cooling Water

Coast Guard Drawing 75E WLR 4103-004, Rev 2, Main Engine Control Piping

Coast Guard Drawing 75E WLR 4301-001, 2, 3, 4 & 5 (Prototype), Rev-1, Shaft Details and Modifications

Coast Guard Drawing 75E WLR 4301-001, Rev-2, Propeller Shaft and Stern Tube, Arrangement and Details

Coast Guard Drawing 75E WLR 4301-002, Rev 1, 48 x47 Propeller Coast Guard Drawing 75E WLR 6101-001, Rev 1, Generators Cooling Piping Arrangement

Coast Guard Drawing 75E WLR 6101-002, Rev-, Gridcooler Installation Dimensions

Coast Guard Drawing 75E WLR 6101-003, Rev-, Generator Cooling Piping Arrangement D/G ReplacementCoast Guard Fleet Drawing FL 2602-10, Rev D, Spud Arrangements and Details NAVSEA Drawing 803-2145807, Rev C, Propulsion Shafting And Components

NAVSEA Drawing 803-921865, Rev R, Cathodic Protection Hull Zinc Anodes

PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (Series), Coatings and Color Manual

INDUSTRY STANDARDS

American Bureau of Shipping (ABS) 2, Rule Requirements for Survey After Construction, 2006, Part 7, Appendix Section 10, Guide for Bronze and Stainless Steel Propeller Castings

American Society of Mechanical Engineers (ASME) B16.34, 2004, Valves-Flanged, Threaded, and Welding End

ASTM International (ASTM), D1709, 2004, Standard Test Methods for Impact Resistance of Plastic Film by the Free-Falling Dart Method

ASTM International (ASTM), D1922, 2005, Standard Test Method for Propagation Tear Resistance of Plastic Film and Thin Sheeting by the Pendulum Method

ASTM International (ASTM) D1330, 2004, Standard Specification for Rubber Sheet Gaskets

ASTM International (ASTM) D3951, Reapproved 2004, Standard Practice for Commercial Packaging ASTM International (ASTM) D882, 2002, Standard Test Method for Tensile Properties of Thin Plastic Sheeting

ASTM International (ASTM) E797, 2001, Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact Method

ASTM International (ASTM) E797, 2005, Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact Method ASTM International (ASTM) F992, 2006, Standard Specification for Valve Label Plates

ASTM International E797, 2005, Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact Method

Commercial Item Description (CID) A-A-52624, Sep 2001, Antifreeze, Multi Engine Type, Ethylene Glycol (For Caterpillar equipment applications, use CAT Extended Life Pre-Mix coolant.)

Commercial Item Description (CID) A-A-59313, Feb 1999, Thread Compound; Antiseize, Zinc Dust-Petrolatum

International Standard For Organization (ISO) 484/2, 1981, Shipbuilding - Ship Screw Propeller - Manufacturing Tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50 m, Inclusive

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) SP-61, 2003 Edition, Pressure Testing Of Steel Valves

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) SP-67, 2002 Edition, Butterfly Valves

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) SP-72, 1999 Edition, Ball Valves with Flanged or Butt-Welding Ends for General Service

Manufacturers' Standardization Society of the Valve and Fittings Industry (MSS) SP-80, 2003 Edition, Bronze Gate, Globe, Angle and Check Valves

Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) G6032, 1999, Grease, Plug Valve, Gasoline and Oil Resistant, NATO Code Number G-363, Metric 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, Electronic Systems Support Unit (ESU) or local Electronic Support Detachment (ESD).

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 Std Spec 0000_STD, paragraph 3.6.2 (Inspection report particulars)):

Work Item Title Remove, Inspect, and Reinstall Propeller Shafts

Remove, Inspect, and Reinstall Intermediate Shaft

Clean, Inspect, and Test Grid Coolers

Remove, Inspect, and Reinstall Rudder Assemblies for Steering and Flanking Systems

Preserve Spud and Spud Well Surfaces Ultrasonic Testing Specification Feedback

The intent of this section is to inform all users that a spec feedback mechanism is in place, and is located on the MLCA Naval Engineering Division’s website. Spec feedback is a very important part of our overall continuous improvement process, and is crucial to specification development. It will allow spec writers to capture all specification-related lessons learned, and avoid mistakes or ambiguities in follow-on availabilities. All feedback will be reviewed, evaluated, and responded to in a timely manner.

If you have access to the CGWeb (Intranet), please use the following link, which will connect you to the MLCA(v) Naval Engineering website, for submitting your feedbacks:

http://webapps.mlca.uscg.mil/vdiv/specifications/feedback/default.cfm

If you do not have access to the CGWeb (Intranet), you may still submit your feedbacks, using the following web link:

http://www.uscg.mil/mlclant/VDiv/specs/specfeedback.htm

PC_75E_WLR_Chena_Barge (26 Oct 2005)

75E WLR

Principal Characteristics

75' WLR (E Class) "Chena" Small Buoy River Tender

PROPELLERS / SHAFT

Tailshaft: 4.5”, Steel, ABS Grade 2.

CG BARGE

00000N_FLT (20 Apr 2007)

General Requirements

1. SCOPE

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

2. APPLICABLE DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0000_STD, 2006 Edition, General Requirements Coast Guard Maintenance and Logistics Command Atlantic (MLCA) Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Commandant Instruction (COMDTINST) M10360.3 (Series) Jun 2006, Coatings and Color Manual

3. REQUIREMENTS

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

NOTICE!

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 nondestructive inspection (NDI), in accordance with Std Spec 0740_STD.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

5.1 Access to COMDTINST M10360.3. The COMDTINST M10360.3 may be accessed at the following URL address: http://www.uscg.mil/ccs/cit/cim/directives/cim/cim_10360_3c.pdf.

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

QA-1: QUALITY ASSURANCE INSPECTION FORM - PRESERVATION CHECKLIST

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).

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 at random, to prevent under or over application.

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.

Verify system cure for service resumption - U/W Body surfaces: 5-8 hours @ 77 degrees F; Potable water tanks: 7 days @ 77 degrees F.

Ensure potable water tank exhaust ventilation is maintained continuously from and during coating application through final system cure (minimum 7 days @ 77 degrees F.), to exhaust all solvent to the atmosphere and to prevent solvent entrapment.

CHECKPOINT 10 – RECORD KEEPING

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

Signature of Inspector:______________________________________________________Date:____________

QA-2. QUALITY ASSURANCE INSPECTION FORM

ENVIRONMENTAL READINGS

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

.Signature of Inspector:__________________________________________________Date:____________

QA-3 QUALITY ASSURANCE INSPECTION FORM

SURFACE PROFILE LOG

Vessel Name And Hull Number:__________________________________________________ Work Item Title:_______________________________________________________________ Location Of Work (Including Frame Numbers):_____________________________________ Area (Square Feet):_____________ Surface Preparation Method:_____________________________________________________ Abrasive Manufacturer And Size:_________________________________________________ Degreasing Method Used:________________________________________________________ Number Of Hours Surfaces (Steel Only) Left Unpainted:______________________________ Sweep blasting performed to remove flash rusting (steel)? Yes/No:_____________________ 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.

AVERAGE MILS

(IAW ASTM D4417, METHOD C)

Place Surface Profile Replica Tape Here

Reading:__________ mils

· Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Date and Time:__________________________________________________ Location of Surface Profile Measurements:___________________________________________________________ Signature of Inspector:____________________________________________________________________________

QA-4. QUALITY ASSURANCE INSPECTION FORM

SURFACE SOLUBLE SALT CONDUCTIVITY LOG

Vessel Name and Hull Number:__________________________________________________ Work Item Title:_______________________________________________________________ Location of Work (including frame numbers):_______________________________________ Area (square feet):____________

(microsiemens/cm)

Date and Time:_________________________________________ Signature of Inspector:___________________________________

QA-5. QUALITY ASSURANCE DATA FORM

DRY FILM THICKNESS (DFT) MEASUREMENTS IAW SSPC PA-2

(Use one sheet for each sequence) Vessel Name and Hull Number:__________________________________________________ Work Item Title:______________________________________________________________ Coating Manufacturer:_________________________________________________________ Product Name:________________________________________________________________ Batch Number:________________________________________________________________ Induction Time:_______________________________________________________________ Coating System Sequence (Indicate whether: primer, touch-up primer, barrier coat, 3rd coat…):__________________

DFT

MEASUREMENT NUMBER

Application Method (Airless, Conventional Spray, Rolled):____________________ Average DFT: __________________________________________________________ Date and Time: _________________________________________________________ Signature of Inspector: ___________________________________ 07400D_FLT (25 Apr 2006) FLT (05 Jan 2004) WORK ITEM 1: Welding Repairs

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to perform welding repairs.

2. APPLICABLE DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes

3. REQUIREMENTS

3.1 General. The Contractor shall perform all welding and nondestructive inspection (NDI) in accordance with Std Spec 0740_STD. This work item includes all welding related activities only and does not include interference removal.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

This section is not applicable to this work item.

24310L_FLT (06 Mar 2006) 75E WLR (14 Jun 2004) WORK ITEM 2: Remove, Inspect, and Reinstall Propeller Shafts

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to remove, inspect, and reinstall a designated propeller shaft.

2. APPLICABLE DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Commandant Instruction (COMDTINST) M10360.3, Coatings and Color Manual Coast Guard Drawing 75E WLR 4301-1, Rev 4, Propeller Shaft and Stern Tube, Arrangement and Details Coast Guard Drawing 75E WLR 4301-2, Shaft Brake, Strut Details, Steady Rest Bearing Support, and Coupling Nut Wrench Coast Guard Drawing 75E WLR 4301-001, 2, 3, 4 & 5 (Prototype), Rev-1, Shaft Details and Modifications

3. REQUIREMENTS

3.1 General.

3.1.1 Critical Inspection Report. The Contractor shall submit a critical inspection report (CIR) for the inspections listed in the following paragraph(s):

· 3.2.2 (Inspections).

3.1.2 Related work item. The Contractor shall accomplish this work item in conjunction with "Remove, Inspect and Reinstall Propellers" which is separate work item of this specification.

3.1.3 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the following:

· Rope guard.

· Fairwater.

3.2 Work to be accomplished. Using Coast Guard Drawings 75E WLR 4301-1, and 75E WLR 4301-2 as guidance, as applicable, the Contractor shall accomplish the following for a designated propeller shaft:

3.2.1 Removals.

· Mark existing shaft position, and match-mark shaft coupling bolts to their respective holes, to facilitate reinstallation procedures.

· Remove the shaft and attached components to a suitable repair facility. Ensure shaft is properly protected and supported at all bearing journals, at all times, until reinstallation.

3.2.2 Inspections. Clean the shaft free of all marine growth, and accomplish the following inspections (Submit CIR):

3.2.2.1 Visually inspect the following components, as applicable, for excessive wear and other mechanical defects such as nicks, cracks, and corrosion, as applicable:

· Shaft surfaces.

· Bearing surfaces.

· All shaft and propeller associated fasteners.

· Couplings.

· Stern tube/shaft sealing systems.

3.2.2.2 Accomplish the following measurements:

· Measure keys and keyways.

· Measure all bearing sleeve or journal diameters.

· Measure runouts for shaft taper, shaft straightness, and coupling end diameters.

· With the coupling fit to shaft and key in-place, measure the coupling face and bore runouts.

3.2.2.3 Perform nondestructive inspection of all bearing sleeves, shaft tapers, coupling bolts, keyways, and welded repair surfaces, in accordance with Std Spec 0740_STD, Appendix C.

3.2.3 Stern tube preservation. Prepare and coat the interior stern tube surfaces in accordance with COMDTINST M10360.3, using the coating system specified for "U/W Body and Boot-Top, Steel Hulls, in Fresh Water" in Appendix A (Cutter and Boat Exterior Paint System). After surface preparation and before coating application, do the following:

3.2.3.1 Perform a visual inspection of the prepared stern tube surfaces.

3.2.3.2 Submit a CFR.

3.2.4 Reinstallation. Reinstall the propeller shaft to its original configuration and accomplish the following, using Coast Guard Drawings WLR 4301-001 and 75E WLR 4301-002, as applicable.

3.2.4.1 Machine, grind, or hand-stone couplings, if necessary, to achieve an 80 percent contact. True couplings to shaft by cutting coupling faces and land area.

3.2.4.2 Renew all stainless steel self-locking nuts for packing glands.

3.2.4.3 Renew all packing materials.

4. QUALITY ASSURANCE

4.1 Post-repair operational testing. In the presence of the Coast Guard Inspector, the Contractor shall thoroughly test and prove the shafting system to be in satisfactory operating condition. Conduct a sea trial to test the propeller shaft in all modes of operation for a minimum of 4 hours. Inspect and correct any excessive leakage, abnormal noise and excessive vibration.

5. NOTES

This section is not applicable to this work item.

24320L_FLT (18 Jun 2004) 75E WLR (23 Mar 2004) WORK ITEM 3: Remove, Inspect, and Reinstall Intermediate Shaft

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to remove, inspect, and reinstall the port and starboard intermediate shafts.

2. APPLICABLE DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Drawing 75E WLR 4301-001, Rev-2, Propeller Shaft and Stern Tube, Arrangement and Details Coast Guard Drawing 75E WLR 4301-002, Rev 1, 48 x47 Propeller

3. REQUIREMENTS

3.1 General. The Contractor shall:

3.1.1 Critical Inspection Report. Submit a critical inspection report (CIR) for the inspections listed in the following paragraph(s):

· 3.4 (Inspections)

3.1.2 Related work item. Accomplish this work in conjunction with "Remove, Inspect, and Reinstall Propeller Shafts", which is a separate work item in this specification package.

3.2 Removals. Using Coast Guard Drawings 75E WLR 4301-1, and 75E WLR 4301-2 as guidance, The Contractor shall accomplish the following:

3.2.1 Mark existing shaft position, and match-mark shaft coupling bolts to their respective holes, to facilitate reinstallation procedures.

3.2.2 Remove the shaft and attached components, including cooper bearing, to a suitable repair facility. Ensure shaft is properly protected and supported at all bearing journals, at all times, until reinstallation.

3.3 Protective measures. The Contractor shall protect the shaft from weather and damage during removal, storage, and reinstallation. Ensure the shaft is properly supported at all bearing journals, at all times, until reinstallation.

3.4 Inspections. The Contractor shall (1) clean each shaft of all marine growth, (2) set up the shaft in a lathe, providing supports at each bearing surface, and (3) accomplish the following inspections (Submit CIR):

3.4.1 Visual inspection. Visually inspect all bearing components and shaft surfaces for excessive wear and other defects..

3.4.2 Measurements and machining. Measure the shaft diameters and runouts at the locations of the cooper bearing and bulkhead stuffing box. Measure each shaft taper and shaft runout at the taper. Measure all keyways and keys. Measure coupling end diameters and runout. Measure the boss ring runouts. With keys installed, fit the shaft coupling to the shaft in shop, perform all necessary coupling machining to achieve a minimum of 80 percent contact, and check by bluing. Install couplings and check face and bore runouts on couplings. True couplings to shaft by cutting coupling faces and land area.

3.4.3 Non-destructive inspection. Conduct nondestructive inspection of all shaft tapers, and keyways, in combination, as appropriate, in accordance with Std Spec 0740_STD, Appendix C.

3.5 Bearing reinstallation. Upon completion inspection, the Contractor shall reinstall the cooper bearing assembly. Lubricate the bearing in accordance with manufacturer's recommendation.

3.6 Shaft reinstallation. The Contractor shall reinstall each intermediate shaft to original configuration.

3.6.1 True couplings to shaft by cutting coupling faces and land area, as necessary.

3.6.2 Renew all stainless steel self-locking nuts and new packing materials.

4. QUALITY ASSURANCE

4.1 Post-repair operational testing. In the presence of the Coast Guard Inspector, the Contractor shall thoroughly test and prove the shafting system to be in satisfactory operating condition. Conduct a sea trial to test the propeller shaft in all modes of operation for a minimum of 4 hours. Inspect and correct any excessive leakage, abnormal noise and excessive vibration.

5. NOTES

This section is not applicable to this work item.

24350L_FLT (06 Mar 2006) 75E WLR (23 Jan 2004) WORK ITEM 4: Straighten Shaft

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to straighten a designated shaft.

2. APPLICABLE DOCUMENTS

MIL-STD-2191, Nov 1992, Repair Welding, Weld Cladding, Straightening, and Cold Rolling of Main Propulsion Shafting Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Drawing 75E WLR 4301-001, Rev 4, Propeller Shaft and Stern Tube, Arrangement and Details

3. REQUIREMENTS

3.1 Shaft straightening requirements. Based on inspection results obtained from a related shaft work item in this specification package, or provided by the Coast Guard Inspector, the Contractor shall straighten the designated shaft, using Coast Guard Drawings 75E WLR 4301-1, and MIL-STD-2191 as guidance and as specified herein.

3.1.1 Pre-straightening inspection. Prior to initiating straightening processes, determine the location, magnitude and type of bend in the shaft, with the entire shaft supported on centers in a lathe, as follows:

· Before taking shaft runout readings, spin the shaft on the lathe for approximately two hours to eliminate any sagging that may have occurred during handling and storage.

· Conduct a dial indicator survey of shaft runout at stations spaced every two feet of shaft length to determine the magnitude and location of the bend.

· At each station, mark the position of maximum runout on the periphery of the shaft.

NOTICE!

Be aware that the marks on the shaft periphery will be in a straight line if the shaft contains a simple bend, and will spiral part way around the shaft, if the shaft is both bent and twisted.

· Plot the maximum runout to an exaggerated scale, in order to locate the center of the bend, and to determine the extent of straightening required.

· Submit a CFR including locations and magnitudes of the bend.

3.1.2 Straightening procedures. Straighten the shaft to equal or less than 0.005" total indicator runout, using the localized heating (hot spotting method for carbon steel shafts, in accordance with MIL-STD-2191, Section 11.2.2.2 and sub-paragraphs).

3.1.3 Post-straightening inspections. After completion of straightening procedures, accomplish inspections, and submit a CFR:

· Conduct non-destructive inspection of all straightened areas in accordance with Std Spec 0740_STD, Appendix C.

· Recheck the shaft surfaces, as specified in paragraph 3.1.1 (Pre-straightening inspection).

4. QUALITY ASSURANCE

No additional requirements.

24400L_FLT (06 May 2005) 75E WLR (25 May 2004) WORK ITEM 5: Renew Water-Lubricated Shaft Bearings

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to renew the water-lubricated bearings for port and starboard shafts.

2. APPLICABLE DOCUMENTS

Coast Guard Drawing 75E WLR 4301-001, Rev 4, Propeller Shaft and Stern Tube, Arrangement and Details Coast Guard Drawing 75E WLR 4301-002, Rev 1, 48x47 Propeller, Shaft Brake, Strut Details, Steady Rest Bearing Support, and Coupling Nut Wrench

3. REQUIREMENTS

3.1 Related work item. The Contractor shall perform this work in conjunction with “Remove, Inspect, and Reinstall Propeller Shafts”, which is a separate work item in this specification package.

3.2 Bearing renewal. The Contractor shall accomplish the following, using Coast Guard Drawings 75E WLR 4301-001 and 75E WLR 4301-002 as guidance:

3.2.1 Removal. Remove the existing water-lubricated bearings; dispose of the removed bearings after visually inspection for any abnormal wear patterns which may indicate misalignment. Submit CFR.

3.2.2 Inspections.

3.2.2.1 Visual. Visually inspect the following:

· Chocking material, if installed in the bearing housings.

· Bearings.

· Bearing housing bores.

· Shaft journal in way of bearings.

3.2.2.2 Measurements. Measure the inner diameter of each bearing housing at forward, middle and aft positions.

3.2.2.3 Documentation. Submit a CFR after the inspection and measurements.

3.2.3 New bearing installation. The Contractor shall furnish water-lubricated bearings, and accomplish the following, using Coast Guard Drawings 75E WLR 4301-001 and 75E WLR 4301-002 as guidance:

3.2.3.1 Alignment check of bearing carriers. In the presence of the Coast Guard Inspector, the Contractor shall check the alignment of the stern tube, forward seal flange, and bearing carriers relative to the shaft centerline including any offsets by running a taut line, using the optical scopes method, or using laser alignment.

3.2.3.2 Machine the new bearings to fit the bearing housing in accordance with the manufacturer's installation recommendations. Drill and tap new bolt holes on the new bearings to match the bearing housings for proper fit.

3.2.3.3 Install the new water-lubricated bearings in accordance with the bearing manufacturer's recommendations, using new monel or type 316 stainless steel fasteners.

3.3 Final measurement. After bearing installation, the Contractor shall:

3.3.1 Measure final bearing clearances at 90-degree intervals around the shaft ataft ends: a total of 4 measurements per bearing.

3.3.2 Submit a CFR after taking the measurements.

3.3.3 Minimum operating bearing clearance shall be as follows:

4. QUALITY ASSURANCE

4.1 Inspection and operational test. The Contractor shall accomplish the following:

4.1.1 Visual inspection. Visually inspect the new bearings and record bearing clearances, after shaft reinstallation.

4.1.2 Operational test. Conduct an operational test of the shaft during sea trials, to ensure there is no evidence of binding, abnormal vibration, and noise during sea trials.

4.1.3 Inspection and test documentation. Submit a CFR upon completion of inspection and test.

24420L_FLT (02 Nov 2004) 75E WLR (30 Jan 2004) WORK ITEM 6: Renew Propeller Shaft Sleeve(s)

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to renew the sleeve(s) on the port and starboard propeller shafts.

2. APPLICABLE DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Drawing 75E WLR 4301-001, Rev 2, Propeller Shaft and Stern Tube, Arrangement and Details NAVSEA Drawing 803-2145807, Rev C, Propulsion Shafting And Components

3. REQUIREMENTS

3.1 Related work item. The Contractor shall perform this work in conjunction with “Remove, Inspect, and Reinstall Propeller Shafts”, which is a separate work item in this specification package.

3.2 Sleeve renewal requirements. Using Coast Guard Drawing 75E WLR 243-002 as guidance, the Contractor shall accomplish the following, for the port and starboard propeller shafts:

3.2.1 Removal. Remove and dispose of the sleeve(s).

3.2.2 Inspections. Clean all shaft journal surfaces, and accomplish the following:

3.2.2.1 Perform a visual inspection of the shaft journal surfaces for corrosion, deterioration, and other signs of failures.

3.2.2.2 Measure and record in the shaft journal outside diameter and the shaft bearing inside diameter in the following positions:

· Forward.

· Middle.

· Aft.

3.2.2.3 Conduct nondestructive testing of all shaft surfaces in the way of sleeve fit areas in, accordance with Std Spec 0740_STD, Appendix C.

3.2.3 Inspection report. The Contractor shall submit a CFR for the completed inspection and measurements.

3.2.4 New sleeve installation requirements. After the Coast Guard Inspector has reviewed all measurement findings, the Contractor shall furnish new hard steel nickel-chrome-boron shaft sleeves (see 5.1) and accomplish the following:

3.2.4.1 Bore new sleeve ID to the dimensions based on the recorded shaft journal OD readings, to facilitate an interference fit, as specified below.

3.2.4.2 Install the new sleeves onto the shaft with a shrink-fit equal to 0.00075-inch per inch of shaft diameter, in accordance with NAVSEA_HM&E-STD 803-2145807, Table 8-1 (Shaft Sleeve Shrink Fit).

3.2.4.3 After installation, machine new steps at the end of each sleeve where the shaft covering is required.

3.2.5 Concentricity measurement. Check the outside diameter of each shaft sleeve to ensure it is concentric with the axis of rotation within 0.0005 inch (0.001 inch runout).

3.2.6 Polishing. Polish the sleeve surfaces to a 32 micro-inch RMS finish, upon completion of installation and all required machining.

3.3 Final documentation. The Contractor shall provide a complete set of the new sleeve dimensional readings to the COR within 48 hours after completion of sleeve installation. At a minimum, the set of readings shall include the new sleeve length, diameters (inside and outside) at the bearing journals, concentricity, and polish.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

5.1 Nickel-chrome-boron shaft sleeve suppliers. Suppliers for the nickel-chrome-boron shaft sleeve include, but are not limited to the following:

National Maintenance and Repair Hartford, Illinois Phone: (618) 254-7451 Dover Corp/Dover Diversified/Waukesha Bearings Corporation Waukesha, Wisconsin Phone: (414) 547-3381

24500L_FLT (29 Sep 2006) 75E WLR (02 Feb 2004) WORK ITEM 7: Remove, Inspect, and Reinstall Propellers

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to remove, inspect, and reinstall port and starboard propellers.

2. APPLICABLE DOCUMENTS

MIL-PRF-16173, Jan 1993, Corrosive Preventive Compound, Solvent Cutback, Cold Application International Standard For Organization (ISO) 484/2, 1981, Shipbuilding - Ship Screw Propeller - Manufacturing Tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50 m, Inclusive

3. REQUIREMENTS

3.1 Protective and safety measures. The Contractor shall accomplish the following:

· Before removing each propeller or propeller nut, fit a shore from the floor of the dock to one propeller blade near the root, to prevent shock transmission to reduction gear, if applicable.

· Protect propeller blade edges and blade roots with suitable covers, at all times until reinstallation, to prevent damage.

3.2 Work to be accomplished. The Contractor shall accomplish the following for each propeller, using drawing provided by the Coast Guard Inspector as guidance.

3.2.1 Removal. Remove the propeller to a suitable repair shop.

NOTICE!

If it becomes necessary to apply heat to facilitate propeller removal, ensure that the hub temperature never exceeds 500 degrees Fahrenheit; in addition, ensure that gland, packing ring, fill and vent plugs are removed, and the adjacent shafting and canvas under the blade edge guards are protected from flame impingement.

3.2.2 Inspection. Visually inspect the propeller for any damage, cracks, and other defects. Examine and record the suction and pressure face thickness, blade tip profiles, leading and trailing edges, contours, track, width, diameter, taper, pitch, and keyway of the propeller in accordance with ISO 484/2. Submit a written condition-found report to COR within 24 hours after the inspection.

3.2.3 Polishing. Polish the propeller to a uniform 63 micro-inch RMS finish.

3.2.4 Propeller hub fitting check. In the presence of the Coast Guard Inspector and with the key in place, carefully check the fit of the propeller hub bore to the shaft taper by applying Prussian blue to the shaft taper.

3.2.4.1 Uniform fit. Obtain a uniform fit of 60 percent contact over the taper, with a slightly heavier fit on the larger end. Do not heat the shaft taper to compensate for a poor fit.

3.2.4.2 Propeller fit. If the fit is less than 60 percent, hand grind/stone the propeller hub bore to achieve the required fit.

WARNING!

Do not machine the shaft taper.

3.2.4.3 Location inscription. When 60 percent fit has been obtained, make a small inscription on the shaft to mark the propeller location. Use this mark as a reference in final assembly.

3.2.5 Balancing. Perform single-plane balancing of both reconditioned propeller and cap on rotational balancing equipment to ensure freedom from vibration in accordance with MIL-STD-167-1 for Type II (internally excited) vibration; observe the following requirements:

3.2.5.1 Material removal. Remove material as evenly as possible from over the entire blade surface (both suction and pressure faces) but not closer to the blade edges than 10 percent of the blade width, to prevent "thin spots" when balancing the propeller.

3.2.5.2 Addition of weight. Add weight to inside the propeller cap by welding, if necessary, to balance the cap, ensuring that the added material is clear of the propeller nut, the locking key, and the end of the propeller shaft.

3.2.5.3 Restrictions. Ensure that the maximum permissible residual unbalance does not exceed the value determined by the following formulas for the speeds specified in table I below if no specific maximum permissible residual unbalance value provided by the Coast Guard Inspector.

TABLE I. Maximum permissible residual unbalance.

SPEED

(RPM)

FORMULA

Where U = Maximum allowable residual unbalance (ounce-inches) W = Weight of rotating part (pounds) N = Maximum operating speed (revolution/minute)

3.3 Propeller Installation.

3.3.1 Cleaning. For the final assembly, the propeller bore and shaft taper surfaces shall be clean and free of bluing, lubricants, dirt, foreign particles, or any other substance, which would hinder moving the propeller along the taper. Install the propeller with dry metal-to-metal contact to obtain the maximum frictional force for torque transmission. Renew the rubber O-rings and packing before reassembly.

3.3.2 Assembly. With the propeller installed on the taper in the same position as when fitted, install the propeller nut and drive up the propeller until it is advanced forward about 1/16" beyond the inscribed mark as specified in 3.2.4.3 (Location inscription). Lock the nut in place with an appropriate locking device.

NOTICE!

It is prohibited to use grease, oil, or other substances on the taper to help drive the propeller.

3.3.3 Void filling. When applicable, the Contractor shall fill all internal voids in the propeller hub and cap with rust preventive compound conforming to MIL-C-16173. Renew all brass plugs.

3.3.4 Adhere to the following warnings:

· Do not heat the propeller hub, to compensate for a poor fit on the shaft taper.

· Do not machine the shaft taper to achieve the required fit.

3.3.4.1 Lock propeller nut in place with new stainless steel lock washer or monel cap screws.

3.4 Propeller change-out. The Contractor shall be aware that the Government reserves the right to furnish a propeller to be installed in-place of the one removed at no additional cost to the Government. When the Government exercises this right the Contractor shall turn over the removed propeller shaft to the Coast Guard PA as an MTI item.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

5.1 Government-furnished property.

($/UNIT)

5.2 Propeller details. 48”dia x 43”pitch 4-blade S/S propeller.

24520L_FLT (14 Apr 2006) 75E WLR (05 Jan 2005) WORK ITEM 8: Perform Minor Repairs and Reconditioning of Propeller

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to perform minor repairs and reconditioning of a designated propeller.

2. APPLICABLE DOCUMENTS

MIL-STD-167-1, Nov 2005, Mechanical Vibrations of Shipboard Equipment (Type I - Environmental and Type II - Internally Excited) Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes American Bureau of Shipping (ABS) 2, Rule Requirements for Survey After Construction, 2006, Part 7, Appendix Section 10, Guide for Bronze and Stainless Steel Propeller Castings ASTM International (ASTM) D3951, Reapproved 2004, Standard Practice for Commercial Packaging International Standard For Organization (ISO) 484/2, 1981, Shipbuilding - Ship Screw Propeller - Manufacturing tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50m, Inclusive

3. REQUIREMENTS

3.1 Related work item. The Contractor shall accomplish the work specified herein in conjunction with "Remove, Inspect, and Reinstall Propellers", which is a separate work item in this specification package.

3.2 Requirements for repairs and reconditioning. The Contractor shall accomplish the following:

3.2.1 General requirements. Perform minor repair and reconditioning tasks on the surfaces of the designated propeller, including threaded holes, in accordance with ABS-2, Part 7, Appendix Section 10, Subsection 3 (Stainless Steel Propellers), for the conditions defined in 5.2.1 (Conditions for minor repair and reconditioning). In addition, perform straightening, welding, heat-treating, re-pitching, and stress-relieving, as necessary, to restore the propeller to a serviceable condition, as defined in section 5.2.2 (Serviceable condition). Ensure that removal and/or addition of material should be limited to the minimum necessary to accomplish the required repairs.

3.2.1.1 All propeller tolerances must conform to the Class I standard specified in ISO 484/2.

3.2.2 Balancing. Perform single-plane balancing of both reconditioned propeller and cap on rotational balancing equipment to ensure freedom from vibration in accordance with MIL-STD-167-1 for Type II (internally excited) vibration; observe the following requirements:

3.2.2.1 Material removal. Remove material as evenly as possible from over the entire blade surface (both suction and pressure faces) but not closer to the blade edges than 10 percent of the blade width, to prevent "thin spots" when balancing the propeller.

3.2.2.2 Addition of weight. Add weight to inside the propeller cap by welding, if necessary, to balance the cap, ensuring that the added material is clear of the propeller nut, the locking key, and the end of the propeller shaft.

3.2.2.3 Restrictions. Ensure that the maximum permissible residual unbalance does not exceed the value determined by the following formulas for the speeds specified in table I below if no specific maximum permissible residual unbalance value provided by the Coast Guard Inspector.

TABLE I. Maximum permissible residual unbalance.

SPEED

(RPM)

FORMULA

Where U = Maximum allowable residual unbalance (ounce-inches) W = Weight of rotating part (pounds) N = Maximum operating speed (revolution/minute)

3.3 Post repair inspections. Upon completion of required repairs and reconditioning, the Contractor shall accomplish the following inspections, and submit a CFR:

3.3.1 Measurements. Measure and record the propeller dimensional tolerances, to ensure they match the requirement provided by the Coast Guard Inspector.

3.3.2 Nondestructive testing. The Contractor shall conduct non-destructive inspection of all repaired areas, in accordance with Std Spec 0740_STD, Appendix C.

3.4 Post repair care and handling. Upon completion of all repairs and inspections specified herein, the Contractor shall accomplish the following, prior to returning the propeller to the place origin:

3.4.1 Polishing. Clean and polish all surfaces of the propeller to a minimum of 63 micro-inches uniform finish.

3.4.2 Labeling. Legibly stamp the following on the propeller hub: (1) propeller's pitch and diameter, and (2) date and location of the propeller reconditioning, (3) material composition, (4) weight, and (5) shaft RPM.

3.4.3 Packaging. Preserve and package the reconditioned propeller in accordance with ASTM D3951.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

5.1 Propeller particulars. The propeller is made of stainless steel, with the following characteristics: 48”dia x 43” pitch, 4 blades.

5.2 Definitions.

5.2.1 Conditions for minor repair and reconditioning.

5.2.1.1 Minor bends. Minor bends are those near the blade tip, normally not farther from the edge than one tenth of the blade section length, or bends outside the 0.95 radius (R). Minor bend should be limited to blade sections under 1-1/4 inches thickness and with a corrected deflection to less than 15 degrees.

5.2.1.2 Minor cracks. Minor cracks are those located within 2 inches of…