87303_DD_L08R4.doc

USCGC MAKO (WPB-87303)

87 FOOT PATROL BOAT

SPECIFICATION FOR DRYDOCK REPAIRS

Developed By:

Alex Lin

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 vi List of Government-furnished Property x List of Critical Inspection Items xii Specification Feedback xiii Principal Characteristics xiv General Requirements Welding Repairs Clean and Inspect Fuel and Waste Oil Tanks (Excludes Disposal) Clean and Inspect Sewage and Grey Water Tanks Realign Main Engine/Reduction Gear Remove, Inspect, and Reinstall Propeller Shafts Repair Shaft Straighten Shaft Renew Water-Lubricated Shaft Bearings Remove, Inspect, and Reinstall Propellers Perform Minor Repair and Recondition of Propeller Renew Transducers and Preserve Transducer Hull Rings Inspect and Clean Sea Strainers Remove, Inspect, and Reinstall Rudder Assemblies Clean Sewage and Grey Water Piping Systems Preserve RHIB Wet Notch Deck and Stern Door Interior Surfaces Prepare and Prime Main Deck Surfaces Preserve Underwater Body Prepare and Prime Freeboard Renew Cathodic Protection System Inspect Transducer Fairing Routine Drydocking Provide Temporary Logistics Ultrasonic Thickness Measurements Preserve Forepeak Compartment Renew Main Diesel Engine Exhaust Piping and Concentric Rings Provide Small Boat Storage

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, May 2005, Anodes, Sacrificial Zinc Alloy (Commercially Accepted - ASTM B418)

MIL-PRF-24647, Feb 2005, Paint System, Anticorrosive And Antifouling, Ship Hull MIL-STD-167-1, Nov 2005, Mechanical Vibrations of Shipboard Equipment (Type I - Environmental and Type II - Internally Excited)

MIL-STD-1687A, Sep 1994, Thermal Spray Processes For Naval Ship Machinery Application

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

Coast Guard Maintenance and Logistics Command Atlantic (MLCA) Standard Specification 1001_STD, 2004 Edition, Temporary Hull Accesses

DRAWINGS

Coast Guard Drawing 87 WPB 085-003, Rev C, Docking Plan Coast Guard Drawing 87 WPB 085-010, Rev C, Docking Plan

Coast Guard Drawing 87 WPB 085-012, Rev-, Lifting Cradle Coast Guard Drawing 87 WPB 085-011, Rev B, Lifting Slings Coast Guard Drawing 87 WPB 161-002, Rev-, Stern Tube Details Anode Access Ports Coast Guard Drawing 87 WPB 165-001, Rev D, Transducer Details Coast Guard Drawing 87 WPB 182-001, Rev-, Main Engine and Generator Foundations

Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details

Coast Guard Drawing 87 WPB 245-002, Rev-, Propeller Details

Coast Guard Drawing 87 WPB 245-003, Rev A, Propeller Details

Coast Guard Drawing 87 WPB 256-001, Rev R, Seawater Cooling Piping Coast Guard Drawing 87 WPB 259-001, Rev C, Engine Exhaust Piping Details

Coast Guard Drawing 87 WPB 304-001, Rev B, Wireway Arrangement Coast Guard Drawing 87 WPB 423-001, Rev L, Speedlog and Depth Sounder System Coast Guard Drawing 87 WPB 561-001, Rev F, Steering System Details

Coast Guard Drawing 87 WPB 562-001, Rev-, Rudder Details

Coast Guard Drawing 87 WPB 583-001, Rev K, RHIB Deployment Structure

Coast Guard Drawing 87 WPB 593-001, Rev H, Sewage PipingDOD-STD-2187, Aug 1987, Chemical Cleaning of Salt Water Piping Systems

Coast Guard Drawing 87 WPB 634-001, Rev C, Sheets 1-2, Deck Covering and Details Coast Guard Drawing FL 6713-201, Rev B, Transducer adapter assembly NAVSEA Drawing 803-921865, Rev R, Cathodic Protection Hull Zinc Anodes

PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (Series) Jun 2006, Coatings and Color Manual Coast Guard Technical Publication (TP) 4564A, July 2006, SWBS 561, Manufacturer’s Instruction Book, Electronic Steering System

Coast Guard Technical Publication (TP) 4593C, Feb 2002, SWBS 243, Manufacturer’s Instruction Book, 87’ WPB Propulsion Shaft Seals, John Crane Type F.S.E.

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

ASTM International (ASTM), D3951, Re-approved 2004, Standard Practice for Commercial Packaging

ASTM International (ASTM) A131, 2004, Standard Specification for Structural Steel for Ships ASTM International (ASTM) D1330, 2004, Standard Specification for Rubber Sheet Gaskets

ASTM International (ASTM) E797, 2005, Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact Method Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) C6183, 1998, Cork and Rubber Composition Sheet; For Aromatic Fuel And Oil Resistant Gaskets

Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) G6032, 1999, Grease, Plug Valve, Gasoline and Oil Resistant, NATO Code Number G-363, Metric The Society for Protective Coatings (SSPC) Paint Application Specification No. 2 (SSPC-PA Guide 2), 2004, Measurement of Dry Coating Thickness with Magnetic Gages The Society for Protective Coatings (SSPC)/NACE International (NACE) Joint Surface Preparation Standard SSPC-SP 5/NACE No.1, 2000, White Metal Blast Cleaning

International Organization for Standardization (ISO) 484/2, 1981, Shipbuilding - Ship Screw Propeller - Manufacturing tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50m, Inclusive Commercial Item Description (CID) A-A-59313, Nov 2003, Thread Compound; Antiseize, Zinc Dust-Petrolatum

Bollinger Shipyard, USCG CPB Project MTU-FA 771903, 07 Feb 2000, Engine/Gearbox Plant Alignment Instructions 8V396 TE94/Flange mounted BW 255

Yokogawa Denshikiki Company, Nov 1998, Instruction Manual IM80B80T10E 10th Edition, CDOH-ELM 500 Electromagnetic Speed Log 87' CPB 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)

NSN: 5330-01-521-3559

NSN: 2040-01-521-2654

NSN: 3120-01-521-2390

NSN: 3120-01-521-2268

NSN: 5330-01-521-4855

NSN: 5340-01-521-3573

(5.5" OD x 4" ID x 11.41" (290mm) LG)

PN: F54615-02-8-0

NSN: 3120-21-914-2011

(5.5" OD x 4" ID x 7.87" (200mm) LG)

PN: F54615-02-8-1

NSN: 3120-21-914-2012

NSN: 2010-01-457-0573

NSN: 2010-01-459-0421

P/N: M78733

P/N: LS571

P/N: 87 WPB 561-001 PORT

P/N: 87 WPB 561-001 STBD

P/N: TBF113090

P/N: SKF21318CC

P/N: H75492-01

*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 Rudder Assemblies

Preserve RHIB Wet Notch Deck and Stern Door Interior Surfaces

Preserve Underwater Body

Preserve Fore Peak Compartment

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_87_WPB

(21 Mar 2005) Principal Characteristics

87' WPB Coastal Patrol Boat

PROPELLERS / SHAFT

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 shall be completed and submitted during each sequence of 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) 87WPB (25 Apr 2006) 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

ASTM International (ASTM) A131, 2004, Standard Specification for Structural Steel for Ships

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.

3.2 Structural steel replacement. The hull structure (plates, shapes, and bars) for the 87WPB class cutters is made primarily with ABS AH36 steel. If the ABS steel cannot be obtained for the hull structure, ASTM A131 Grade AH36 can be substituted.

3.3 Electronic equipment protection. The Contractor shall safeguard electronic equipment before welding to prevent damage from stray current and electromagnetic interference. Electrically isolate or disconnect ungrounded or sensitive equipment as necessary. Locate all welder ground connections as close to the work as possible.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

5.1 Electronic equipment protection. The Coast Guard Inspector shall accomplish the following prior to welding:

1. Secure wheelhouse power supply to the ODR, MCS, and RCS systems.

2. Secure engine room power supply to the GCU and CCS box.

3. Disconnect all cannon plugs to the main engine governors (ECS-UNI).

4. Remove all PIMS on MTU control systems.

5. Disconnect all power to the Bridge electronics.

6. Secure power to the battery chargers.

7. Disconnect engine room batteries.

12311A_FLT (31 Aug 2006)

87 WPB (03 July 2007) WORK ITEM 2: Clean and Inspect Fuel and Waste Oil Tanks (Excludes Disposal)

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to clean the following tanks:

(gallons)

2. APPLICABLE DOCUMENTS

Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) C6183, 1998, Cork and Rubber Composition Sheet; For Aromatic Fuel And Oil Resistant Gaskets

3. REQUIREMENTS

3.1 General. The Contractor shall accomplish the following for the designated tanks:

3.1.1 Operational test – initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of all designated tank TLI’s to demonstrate existing operational condition.

3.1.2 Cleaning requirements. Remove tank covers; clean tank interior surfaces free of all foreign materials, such as sediment or sludge, taking care not to damage the coating system (if applicable). Remove cleaning media and residues continuously during the washing process. Remove any residual wash media and wipe up residual moisture with clean cloths.

3.1.3 Tank content and waste disposal. Dispose of residual tank contents and all cleaning fluids in compliance with all applicable Federal, state, and local laws, ordinances and regulations. Document a complete chain of custody record of the removed tank contents and generated wastes, from the vessel to the point of final destination or delivery. Submit document to the COR upon completion of work.

3.1.4 Inspection. Visually inspect all tank interior surfaces, including, but not limited to bulkheads, floor and overhead plating, structural members, manhole cover surfaces, fasteners and gasket seating surfaces. Submit a CFR including the following, as applicable:

· Tank structural condition.

· Inaccessible areas.

· Condition of tank coating, including measurements taken, percentage, location, and type of coating failure.

· Tank level indicator (TLI).

· Sounding tube and striker plate condition.

· Suction and fill piping condition.

· Fastener material and condition (correct fastener material is stainless steel).

3.2 Tank closing. The Contractor shall ensure that the tanks remain open for approximately 24 hours after completion of all authorized repair and preservation procedures. Notify the COR at least 24 hours prior to closing the tanks. After satisfactory inspection by the Coast Guard Inspector and completion of all authorized repairs, close tank manhole covers with new gasket material conforming to AMS-C-6183 and renew all stainless steel fasteners.

4. QUALITY ASSURANCE

4.1 Operational test – final. In the presence of the Coast Guard Inspector, the Contractor shall thoroughly test and prove the TLI’s to be in satisfactory operating condition (see 5.1 (Equipment operation)).

5. NOTES

5.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests.

12319A_FLT (05 July 2007)

87 WPB (18 Sep 2007) WORK ITEM 3: Clean and Inspect Sewage and Grey Water Tanks

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to clean the below designated tanks:

2. APPLICABLE DOCUMENTS

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

3. REQUIREMENTS

3.1 General.

3.1.1 Related work items. The Contractor shall accomplish this work item in conjunction with the following, which is a separate work item in this specification package:

· “Routine Drydocking.”

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

· Stateroom berthing locker

· Toilets.

· Controllers.

· Sewage pump.

· Piping.

· TLI’s

3.2 Cleaning requirements. The Contractor shall do the following for the designated tank(s) listed in paragraph 1.1:

3.2.1 Operational test – initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of all designated tank TLI’s and toilets to demonstrate existing operational condition.

3.2.2 Content removal. Remove and dispose of all contents, fluids, and/or residues in accordance with all applicable Federal, state, and local regulations.

3.2.3 Cleaning requirements. Remove manhole covers. Clean the designated structure’s interior surfaces and TLI’s free of all foreign materials, sediment, and sludge. Remove all persistent residues. Remove cleaning media and residues continuously from the tank during the washing process. Remove any residual wash media and wipe up residual moisture with clean cloths. Collect, contain, and dispose of all wash media, residues, and cleaning materials in accordance with all Federal, state, and local regulations.

3.2.4 Inspection. Visually inspect all interior surfaces; including, but not limited to bulkheads, floor and overhead plating, structural members, manhole cover surfaces, fasteners and gasket seating surfaces. Submit a CFR including the following, as applicable:

· Tank structural condition.

· Inaccessible areas.

· Condition of tank.

· Tank level indicator (TLI).

· Suction and discharge piping condition.

· Fastener material and condition (correct fastener material is stainless steel).

3.3 Closing. The Contractor shall ensure that the tanks remain open for approximately 24 hours after completion of the tasks specified above. Notify the COR at least 24 hours prior to closing the tanks. After satisfactory inspection by the Coast Guard Inspector and after authorized repairs, if any, reinstall manhole covers with new gasket material conforming to ASTM D1330. Renew stainless steel hardware.

4. QUALITY ASSURANCE

4.1 Operational test – final. In the presence of the Coast Guard Inspector, the Contractor shall thoroughly test and prove the TLI’s and toilets to be in satisfactory operating condition (see 5.1 (Equipment operation)).

5. NOTES

5.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests.

23320L_87 (20 Aug 2007)

WORK ITEM 4: Realign Main Engine/Reduction Gear

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to realign a designated main diesel engine and its corresponding reduction gear assembly to the propeller shaft.

2. APPLICABLE DOCUMENTS

Coast Guard Drawing 87 WPB 182-001, Rev-, Main Engine and Generator Foundations

Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details

Bollinger Shipyard, USCG CPB Project MTU-FA 771903, 07 Feb 2000, Engine/Gearbox Plant Alignment Instructions 8V396 TE94/Flange mounted BW 255

3. REQUIREMENTS

3.1 General. The Contractor shall use USCG CPB Project MTU-FA 771903 as a guide.

3.1.1 Related work item. The Contractor shall accomplish this work in conjunction with "Remove, Inspect, and Reinstall Propeller Shafts", which is a separate work item in this specification package.

3.1.2 Personnel qualification. The Contractor shall ensure that the shaft alignment is performed under the direct supervision of personnel experienced in and regularly engaged in shaft and engine alignment. The qualified personnel shall meet the following requirements:

· Be familiar with proprietary installation techniques, able to assist with proper bearing and shaft alignment, analyze shaft and bearing clearances, and ensure compliance with engine/reduction gear manufacturer's standards during inspection and installation of the engine and shaft system.

· Have a resume of previously demonstrated alignment experience as described within this work item.

· Be able to provide a list of references upon request to the COR.

3.2 Alignment preparation. Prior to shaft realignment, the Contractor shall ensure the following conditions are met for at least 24 hours before the alignment check:

· The vessel is waterborne with fuel and water tanks filled to normal operating levels, a minimum of three-quarters capacity.

· All major equipment and machinery weighing over 1,000 pounds (450 kilograms) are either installed or simulated by equivalent weights appropriately located.

3.3 Shaft realignment. The Contractor shall accomplish the shaft realignment using Coast Guard Drawings 87 WPB 182-001, 87 WPB 243-001, and Engine/Gearbox Plant Alignment Instructions (USCG CPB Project MTU-FA 771903) as guidance.

3.3.1 Alignment between flywheel and flexible coupling. The Contractor shall check the flywheel to flexible coupling alignment when the vessel is waterborne at least 75% of normal operational load. Use lead weights to meet at least the 75% normal load condition if the actual tank fluids are not readily available. Submit CFR.

3.3.2 Alignment adjustment. Correct any misalignment by repositioning the propulsion engines and reduction gears in accordance with USCG CPB Project MTU-FA 771903. Shim the engine foundations in place as necessary.

3.3.3 Final readings. Recheck all alignment readings, insert the bolts in the flanges, and tighten to the proper torque for the size and type.

3.3.4 Report. After taking the alignment readings, submit to the COR a written report of all the final readings within 24 hours after alignment check.

4. QUALITY ASSURANCE

4.1 Operational test. The Contractor shall demonstrate proper operation of the propeller shaft without binding during sea trials. Inspect and correct any abnormal noise and vibration generated from the shaft or bearings.

5. NOTES

This section is not applicable to this work item.

24313L_87 (25 Oct 2007)

WORK ITEM 5: 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 the port and starboard propeller shafts.

NOTICE

The Ship’s Force has noted excessive vibrations on the port and starboard (especially at 1300-1500 rpm’s and 2000-2100 rpm’s).

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), Coatings and Color Manual Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details

Coast Guard Technical Publication (TP) 4593C, Feb 2002, SWBS 243, Manufacturer’s Instruction Book, 87’ WPB Propulsion Shaft Seals, John Crane Type F.S.E.

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 paragraphs:

· 3.3 (Shaft inspections).

· 3.3.6 (forward flange inspection).

· 3.5 (Establishing baseline bearing positions).

· 3.7.4 (Stern tube inspection).

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

3.1.3 Technical representative services. The Contractor shall provide an on-site qualified technical representative (Tech Rep), who is familiar with the Warsila shaft seal system, to advise on manufacturer's proprietary information, dimensions, and clearances associated with the system, assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, and reassembly of the Wartsila shaft seal system. The Tech Rep shall be a Wartsila technical representative or its licensee.

3.1.4 Weigh Shaft Coupling. The Contractor shall weigh the shaft coupling and its hardware and clearly stamp the total weight into the body of the coupling (i.e. WT XX#).

3.1.5 Standard Forms. The Contractor shall complete and submit the measurement forms at the end of this work item as part of the required CFR/CIR’s.

3.1.6 Initial shaft coupling alignment check. The Contractor shall, prior to the vessel’s initial drydocking, perform the bore and face alignment between the reduction gear output flange and shaft coupling per paragraphs 3.10.1 and 3.10.2. Submit CFR.

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

· Deck plates.

· Deck plate framing.

3.2 Removal. The Contractor shall remove each shaft, using Coast Guard Drawing 87 WPB 243-001 as guidance.

3.2.1 Protect the shaft from damage during removal, storage, and reinstallation.

3.2.2 Ensure the shaft is properly supported at all bearing journals while being transported, inspected, and stored.

3.3 Shaft inspections. The Contractor shall clean each shaft of all surface contaminants; set up the shaft in a lathe, and accomplish the following in-shop inspections (Submit CIR).

3.3.1 Visual inspection. Visually inspect the propeller shaft, shown on Coast Guard Drawing 87 WPB 243-001, and all associated components including propeller nut, gear nut, locking fasteners, and coupling, for evidence of corrosion, pitting, surface cracks, or other defects.

3.3.2 Measurements.

· Before taking shaft runout readings, spin the shaft on a lathe for approximately two hours at 800 RPM’s to eliminate any sagging that may have occurred during handling and storage.

· Measure the shaft journal diameters and runout in way of aft and mid strut bearings, and seal assembly.

NOTICE:

The entire shaft bearing journal must be machined uniformly to the deepest pit or crack. If the wear exceeds the maximum allowable of 0.125 inch, the shaft must be shaft renewed. If there is ANY wear in the shaft bearing journal, then it must be repaired to "as-new" condition

· Check run-out of the shaft tapers and journals.

· Check the face and bore runouts on the shaft coupling.

NOTICE!

Coast Guard Drawing 87 WPB 243-001 has tolerances for new construction shafts, not used shafts.

3.3.3 Nondestructive. Perform non-destructive inspection (NDI) of the shaft taper, coupling bolts, keys and keyways at both shaft ends, in accordance with Std Spec 0740_STD, Appendix C.

3.3.4 Inspect and overhaul the split shaft seals, under the supervision and guidance of the Wartsila Tech Rep, with new government furnished seal components in accordance with the TP-4593C. Fabricate new gaskets for the seals (not provided with GFP kit). Submit CFR.

3.3.5 Fabricate and install new gaskets, of the same fit, form, and function, for the split shaft seal.

3.3.6 Inspect the forward seal flange to ensure it is square and centered with the stern tube. Measure the face and bore runout of the forward seal flange. Submit CIR.

NOTICE

Flange face runout tolerance shall not exceed 0.001”

Flange bore runout tolerance shall not exceed 0.002”

3.4 Bearing inspections. The Contractor shall accomplish the following inspections. Submit a CFR.

3.4.1 Visual. Visually inspect the following:

· Chocking material in the bearing housings.

· Bearing wear patterns.

· Bearing wear locations.

· Bearing housing bores.

· Shaft journal in way of bearings.

· Inspect shaft seal bellows.

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

3.4.3 The shaft bearing clearance shall not exceed 0.120” for 4” diameter shafts, otherwise condemn and renew the bearing.

3.5 Establishing baseline bearing positions. After removal of the propeller shaft, in the presence of the Coast Guard Inspector, the Contractor shall measure and record the vertical and horizontal positions of the stern tube, forward seal flange, and shaft bearings relative to the theoretical straight line including any offsets by running a taut line, using the optical scopes method, or using laser alignment. Use the reduction gear output flange, not the stern tube seal flange, as the forward target for the alignment inspection. The three targets shall be the reduction gear output flange, intermediate bearing, and aft bearing. Submit CIR.

NOTICE!

The optical scopes method is defined as simulating a theoretical straight line using optically precise targets that are set in holders along the shaft line and seal. The optical alignment shall also include a telescope, located at the end of the aft-most bearing, with adjustable height, horizontal position, and angular positions. The scope lines up to the centers of the targets and becomes an extension and representation of the theoretical straight line. A machined fixture fits on the reduction gear output coupling and holds an optically precise mirror with crosshairs. The crosshairs on the target are compared to the crosshairs in the scope. The optical scopes and laser alignment methods are different, yet equally acceptable methods of checking shaft alignment.

WARNING!

Running a taut line alone cannot accurately determine any shaft misalignment; therefore, DO NOT use the taut line alignment check to ascertain shaft misalignment. The taut line alignment check shall be used only to establish the baseline hull shape prior to the start of any work.

3.5.1 Perform this work at the following times:

· Within 72 hours after the shaft is removed, so that any misalignment noted can be corrected in a timely fashion.

· Late in the evening or early in the morning before sunrise to avoid the thermal effect from the sun.

3.5.2 Submit a CFR for how the shaft center reference line is established and any offsets as noted.

3.5.3 Inspect the water-lubricated bearing wear patterns and verify if the bearing wear is consistent with the taut line offset positions. Submit CFR.

3.5.4 After completion of all work and prior to reinstalling the propeller shafts, the Contractor shall perform a final theoretical straight line check. The final readings shall be compared with the baseline readings in order to ascertain if there are any changes in the hull shape. Submit CFR.

3.6 Fit check. The Contractor shall fit the shaft couplings, and check by bluing, with the key in-place. Perform all necessary coupling machining, grinding, hand-stoning, to achieve a minimum of 80 percent uniform contact, and verify by bluing again. Check for any shaft to coupling offset. Submit a CFR.

3.7 Stern tube interior surfaces preservation. The Contractor shall accomplish the following:

3.7.1 Interferences. Be aware that interferences in way of work include, but are not limited to the following:

· Stern tube mid bearing access hatch.

3.7.2 Protective measures. Blank the stern tube flange as necessary to prevent any entry of debris and dirt into the Engine Room. Take measures to protect bearings and bearing housings from sand grit or any contamination. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

3.7.3 Surface preparation and coating application. Prepare and coat the stern tube interior surfaces (from the forward end of the stern tube aft to the access hatch opening, then from the access hatch to the aft end of the stern tube), using the system specified for “Underwater Water (U/W) Body and Boot-Top (U/W Body and Boot-Top, Steel Hulls (Up to 7 Years), in Salt Water)”, in COMDTINST M10360.3, Appendix A (Cutters and Boats Exterior Coating Systems). Blank the stern tube flanges as necessary to prevent any entry of debris and dirt into the Engine Room.

3.7.4 Inspection. Visually inspect the stern tube interior surfaces, for evidence of corrosion and other defects, using a remote optical device. Inspect forward flange for correct form and fit. Submit a written report of findings to COR within 24 hours after inspection. (Submit CIR).

3.8 Reinstallation. Using Coast Guard Drawing 87 WPB 243-001 as guidance, the Contractor shall reinstall the propeller shafts to their original configurations.

NOTICE:

Ensure both the maximum allowable bearing clearance of 0.120” and maximum allowable journal wear of 0.125” are not exceeded.

3.8.1 Reinstall the propeller shafts to their original configurations.

3.8.2 Perform angular and bore alignment of the reduction gear output flange to shaft coupling flange, while the vessel is out of the water, in order to install the Wartsila shaft seal. The gap and sag readings shall meet the Wartsila Tech Rep’s satisfaction to install the shaft seal. Verify the condition of the angular and bore alignment with the vessel waterborne as specified in paragraph 3.10.

3.9 Spare shaft change-out. The Contractor shall be aware that the Government reserves the right to furnish a new propeller shaft for installation in-place of the one removed. When the Government exercises this right, the Contractor shall perform the visual inspection and measurement checks as specified in paragraphs 3.3.1 (visual) and 3.3.2 (Measurements) to the spare shaft(s); submit a CFR.

3.10 Alignment between coupling flanges. The Contractor shall check and correct reduction gear/propeller shaft alignment upon reinstallation and the final coupling of the reduction gear and propulsion shaft. These alignment checks must be done while the vessel is waterborne. Use the Government-furnished alignment kit to ensure shaft is centered on the flange in lieu of pre-loading the overhung shaft.

3.10.1 Parallel or bore alignment. Position the coupling flanges within 0.5" of each other and place a straight edge at the following points, Top/Bottom, and Outboard/Inboard. The bore or parallel misalignment shall not be greater than 0.005 inches.

3.10.2 Angular or Face Alignment. Bring the coupling flanges forward to within 0.5" face gap at all points about the diameter of the flanges. Take measurements of face gap at four equally spaced positions on the flange diameters using feeler gauge. Compare diametrically opposite face gap readings top to bottom, and inboard to outboard. Subtract the smaller of diametrically opposite readings from the larger. The resulting difference is proportional to the amount of angular or face misalignment. These readings shall not exceed 0.0005 inches per inch of companion flange outside diameter (0.004” for an 8” flange).

3.10.3 Adjust and correct any misalignment that is discovered during the alignment process.

4. QUALITY ASSURANCE

4.1 Operational test. The Contractor shall demonstrate proper operation of the propeller shaft without binding during sea trials. Inspect and correct any abnormal noise and vibration generated from the shaft or bearings.

5. NOTES

5.1 Government-furnished property.

($/UNIT)

NSN: 5330-01-521-3559

NSN: 2040-01-521-2654

NSN: 3120-01-521-2390

NSN: 3120-01-521-2268

NSN: 5330-01-521-4855

NSN: 5340-01-521-3573

Shaft Keyway and Key Measurement Form

Vessel Name and Hull Number:

CGC MAKO (WPB-87303)

Port Shaft Keyway and Key Measurements (inch)

Starboard Shaft Keyway and Key Measurements (inch)

Inspection Facility:

Inspector Signature:

Date and Time:

Shaft Journal Measurement Form

Forward Port Shaft Journal OD in Stern Tube (inch)

Forward Stbd Shaft Journal OD in Stern Tube (inch)

Aft Port Shaft Journal OD in Stern Tube (inch)

Aft Stbd Shaft Journal OD in Stern Tube (inch)

Port Shaft Runout Measurement Form

Port Shaft Runout Measurements (inch)

Shaft Location1

Aft Taper

Aft Bearing Journal 1

Aft Bearing Journal 2

Fwd Bearing Journal 1

Fwd Bearing Journal 2

Shaft Seal

Fwd Taper

1Measurements…