SPEC FOR OSAGE 65505 REV0 DRYDOCK.doc

USCGC OSAGE (WLR-65505)

65 FOOT “B” CLASS RIVER BUOY TENDER AND 100 FOOT BARGE

SPECIFICATION FOR DRYDOCK REPAIRS

Developed By:

Dale Douglas

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 ix List of Critical Inspection Items x Specification Feedback xi Principal Characteristics xii General Requirements Welding Repairs Remove, Inspect, and Reinstall Propeller Shafts Install Shaft Covering Straighten Shaft Renew Water-Lubricated Shaft Bearings Renew Propeller Shaft Sleeve(s) Remove, Inspect, Modify Pitch, and Reinstall Propellers Perform Minor Repairs and Reconditioning of Propeller Clean, Inspect, and Test Grid Coolers Remove, Inspect, and Reinstall Rudder Assemblies Rebuild Rudder Stock Preserve Spud and Spud Well Surfaces Protect Aton Crane, Boat Davits, and Deck Machinery Preserve Barge Buoy Deck Preserve Underwater Body of Tender and Barge Routine Drydocking Provide Temporary Logistics Renew Doors Inspect and Overhaul Strainers Preserve Barge Bulkhead and Bilge Surfaces

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

MIL-G-23549C(I1), Rev C, Amend 1, 30 Apr 1997, Grease, General Purpose MIL-PRF-16173, 2006, Corrosive Preventive Compound, Solvent Cutback, Cold Application

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

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 MIL-STD-2199, Oct 1993, Glass Reinforced Plastic Coverings for Propeller 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

Code of Federal Regulations (CFR) Title 29, Part 1915, Jul 2006, Occupational Safety and Health Standards for Shipyard Employment

Code of Federal Regulations (CFR) Title 29, Part 1926, Jul 2006, Safety and Health Regulations for Construction

Code of Federal Regulations (CFR) Title 40, Jul 2006, Chapter I, Environmental Protection Agency

DRAWINGS

Coast Guard Drawing 100B CGB 0700-3, Rev -, Docking Block Arrangement Coast Guard Drawing 100B CGB 4103-1, Rev 3, Engine Cooling System Coast Guard Drawing 65 WD 0700-4, Rev -, Docking Block Arrangement Coast Guard Drawing 65B WD 0700-1, Rev -, Docking Plan

Coast Guard Drawing 65B WD 2200-1, 19 Apr 1962, Rudder & Steering Details Coast Guard Drawing 65B WD 2602-1, Rev D, Spud and Spud Well Coast Guard Drawing 65B WD 4103-2, Rev -, Engine Cooling System Coast Guard Drawing 65B WD 4302-1, Rev C, Propeller Shaft & Details

Coast Guard Drawing 65B WD 4302-3, Rev 3, Propeller Shaft Coast Guard Drawing 65B WD 4400-2, Rev A, 48" x 46" Pitch, 5 Bladed Propeller

Coast Guard Fleet Drawing FL 2602-10, Rev D, Spud Arrangements and Details NAVSEA Drawing 803-2145807, Rev C, Propulsion Shafting And Components

PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 Jun 2006, Coatings and Color Manual Commercial Item Description (CID) A-A-52624, Sep 2001, Antifreeze, Multi Engine Type, Ethylene Glycol (For Caterpillar equipment applications, use CAT Extended Life Pre-Mix coolant.)

Fernstrum Gridcooler Installation and Maintenance Manual, 2006, Form 165

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

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

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

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

ASTM International (ASTM) D3951, Reapproved 2004, Standard Practice for Commercial Packaging

ASTM International (ASTM) D882, 2002, Standard Test Method for Tensile Properties of Thin Plastic Sheeting ASTM International (ASTM) E797, 2005, Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact Method 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 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)/NACE International, 2004, Joint Surface Preparation Standard SSPC-SP 10/NACE 2, Near-White Blast Cleaning 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)

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

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

Clean, Inspect, and Test Grid Coolers

Remove, Inspect, and Reinstall Rudder Assemblies

Preserve Spud and Spud Well Surfaces 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_65B_WLR_Osage_Barge (09 Jan 2004)

65B WLR

Principal Characteristics

65' WLR (B Class)"Osage" Small Buoy River Tender

PROPELLERS / SHAFT

CG BARGE

00000_PWB_FLT (08 Apr 2008) 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), 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.

3.4 Term substitution – COTR for COR. The Contractor shall be aware that the term “COR” (Contracting Officer’s Representative) has been discontinued in favor of “COTR” (Contracting Officer’s Technical Representative); consequently, whenever “COR” is encountered in this specification package, including referenced standard specifications and other referenced documents, it shall refer to “COTR”, explicitly.

3.5 Small boat storage particulars. The Contractor shall provide a suitable pierside storage cradle, for safely storing the 2 small boats.

3.5.1 Cradle design. Ensure that the cradle meets the following criteria:

· Be capable of safely supporting a boat weighing approximately 5100 pounds.

· Support the boat at the following locations:

· Along the full length of the flat portion of the keel.

· Forward and aft, in the locations similar to those provided by the shipboard davit cradle.

· Have the portions of the cradle directly contacting the hull or keel of the boat made from a homogeneous soft wood, such as Yellow Pine or Douglas Fir.

3.5.2 Boat protective cover. Provide a watertight cover with raised wooden spreaders, to protect the small boat from nature, during the storage period.

3.5.3 Boat accessibility. Ensure the storage is located in the vicinity of the vessel, and is unrestricted, to allow for ship's force to complete maintenance.

3.6 Report submission time. The Contractor shall submit critical inspection report (CIR) and condition found report (CFR), when required in particular work items, within 24 hours after completing the inspection and as follows:

3.6.1 CIR and CFR. If the tender and barge are drydocked at separate times, submit CIR within the first 25 percent and CFR within the first 40 percent of the duration that the tender/barge is in drydock versus the availability contract period as specified in paragraph 3.6.2.1 of Std Spec 0000_STD. See example in table I.

Table I. Using a 40 Day Availability Contract Period, CIR and CFR are Due Within the Specified Number of Days.

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 preservation and interference removal.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

This section is not applicable to this work item.

24310L_FLT (12 Apr 2007) 65B WLR (26 Oct 2007) D(25 Apr 2008) 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 the propeller shafts.

2. APPLICABLE DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA) Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Commandant Instruction (COMDTINST) M10360.3 (Series), Coatings and Color Manual Coast Guard Drawing 65B WD 4302-1, Rev C, Propeller Shaft & Details Coast Guard Drawing 65B WD 4302-3, Rev 3, Propeller Shaft

3. REQUIREMENTS

3.1 General.

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

· 3.2.2 (Inspections).

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

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

· Rope guards.

· Fairwaters.

· Shaft tachs.

· Deck plates.

· Shaft guards.

3.1.4 Initial shaft coupling alignment check. The Contractor shall, prior to the vessel’s initial drydocking, perform the bore and face alignment check between the reduction gear output flange and shaft coupling per paragraph 3.3. Submit CFR.

3.2 Work to be accomplished. Using Coast Guard Drawings 65B WD 4302-1 and 65B WD 4302-3 as guidance, as applicable, the Contractor shall accomplish the following for each propeller shaft:

3.2.1 Removals.

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

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

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

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

· Shaft surfaces.

· Bearing surfaces (sleeves and shaft at roller bearing).

· All shaft associated fasteners.

· Coupling.

· Stern tube/shaft sealing systems.

· Packing rings and glands.

3.2.2.2 Accomplish the following measurements and record data on the forms at the end of this work item:

· Measure shaft keyways and keys.

· Measure all shaft sleeve diameters and shaft journal diameter at the roller bearing.

· Measure shaft runouts at a minimum of 5 locations along the shaft (at shaft tapers, roller bearing, and shaft sleeves). 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.

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

3.2.2.3 Perform nondestructive inspection of all shaft sleeves, shaft tapered areas, shaft at roller bearing, shaft keyways, and shaft welded repair surfaces, in accordance with Std Spec 0740_STD, Appendix C.

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

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

3.2.3.2 Submit a CFR.

3.2.4 Reinstallation. Using Coast Guard Drawings 65B WD 4302-1 and 65B WD 4302-3, as applicable, reinstall the propeller shaft and shaft coupling to its original configuration.

3.2.4.1 Fit the shaft coupling on the shaft and check the contact area by bluing. If the contact is less than 80 percent, the Contractor shall grind and hand stone the shaft coupling tapered surface to achieve a minimum of 80 percent contact, and verify by bluing again. True shaft coupling to shaft.

3.2.5.2 Connect the propeller shaft and reduction gear couplings; by installing the coupling bolts and nuts in their respective holes.

3.2.4.3 Renew all packing gland fasteners.

3.2.4.4 Renew all packing materials.

3.3 Alignment between coupling flanges. The Contractor shall check the port and starboard propeller shaft/reduction gear alignment after the tender is waterborne for at least 24 hours at full load. Submit CFR with the final alignment results.

3.3.1 Parallel or bore alignment. Position the coupling flanges within 0.5" of each other and place a straight edge at the top, bottom, outboard, and inboard points. The bore or parallel misalignment shall not be greater than 0.005 inches.

3.3.2 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 a 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.

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

3.4 Propeller shaft change-out. The Contractor shall be aware that the Government reserves the right to furnish a shaft to be installed in-place of the one removed. When the Government exercises this right, the Contractor shall turn over the removed shaft 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 shaft, and submit a CFR which includes any additional work that may be required to install the new shaft.

4. QUALITY ASSURANCE

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

5. NOTES

5.1 Government-furnished property.

($/UNIT)

5.2 Measurement data forms. Measurement data forms are provided at the end of this work item.

Shaft Keyway and Key Measurement Form

Vessel Name and Hull Number:

CGC OSAGE (WLR-65505)

Work Item Title:

Remove, Inspect, and Reinstall Propeller Shafts

Port Shaft Keyway and Key Measurements (inch)

Starboard Shaft Keyway and Key Measurements (inch)

Inspection Facility:

Inspector Signature:

Date and Time:

Shaft Sleeve and Shaft Journal Measurement Form

CGC OSAGE (WLR-65505)

Port Shaft Sleeve Outside Diameter (inch)

Stbd Shaft Sleeve Outside Diameter (inch)

Port Shaft Journal OD at Roller Bearing (inch)

Stbd Shaft Journal OD at Roller Bearing (inch)

Port Shaft Runout Measurement Form

CGC OSAGE (WLR-65505)

Port Shaft Runout Measurements (inch)

Shaft Location

Aft Taper2

Strut sleeve3

Stern tube sleeve3

Bhd No 28 sleeve3

Fwd Taper4

1Measurements are to be taken at a minimum of 5 locations along the shaft.

2At adjacent land area just forward of 11” shaft taper (See CG Drwg 65B WD 4302-3).

3See CG Drwg 65B WD 4302-1.

4At adjacent land area just aft of 7-1/2” shaft taper (See CG Drwg 65B WD 4302-3).

Starboard Shaft Runout Measurement Form

CGC OSAGE (WLR-65505)

Starboard Shaft Runout Measurements (inch)

Shaft Location

Aft Taper2

Strut sleeve3

Stern tube sleeve3

Bhd No 28 sleeve3

Fwd Taper4

1Measurements are to be taken at a minimum of 5 locations along the shaft.

2At adjacent land area just forward of 11” shaft taper (See CG Drwg 65B WD 4302-3).

3See CG Drwg 65B WD 4302-1.

4At adjacent land area just aft of 7-1/2” shaft taper (See CG Drwg 65B WD 4302-3).

24340L_FLT (04 Nov 2006)

DOD(25 Apr 2008)

WORK ITEM 3: Install Shaft Covering

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to install a fiberglass reinforced plastic (FRP) covering for a designated propeller shaft.

2. APPLICABLE DOCUMENTS

MIL-STD-2199, Oct 1993, Glass Reinforced Plastic Coverings for Propeller Shafting

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (Series), Coatings and Color Manual The Society for Protective Coatings (SSPC)/NACE International, 2004, Joint Surface Preparation Standard SSPC-SP 10/NACE 2, Near-White Blast Cleaning

3. REQUIREMENTS

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

3.2 Installation procedures. The Contractor shall perform the FRP covering installation in accordance with MIL-STD-2199, and as specified herein:

3.2.1 Surface preparation. Abrasive-blast the bare shaft surfaces to a “Near-White Blast” standard, in accordance with SSPC SP-10/NACE No. 2, and obtain a surface anchor profile of 3.0-4.5 mils.

3.2.2 Shaft surface inspection. Perform a visual inspection of the cleaned shaft surfaces for signs of corrosion, wear, and other defects; submit a CFR.

3.2.3 New covering installation. Before the cleaned shaft surfaces begin to flash-rust, accomplish the following:

· Prepare resin in accordance with manufacturer’s recommendations, and apply a coat to the cleaned shaft surfaces, not to exceed a total of 60 mils thickness.

· Apply a ply of glass tape wound spirally onto the coated surfaces, butting the edges.

· Repeat the resin and glass tape applications, reversing the direction of the spiral wrap for each subsequent application, until a four-ply covering has been formed.

· Ensure that all entrapped air is worked out, and the glass tape is wet-out properly, during each ply installation.

3.2.4 Covering inspection. Conduct a high voltage spark test of the covering, after it has hardened, at 250 to 300 volts per mil of glass reinforcement (approximately 15,000 volts for a four-ply covering), paying particular attention to the joining line between sleeves and shaft. Pinholes are evidenced by bright sparks. Submit a CFR.

3.2.5 Preservation of covering. Upon completion of covering inspection, and after all repairs, if any, prepare and coat the FRP covering, using the system specified for “Underwater Water (U/W) Body and Boot-Top (U/W Body and Boot-Top, Steel Hulls, in Fresh Water)”, in COMDTINST M10360.3, Appendix A (Cutters and Boats Exterior Coating System).

4. QUALITY ASSURANCE

4.1 Quality control. The Contractor shall observe the quality control procedure specified in paragraph 5.5 (Quality control) of MIL-STD-2199.

5. NOTES

This section is not applicable to this work item.

24350L_FLT (06 Mar 2006) 65B WLR (23 Jan 2004) D(14 Feb 2008) 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 65B WD 4302-1, Rev C, Propeller Shaft & Details

3. REQUIREMENTS

3.1 Shaft straightening requirements. Based on the inspection results obtained from "Remove, Inspect, and Reinstall Propeller Shafts" which is a separate work item in this specification package, the Contractor shall straighten the designated shaft, using Coast Guard Drawing 65B WD 4302-1, and MIL-STD-2191 as guidance and as specified herein.

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

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

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

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

NOTICE!

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

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

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

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

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

· Conduct nondestructive 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) 65B WLR (25 May 2004) WORK ITEM 5: Renew Water-Lubricated Shaft Bearings

1. SCOPE

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

2. APPLICABLE DOCUMENTS

Coast Guard Drawing 65B WD 4302-1, Rev C, Propeller Shaft & Details

3. REQUIREMENTS

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

3.2 Bearing renewal. The Contractor shall accomplish the following, using Coast Guard Drawing 65B WD 4302-1 as guidance:

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

3.2.2 Inspections.

3.2.2.1 Visual. Visually inspect the following:

· Chocking material, if installed in the bearing housings.

· Bearings.

· Bearing housing bores.

· Shaft journal in way of bearings.

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

3.2.2.3 Documentation. Submit a CFR after the visual inspections and measurements.

3.2.3 New bearing installation. The Contractor shall furnish water-lubricated bearings, and accomplish the following, using Coast Guard Drawing 65B WD 4302-1 as guidance:

3.2.3.1 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 scope 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:

Diameter of Journal (inches) Minimum operating Clearance of new water-lubricated Bearings (inches)

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

This section is not applicable to this work item.

24420L_FLT (15 Dec 2006) 65B WLR (10 Feb 2006)

D(16 Feb 2008) WORK ITEM 6: Renew Propeller Shaft Sleeve(s)

1. SCOPE

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

2. APPLICABLE DOCUMENTS

Coast Guard Maintenance and Logistics Command Atlantic (MLCA) Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Drawing 65B WD 4302-1, Rev C, Propeller Shaft & Details Coast Guard Drawing 65B WD 4302-3, Rev 3, Propeller Shaft NAVSEA Drawing 803-2145807, Rev C, Propulsion Shafting And Components

3. REQUIREMENTS

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

3.2 Sleeve renewal requirements. Using Coast Guard Drawings 65B WD 4302-1 and 65B WD 4302-3 as guidance, the Contractor shall accomplish the following, for the port and starboard propeller shafts:

3.2.1 Removal. Remove and dispose of the sleeve.

3.2.2 Inspections. Clean all shaft journal surfaces in the way of the sleeve, and accomplish the following:

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

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

· Forward.

· Middle.

· Aft.

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

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

3.2.4 New sleeve installation requirements. After the Coast Guard Inspector has reviewed all measurements, the Contractor shall renew the designated shaft sleeve and accomplish the following:

3.2.4.1 Machine/cut each sleeve to the required length.

3.2.4.2 Bore new sleeve ID to the dimensions based on the recorded journal outside diameter readings to facilitate an interference fit, as specified below.

3.2.4.3 Install the new sleeve onto the shaft with a shrink-fit equal to 0.00075-inch per inch of shaft diameter, in accordance with NAVSEA DRAWING 803-2145807, Table 8-1 (Shaft Sleeve Shrink Fit).

3.2.4.4 After installation, machine the sleeve OD based on the shaft bearing ID readings, including the required bearing clearance.

3.2.4.5 The strut and stern tube sleeve shall be “hard coated steel”. The sleeve shall be mild steel coated with a minimum thickness of 0.050” of nickel-chrome-boron composite material.

3.2.4.6 The sleeve at bulkhead 28 shall be bronze.

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

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

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

4. QUALITY ASSURANCE

4.1 No additional requirements.

5. NOTES

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

National Maintenance and Repair Hartford, Illinois Phone: (618) 254-7451 Dover Corp/Dover Diversified/Waukesha Bearings Corporation Waukesha, Wisconsin Phone: (414) 547-3381 24500L_FLT (20 June 2007) 65B WLR (24 July 2006) DOD (25 Apr 2008) WORK ITEM 7: Remove, Inspect, Modify Pitch, and Reinstall Propellers

1. SCOPE

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

2. APPLICABLE DOCUMENTS

MIL-PRF-16173, 2006, Corrosive Preventive Compound, Solvent Cutback, Cold Application Coast Guard Drawing 65B WD 4400-2, Rev A, 48" x 46" Pitch, 5 Bladed Propeller 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 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.

· 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 65B WD 4400-2 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 CFR.

3.2.3 Pitch reduction. Modify the pitch by reducing it at least two inches and no more than three inches. Reinspect 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 CFR.

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

3.2.5 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.

3.2.5.1 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.

3.2.5.2 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.

3.2.5.3 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.

3.3 Propeller Installation.

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

3.3.2 Assembly. With the propeller installed on the taper in the same position as when fitted, install the propeller nut and drive up the propeller until it is advanced forward about 1/16" beyond the inscribed mark as specified in 3.2.5.3 (Location inscription). Lock the nut in place with an appropriate locking device.

NOTICE!

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

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

3.3.4 Adhere to the following warnings:

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

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

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

3.4 Propeller change-out. The Contractor shall be aware that the Government reserves the right to furnish a propeller to be installed in-place of the one removed. 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)

5.2 The propeller is NiAlBr with 5 blades with a 48" dia. x 46" pitch.

24520L_FLT (20 Jun 2007) 65B WLR (14 Dec 2006) 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 Coast Guard Drawing 65B WD 4400-2, Rev A, 48" x 46" Pitch, 5 Bladed Propeller 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, Modify Pitch, 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 5.1.1 (Conditions for minor repair and reconditioning).