AXE SPECIFICATION 75310_DD_P08R2.Doc

USCGC AXE (WLIC-75310)

75 FOOT CONSTRUCTION BUOY TENDER

SPECIFICATION FOR DRYDOCK REPAIRS

Developed By:

LT Robert Mohr, PE CWO3 Bryan Wright, TDM EMC C.A. Pinaula, Spec.

MKC John Comeaux, EPO EM1 Sarah Walker, LST Ki Pak, Spec.

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 Fabricate Shaft Straighten Shaft Renew Water-Lubricated Shaft Bearings Overhaul Stern Tube Seal Assemblies Remove, Inspect, and Reinstall Propellers Perform Minor Repairs and Reconditioning of Propeller Renew Transducers and Preserve Transducer Hull Rings Remove, Inspect and Reinstall Sea Strainers and Renew Valves Inspect, and Preserve Rudder Assembly Rebuild Rudder Stock and Rudder Renew Rudder Lower Bearing Trunk Preserve Spud Well Surfaces and Renew Spud Well Liners Shrink Wrap Crane Inspect Various Deck Fittings Preserve Buoy Deck Preserve Complete Underwater Body Renew Cathodic Protection System Routine Drydocking Provide Temporary Logistics Install Ballast Weight for Vessel Trim Correction Renew Barge Sea Chests Reweld Fuel Piping Joint Renew Scuttles On Barge Repair Weld In Tender Starboard Fuel Tank Preserve Barge Main Hold Preserve Aft Barge Void Install Frame in Fwd Rake of Barge Complete Welding of Engine Room Interior Door 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, May 2005, Anodes, Sacrificial Zinc Alloy (Commercially Accepted - ASTM B418)

MIL-PRF-16173, 2006, 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

NAVSEA Standard Item 009-45, Tapered Plug Valve; repair, 14 Sep 2000

DRAWINGS

Coast Guard Drawing 68B CGB 0700-1, Rev A, Docking Plan Coast Guard Drawing 68B CGB 1101-001, Rev-, Structural Sections & Details.

Coast Guard Drawing 68B CGB 2602-1, Rev-, Spud Well and Stern Log Coast Guard Drawing 68B CGB 2602-2, Rev-, Spud Details Coast Guard Drawing 68B CGB 2602-4, Rev-, Spud Details Coast Guard Drawing 68B CGB 4823-002, Rev-, Sea Chests Coast Guard Drawing 68B CGB-0103-003, Rev-, Inboard Profile Coast Guard Drawing 75 WILC 243-002, Rev-, Shaft Alignment

Coast Guard Drawing 75 WLIC 085-011, Rev A, Docking Plan Coast Guard Drawing 75 WLIC 243-001, Rev-, Shafting Arrgt & Details

Coast Guard Drawing 75 WLIC 245-001, Rev-, Propeller Details Coast Guard Drawing 75 WLIC 261-001, Rev. A, Diagram – F.O. service Systems

Coast Guard Drawing 75 WLIC 261-002, Rev. B, ARRG’T – F.O. Service Systems

Coast Guard Drawing 75 WLIC 521-001, Rev. B, Firemain System Diagram

Coast Guard Drawing 75 WLIC 524-001, Rev. A, Arrangement Firemain

Coast Guard Drawing 75 WLIC 524-002, Rev. A, S.W. To HVAC Condenser System Arrangement

Coast Guard Drawing 75 WLIC 561-001, Rev A, Steering Gear Arrangement

Coast Guard Drawing 75 WLIC 561-001, Rev-A, Steering Gear Arrangement

Coast Guard Drawing 75 WLIC 561-004, Rev-, Flanking Rudder Gear Arrangement and Details

Coast Guard Drawing 75 WLIC 561-007, Rev A, Rudder Stock & Fittings Coast Guard Drawing 75 WLIC 561-007, Rev. A, Rudder Stock and Fittings

Coast Guard Drawing 75 WLIC 561-008, Rev. A, Flanking Rudder Stocks & fittings Details

Coast Guard Drawing 75 WLIC 633-001, Cathodic Protection Coast Guard Drawing 75D WAGL 4301-2, Rev. B, Shafting & Bearings (75309-75310) Coast Guard Drawing FL 6713-201, Rev B, CRP-V850 Transducer (B-14) Adapter Assembly Fleet Drawing FL 2602-10, Rev D, Spud Arrangements and Details NAVSEA Drawing 803-921865, Rev R, Cathodic Protection Hull Zinc Anodes

NAVSEA Drawing 804-1385781, REV E (9-26-77), Hangers, Pipe, for Surface Ships

PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Jun 2006, Coatings and Color Manual Coast Guard Technical Publication (TP) 3494, Feb 2002, Section A, Technical Manual for Type FSE Seal

INDUSTRY STANDARDS

American Bureau of Shipping (ABS) 2, Rule Requirements for Survey After Construction, 2007, Part 7, Appendix Section 10, Guide for Bronze and Stainless Steel Propeller Castings

American Society for Testing and Materials (ASTM), D1709, 10 August 2001, Standard Test Methods for Impact Resistance of Plastic Film by the Free-Falling Dart Method

American Society for Testing and Materials (ASTM), D1922 Rev A, 10 November 2000, Standard Test Method for Propagation Tear Resistance of Plastic Film and Thin Sheeting by the Pendulum Method

American Society for Testing and Materials (ASTM) D882, 2002, Standard Test Method for Tensile Properties of Thin Plastic Sheeting

American Society for Testing and Materials (ASTM) E797, 2001, Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact Method Commercial Item Description (CID) A-A-59313, Nov 2003, Thread Compound; Antiseize, Zinc Dust-Petrolatum

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS), SP-69, 2003, Pipe Hangers and Supports - Selection and Application

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS), SP-89, 2003, Pipe Hangers and Supports – Fabrication and Installation Practices

Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) G-6032, 1999, Grease, Plug Valve, Gasoline and Oil Resistant, NATO Code Number G-363, Metric

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

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 2.50 m, Inclusive 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 Raytheon V850 Color Echosounder, 2nd Edition, Mar 1993, Operation Manual The Society for Protective Coatings (SSPC) Paint Application Specification No. 2 (SSPC-PA Guide 2), 2004, Measurement of Dry Coating Thickness with Magnetic Gages 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.

WORK

ITEM

COST

($/Unit)

4-½”ID X 5-½”OD X 18”LEN

*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 Renew Water-Lubricated Shaft Bearings Remove, Inspect and Reinstall Sea Strainers and Renew Valves Inspect, and Preserve Rudder Assembly Preserve Spud Well Surfaces and Renew Spud Well Liners Routine Drydocking 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_75D_WLIC_Axe_Barge (09 Jan 2004)

75D WLIC

Principal Characteristics

75' WLIC (D Class) "Axe" Inland Construction Tender

PROPELLERS / SHAFT

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 extinguishers. The Contractor shall provide portable fire extinguishers.

NOTICE!

The Coast Guard will provide maximum of three fire watch personnel at normal working 8 hours each and no weekend.

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 and preservation.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

This section is not applicable to this work item.

24310L_FLT (12 Apr 2007) 75D WLIC (14 Feb 2007) 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 (series), Coatings and Color Manual Coast Guard Drawing 75 WLIC 243-001, Rev-, Shafting Arrgt & Details Coast Guard Drawing 75 WILC 243-002, Rev-, Shaft Alignment Coast Guard Drawing 75D WAGL 4301-2, Rev. B, Shafting & Bearings (75309-75310)

3. REQUIREMENTS

3.1 General.

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

· “Remove, Inspect and Reinstall Propellers”.

· “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:

· Rope guard.

· Fairwater.

3.1.3 Technical representative services. The Government shall provide an on-site qualified technical representative (Tech Rep), who is familiar with the Wartsila Lips 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 Lips Shaft Seal System. The Tech Rep shall be a Wartsila Lips technical representative or its licensee.

NOTICE:

Determine the timeline for all work associated with the shaft seal at the arrival conference.

3.1.3.1 The Contractor shall provide 14 days notice to the Coast Guard Inspector prior to reinstallation of shaft and seal assemblies.

3.2 Work to be accomplished. Using Coast Guard Drawing 75 WLIC 243-001, 75 WILC 243-002 and 75D WAGL 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. In the presence of the Coast Guard Inspector, the Contractor shall clean the shaft free of all marine growth, and accomplish the following inspections (Submit CFR):

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.

· Packing ring and glands.

NOTICE

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

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 key in-place, fit the shaft coupling to the shaft in shop and check the contact percentage by bluing. If the contact is less than 80%, the Contractor shall grind and hand stone the coupling hub to achieve a minimum of 80 percent contact, and verify by bluing again. Make a small inscription on the shaft to mark the coupling hub location and use it as a reference in final assembly. Measure and record 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 system specified for "U/W Body and Boot-Top, Steel Hulls (up to 7 Years), in Salt Water" in Appendix A (Cutters and Boats 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 Drawing 75 WLIC 243-001,75 WILC 243-002 and 75D WAGL 4301-2, 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.

3.3 Government-furnished shaft. The Contractor shall be aware that the Government reserves the right to furnish a spare propeller shaft to be installed in lieu of the one removed. After a Change Request has been released and authorized by the KO, the Contractor shall transport the spare shaft to a suitable inspection facility, perform the inspections specified in paragraph 3.2.2 (Inspections), and submit a CFR.

4. QUALITY ASSURANCE

4.1 Post-repair operational testing. In the presence of the Coast Guard Inspector and a Government provided Wartsila Lips technical representative or its licensee, 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

5.1 Government-furnished property.

($/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).

5.2 Wartsila-Lips seal supplier. Supplier for the Wartsila-Lips seals include, but is nor limited to the follwing:

Wartsila Lips, Inc.

3617 Koppens Way Chesapeake, VA 23323

Dir. (757)966-5420 Fax (757)558-3627 Mobile (757)537-9555

24340L_WLIC_WLR (15 Apr 5 2005) 75D WLIC/WLR (12 Jan 2004) WORK ITEM 3: Fabricate Shaft

1. SCOPE

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

2. APPLICABLE DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Drawing 75 WLIC 243-001, Rev-, Shafting Arrgt & Details Coast Guard Drawing 75 WILC 243-002, Rev-, Shaft Alignment Coast Guard Drawing 75D WAGL 4301-2, Rev. B, Shafting & Bearings (75309-75310)

3. REQUIREMENTS

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

3.2. New propeller shaft. The Contractor shall fabricate a propeller shaft, complete with associated coupling, sleeves, and keys, as shown on Coast Guard Drawing 75 WLIC 243-001, 75 WILC 243-002 and 75D WAGL 4301-2. Ensure that the new sleeves are made of hard steel nickel-chrome-boron.

4. QUALITY ASSURANCE

4.1 Inspections. The Contractor shall perform the following inspections on each new shaft assembly in the presence of the Coast Guard Inspector, and submit a CFR:

4.1.1 Visual. Complete a visual inspection for mechanical defects.

4.1.2 Measurements. Perform the following measurement inspections and compare findings to measurements shown on Coast Guard Drawing 75D:

1. Measure the bearing sleeves diameters and runouts.

2. Measure the shaft taper and shaft runout at the taper.

3. Measure all keyways and keys.

4.1.3 Non-destructive inspection. Conduct non-destructive inspection of all shaft tapers and keyways, in accordance with Standard Specification 0740_STD.

5. NOTES

This section is not applicable to this work item.

24350L_FLT (06 Mar 2006) 75D_WLIC (75309-75310) (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 75 WLIC 243-001, Rev-, Shafting Arrgt & Details Coast Guard Drawing 75 WILC 243-002, Rev-, Shaft Alignment Coast Guard Drawing 75D WAGL 4301-2, Rev. B, Shafting & Bearings (75309-75310)

3. REQUIREMENTS

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

3.2 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 Drawing 75 WLIC 243-001, 75 WILC 243-002 and 75D WAGL 4301-2, and MIL-STD-2191 as guidance and as specified herein.

3.2.1 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.

3.2.2 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).

3.2.3 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.

5. NOTES

This section is not applicable to this work item.

24400L_FLT (01 Aug 2007) 75309-75310 (07 Mar 2006) 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 the port and starboard shafts.

2. APPLICABLE DOCUMENTS

Coast Guard Drawing 75 WLIC 243-001, Rev-, Shafting Arrgt & Details Coast Guard Drawing 75 WILC 243-002, Rev-, Shaft Alignment Coast Guard Drawing 75D WAGL 4301-2, Rev. B, Shafting & Bearings (75309-75310)

3. REQUIREMENTS

3.1 General.

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

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).

3.2 Bearing renewal. The Contractor shall accomplish the following, using Coast Guard Drawing 75 WLIC 243-001, 75 WILC 243-002 and 75D WAGL 4301-2 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 the forward, middle and aft positions.

3.2.2.3 Documentation. Submit a CIR 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 Drawing 75 WLIC 243-001, 75 WILC 243-002 and 75D WAGL 4301-2 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 at forward and aft ends of the bearing: a total of 8 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.

5. NOTES

5.1 Government-furnished property.

($/UNIT)

4-½”ID X 5-½”OD X 18”LEN

*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).

24360L_AXE (27October 2007) WORK ITEM 6: Overhaul Stern Tube Seal Assemblies

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to overhaul the stern tube seals for the port and starboard propulsion shafts.

2. APPLICABLE DOCUMENTS

Coast Guard Drawing 75 WLIC 243-001, Rev-, Shafting Arrgt & Details Coast Guard Drawing 75 WILC 243-002, Rev-, Shaft Alignment Coast Guard Drawing 75D WAGL 4301-2, Rev. B, Shafting & Bearings (75309-75310) Coast Guard Technical Publication (TP) 3494, Feb 2002, Section A, Technical Manual for Type FSE Seal

3. REQUIREMENTS

3.1 General.

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

· “Remove and Reinstall Propeller Shafts.”

3.1.2 Technical representative services. The Government shall provide an on-site qualified technical representative (Tech Rep), who is familiar with the Wartsila Lips 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 Lips Shaft Seal System. The Tech Rep shall be a Wartsila Lips technical representative or its licensee.

NOTICE!

Determine the timeline for all work associated with the stern tube seals at the arrival conference.

3.2 Overhaul requirements. Using TP-3494 and Coast Guard Drawings 75 WLIC 243-001, 75 WILC 243-002 and 75D WAGL 4301-2 as guidance and under the supervision of the tech rep, the Contractor shall overhaul the port and starboard stern tube seal assemblies with the following Government-furnished seal overhaul components (see 5.1 (Government-furnished property)).

3.3 Port seal bladder assembly. The Contractor shall renew the port seal bladder assemble using Government-furnished bladder components (see 5.1 (Government-furnished property)).

3.4 Stern tube split seal renewal change-out. The Contractor shall be aware that the Government reserves the right to furnish a new stern tube split seal for installation in-place of the one removed. When the Government exercises this right, the Contractor shall turn over the removed stern tube split seals to the Coast Guard Property Administrator as a MTI item.

WARNING!

Do not rotate shaft while testing inflatable seal!

3.5 Tests. Under the Tech Rep’s supervision, the Contractor shall perform testing of the seals in accordance with chapter 8 of TP-3494.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

5.1 Government-furnished property.

($/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).

24500L_FLT (20 June 2007) 75D WLIC (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, 2006, Corrosive Preventive Compound, Solvent Cutback, Cold Application Coast Guard Drawing 75 WLIC 245-001, Rev-, Propeller Details 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, as necessary.

· 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 Coast Guard Drawing 75 WLIC 245-001 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, Class I. Submit a written CFR.

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, if applicable.

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.

3.3.4 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. When the Government exercises this right, the Contractor shall turn over the removed propeller to the Coast Guard PA as a MTI item. If a Change Request has been authorized and released by the KO, the Contractor shall inspect the Government-furnished propeller, and submit a CFR including any additional work that may be required to install the new propeller to the existing shaft.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

5.1 Government-furnished property.

($/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).

5.2 Propeller details. 48” dia x 40”pitch 4-blade Nickel Aluminum Bronze propellers.

24520L_FLT (20 Jun 2007) 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, 2007, 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 1 (Bronze Propellers), for the conditions defined in 5.2.1 (Conditions for minor repair and reconditioning).