65602_DD_K08R1.doc

USCGC CHOCK (WYTL-65602)

65 FOOT A CLASS HARBOR TUG

SPECIFICATION FOR DRYDOCK REPAIRS

Developed By:

Keith Schott LT

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

TABLE OF CONTENTS

Work Item Title Page ivList of Sketches

List of Sketches iv Revisions Record v List of Applicable References vi List of Government-furnished Property xi List of Critical Inspection Items xii Specification Feedback xiii Principal Characteristics xiv General Requirements Welding Repairs Clean and Inspect Sewage and Grey Water Collection and Holding Tanks Renew Propeller Shaft Remove, Inspect, and Reinstall Propeller Perform Minor Repairs and Reconditioning of Propeller Clean, Inspect, and Test Grid Coolers Remove Transducer and Preserve Transducer Hull Ring Renew Valves Remove, Inspect, and Reinstall Rudder Assembly Inspect Various Deck Fittings Preserve and Disinfect Potable Water Tanks Prepare and Coat Main Deck Surfaces Preserve Underwater Body Preserve Freeboard Perform Boat Davit Maintenance Renew Cathodic Protection System Routine Drydocking Provide Temporary Logistics Clean Exhaust Piping Reseal One-Step Deck Covering Systems Renew Fire and Smoke Detection System Renew Bulkhead Sheathing Engine Room Renew Sewage Piping Ultrasonic Thickness Measurements – Underwater Body Ultrasonic Thickness Measurements – Freeboard

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-D-16791, Jan 1993, Detergents, General Purpose (Liquid, Nonionic)

MIL-D-3134, Sep 1989, Deck Covering Materials

MIL-PRF-16173, 2006, Corrosive Preventive Compound, Solvent Cutback, Cold Application

MIL-PRF-24613, Dec 1990, Deck Covering Materials, Interior, Cosmetic Polymeric MIL-PRF-24647, Feb 2005, Paint System, Anticorrosive And Antifouling, Ship Hull MIL-PRF-24647B(1), Paint System, Anti-Corrosive and antifouling, Ship Hull, Rev B, Amend 1, 9 Aug 94

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

MIL-STD-2035A, May 1995, Nondestructive Testing Acceptance Criteria, Section 4, Visual Inspection, Section 6, Magnetic Particle Inspection, Section 7, Liquid Penetrant Inspection, and Section 9, Eddy Current Inspection

OTHER GOVERNMENT DOCUMENTS, DRAWINGS, AND PUBLICATIONS

DOCUMENTS

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

Coast Guard Drawing 65 WTL 4808-4, Rev B, Type C Secondary Drain SYS ALT (A, B, C, & D Class) Coast Guard Drawing 65 WYT 0103-3, Rev-, Booklet of General Plans, (65601-65602) Coast Guard Drawing 65 WYT 0700-2, Rev A, Docking Plan

Coast Guard Drawing 65 WYT 1101-1, Rev -, Superstructure Plan and Details

Coast Guard Drawing 65 WYT 2200-001, Rev-, Rudder Drawing Coast Guard Drawing 65 WYT 4000-1, Rev -, Machinery Arrangement

Coast Guard Drawing 65 WYT 4103-003, Rev -, Exhaust Piping

Coast Guard Drawing 65 WYT 4103-006, Rev -, General Cooling Piping arrangement D/G Replacement (Tackle 65604)

Coast Guard Drawing 65 WYT 4103-007, Rev-, Generator Diesel Exhaust System Replacement (Tackle 65604)

Coast Guard Drawing 65 WYT 4301-001, Rev H, Shafting Plan

Coast Guard Drawing 65 WYT 4301-002, Rev -, Shafting Plan Coast Guard Drawing 65 WYT 4400-003, Rev B, Propeller

Coast Guard Drawing 65 WYT 9300-003, Rev-, Fire Alarm/Detection System Mods

Coast Guard Drawing 65 WYT-1901-1, Rev -, Painting Insulation Sheath and Deck Covering Schedule

Coast Guard Drawing 65 WYT 4103-001, Rev -, Engine Cooling System

Coast Guard Drawing FL 6713-203, Rev B, CRP-V850 Transducer (SS505) Adapter Assembly

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 1001_STD, 2004 Edition, Temporary Hull Accesses

Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 5000_STD, 2004 Edition, Auxiliary Machinery Systems

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

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

DRAWINGS

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

PUBLICATIONS

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

Coast Guard Technical Publication (TP) 3957, July 2005, Fire Alarm Control Panel

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 National Standards Institute/NSF International (ANSI/NSF) 61, 2005, Drinking Water System Components - Health Effects

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM), F722-82, Standard Specification for Welded Joints for Shipboard Piping Systems (Reapproved 1993)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) F1076-87, Standard Practice for Expanded Welded and Silver Brazed Socket Joints for Pipe and Tube (Reapproved 1997)

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

American Water Works Association (AWWA) C652, 2002, Disinfection of Water-Storage Facilities

American Welding Society (AWS), Welding Inspection, Second Edition, 1980

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

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

ASTM International (ASTM) E797, 2005, Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse-Echo Contact Method ASTM International (ASTM) F992, 2006, Standard Specification for Valve Label Plates International Organization for Standardization (ISO) 484/2, 1981, Shipbuilding - Ship Screw Propeller - Manufacturing tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50m, Inclusive

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

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

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

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

The Society for Protective Coatings (SSPC) Paint Application Specification No. 2 (SSPC-PA Guide 2), 2004, Measurement of Dry Coating Thickness with Magnetic Gages Steel Structures Painting Council (SSPC), Surface Preparation Specification No.3 (SSPC-SP 3), Power Tool Cleaning, 01 JUL 1995

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

Commercial Item Description (CID) A-A-59313, Nov 2003, Thread Compound; Antiseize, Zinc Dust-Petrolatum

Raytheon V850 Color Echosounder, 2nd Edition, Mar 1993, Operation Manual Fernstrum Gridcooler Installation and Maintenance Manual, 2006, Form 165 List of Government-furnished Property

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

($/Unit)

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

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

***Government-furnished property, which is to be supplied by either the vessel, Electronic Systems Support Unit (ESU) or local Electronic Support Detachment (ESD).

List of Critical Inspection Items

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see Std Spec 0000_STD, paragraph 3.6.2 (Inspection report particulars)):

Work Item Title Clean, Inspect, and Test Grid Coolers

Remove, Inspect, and Reinstall Rudder Assembly Preserve Underwater Body Perform Boat Davit Maintenance

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_65A_WYTL

(18 Mar 2005) Principal Characteristics

65' WYTL (A Class) Small Harbor Tug

mast lowered

PROPELLERS / SHAFT

00000N_FLT (20 Apr 2007)

General Requirements

1. SCOPE

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

2. APPLICABLE DOCUMENTS

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

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

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

3. REQUIREMENTS

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

NOTICE!

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

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

3.3 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and nondestructive inspection (NDI), in accordance with Std Spec 0740_STD.

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

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

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

QA-1: QUALITY ASSURANCE INSPECTION FORM - PRESERVATION CHECKLIST

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

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

CHECKPOINT 2 - PAINT STORAGE

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

CHECKPOINT 3 - AMBIENT CONDITIONS

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

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

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

CHECKPOINT 4 - PRE-SURFACE PREPARATION

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

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

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

Verify surface anchor profile (1.5-3.5 mils for abrasive-blasted steel surfaces; 1.0 mil (minimum) for power-tool cleaned surfaces; 1.0-1.5 mils for abrasive-blasted aluminum surfaces); and 1.5 –2.5 for surfaces to be coated w/single coat of inorganic zinc).

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

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

Ensure surfaces are completely dry, unless otherwise allowed by the Coating Manufacturer(s).

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

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

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

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

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

CHECKPOINT 9 – FINAL INSPECTION

Verify final system dry film thickness.

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

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

CHECKPOINT 10 – RECORD KEEPING

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

Signature of Inspector:______________________________________________________Date:____________

QA-2. QUALITY ASSURANCE INSPECTION FORM

ENVIRONMENTAL READINGS

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

.Signature of Inspector:__________________________________________________Date:____________

QA-3 QUALITY ASSURANCE INSPECTION FORM

SURFACE PROFILE LOG

Vessel Name And Hull Number:__________________________________________________

Work Item Title:_______________________________________________________________

Location Of Work (Including Frame Numbers):_____________________________________

Area (Square Feet):_____________

Surface Preparation Method:_____________________________________________________

Abrasive Manufacturer And Size:_________________________________________________

Degreasing Method Used:________________________________________________________

Number Of Hours Surfaces (Steel Only) Left Unpainted:______________________________

Sweep blasting performed to remove flash rusting (steel)? Yes/No:_____________________

Place Surface Profile Replica Tapes In The Spaces Provided Below, To Serve As Permanent QA record.

Maintain separate log for each area/location. When an Area Is Divided Into Separate Sections, Maintain A Separate Log for Each Section.

AVERAGE MILS

(IAW ASTM D4417, METHOD C)

Place Surface Profile Replica Tape Here

Reading:__________ mils

· Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Date and Time:__________________________________________________

Location of Surface Profile Measurements:___________________________________________________________

Signature of Inspector:____________________________________________________________________________

QA-4. QUALITY ASSURANCE INSPECTION FORM

SURFACE SOLUBLE SALT CONDUCTIVITY LOG

Vessel Name and Hull Number:__________________________________________________

Work Item Title:_______________________________________________________________ Location of Work (including frame numbers):_______________________________________

Area (square feet):____________

(microsiemens/cm)

Date and Time:_________________________________________

Signature of Inspector:___________________________________

QA-5. QUALITY ASSURANCE DATA FORM

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

(Use one sheet for each sequence)

Vessel Name and Hull Number:__________________________________________________

Work Item Title:______________________________________________________________

Coating Manufacturer:_________________________________________________________

Product Name:________________________________________________________________

Batch Number:________________________________________________________________

Induction Time:_______________________________________________________________

Coating System Sequence (Indicate whether: primer, touch-up primer, barrier coat, 3rd coat…):__________________

DFT

MEASUREMENT NUMBER

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

Average DFT: __________________________________________________________

Date and Time: _________________________________________________________

Signature of Inspector: ___________________________________ 07400D_FLT (25 Apr 2006) FLT (05 Jan 2004) WORK ITEM 1: Welding Repairs

1. SCOPE

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

2. APPLICABLE DOCUMENTS

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

3. REQUIREMENTS

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

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

This section is not applicable to this work item.

12319A_FLT (09 Nov 2007)

65AWYTL (12 Dec 2003) WORK ITEM 2: Clean and Inspect Sewage and Grey Water Collection and Holding Tanks

1.1 Scope. This work item describes the requirements for the Contractor to clean the below designated tank(s):

2. APPLICABLE DOCUMENTS

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

3. REQUIREMENTS

3.1 General.

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

· "Routine Drydocking".

· “Renew Sewage Piping”.

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

3.2.1 Operational test - initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of all designated tank TLIs to demonstrate existing operational condition. Submit a CFR.

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

3.2.3 Cleaning requirements. Remove manhole cover(s). Clean the designated structure's interior surfaces free of all foreign materials, sediment, and sludge. Remove all persistent residues, taking care not to damage the tank coating system. Remove cleaning media and residues continuously from the tank during the washing process. Remove any residual wash media and wipe up residual moisture with clean lint-free cloths. Collect, contain, and dispose of all wash media, residues, and cleaning materials in accordance with all Federal, state, and local regulations.

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

· Tank structural condition.

· Inaccessible areas.

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

· Tank level indicator (TLI) and/or float switch condition.

· Suction and discharge piping condition.

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

3.3 Closing. The Contractor shall ensure that the tanks remain open for approximately 24 hours after completion of the tasks specified above. Notify the COR at least 24 hours prior to closing the tank(s). After satisfactory inspection by the Coast Guard Inspector and after authorized repairs, if any, reinstall manhole cover(s) with new gasket material conforming to ASTM D1330. The Contractor shall clean and reseal all tank sight glasses, if applicable, prior to reinstallation.

4. QUALITY ASSURANCE

4.1 Operational test - final. In the presence of the Coast Guard Inspector, the Contractor shall thoroughly test and prove the TLIs to be in satisfactory operating condition (see 5.1 (Equipment operation)). Submit a CFR.

5. NOTES

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

24315L_65WYTL (10 Mar 2008)

WORK ITEM 3: Renew Propeller Shaft

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to renew the 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, Jun 2006, Coatings and Color Manual

Coast Guard Drawing 65 WYT 4301-002, Rev -, Shafting Plan

3. REQUIREMENTS

3.1 General.

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

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

· Fairwater.

3.1.3 Technical representative services. The Contractor shall provide an on-site qualified technical representative (Tech Rep), who is familiar with the Duramax 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 Duramax shaft seal system. The Tech Rep shall be a Duramax technical representative or its licensee.

3.2 Work to be accomplished. Using Coast Guard Drawing 65B WYT 4301-002 and 65 WYT 4301-002 as guidance, as applicable.

NOTICE:

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

3.2.1 Measurements. The Contractor shall perform the following tasks for the new Government-furnished propeller shaft:

· Check the straightness by measuring the total indicator run out of the propeller shaft.

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

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

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

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

3.2.2 Shaft Alignment. After removal of the propeller shaft, the Contractor shall check and monitor the alignment of the stern tube, struts, and bearing housing bores relative to the shaft centerline including any offsets using an optical method (bore sighting) or taut wire method. This inspection shall be done within 72 hours after the shaft is removed so that any misalignment can be corrected in a timely fashion. Take all readings at night, between midnight and dawn, to reduce the thermal distortion on the hull due to sunlight.

3.2.3 Take the initial reading and establish a baseline.

3.2.4 The shaft center reference line established by optical or piano wire method shall start from the center of reduction gear output shaft flange to a fixed point location where the propeller hub is centered.

3.2.5 Use as many reference points as possible to show if the bearing bores have been affected by the structural repair or hot work. Submit a CFR of how the shaft center reference line is established, locations of fix points, and any bearing offsets as noted.

3.2.5.1 Submit a CFR of findings, include any recommended repairs if the shaft alignment was affected by the structural repair or hot work.

3.2.6 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:

3.2.6.1 Perform a visual inspection of the prepared stern tube surfaces. Submit a CFR.

3.2.7 Removal. The Contractor shall remove the existing propeller shaft, using Coast Guard Drawing 65 WYT 4301-002 as guidance. Disposed of the removed shaft in accordance with all Federal, State, and local regulations.

3.2.8 Reinstallation. Install the new Government-furnished propeller shaft in the existing bearing positions and accomplish the following, using Coast Guard Drawing 65B WYT 4301-002 and 65 WYT 4301-002, as applicable.

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

3.2.9 Alignment between coupling flanges. The Contractor shall check and correct reduction gear/propeller shaft alignment upon reinstallation and the final coupling of the reduction gear and propulsion shaft. These alignment checks must be done while the vessel is waterborne. Calculate the pre-load weight and support the overhung shaft/coupling to ensure an accurate gap and sag measurement.

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

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

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

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 Shaft coupling fasteners. The shaft coupling fasteners are interference fit.

24500L_FLT (20 June 2007) 65A WYTL (31 Dec 2007) WORK ITEM 4: Remove, Inspect, and Reinstall Propeller

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

2. APPLICABLE DOCUMENTS

MIL-PRF-16173, 2006, Corrosive Preventive Compound, Solvent Cutback, Cold Application Coast Guard Drawing 65 WYT 4301-001, Rev H, Shafting Plan Coast Guard Drawing 65 WYT 4400-003, Rev B, Propeller International Organization for Standardization (ISO) 484/2, 1981, Shipbuilding - Ship Screw Propeller - Manufacturing tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50m, Inclusive

3. REQUIREMENTS

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

· Before removing the 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 the propeller, using Coast Guard Drawings 65 WYT-4301-001 and 65B WYT-4400-003 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.

3.3 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.

3.3.3 Void filling. When applicable, the Contractor shall fill all internal voids in the propeller hub and cap with rust preventive compound conforming to MIL-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 Propeller details. Nickel Aluminum Bronze , 4 blades, 56" diameter x 46" pitch.

24520L_FLT (20 Jun 2007) 65614_65615 WYTL (27 Feb 2003) WORK ITEM 5: 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 65 WYT 4400-003, Rev B, Propeller ASTM International (ASTM) D3951, Reapproved 2004, Standard Practice for Commercial Packaging International Organization for Standardization (ISO) 484/2, 1981, Shipbuilding - Ship Screw Propeller - Manufacturing tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50m, Inclusive

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). In addition, perform straightening, welding, heat-treating, re-pitching, and stress-relieving, as necessary, to restore the propeller to a serviceable condition, as defined in section 5.2.2 (Serviceable condition). Ensure that removal and/or addition of material should be limited to the minimum necessary to accomplish the required repairs.

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

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

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

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

3.2.2.3 Restrictions. Ensure that the maximum permissible residual unbalance does not exceed the value determined by the following formulas for the speeds specified in table I below if no specific maximum permissible residual unbalance value specified on Coast Guard Drawing 65B WYT 4400-003.

TABLE I. Maximum permissible residual unbalance.

SPEED

(RPM)

FORMULA

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

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

3.3.1 Measurements. Measure and record the propeller dimensional tolerances, to ensure they match the requirement specified on Coast Guard Drawing 65B WYT 4400-003 and ISO 484/2, Class I.

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

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

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

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

NOTICE!

Include the label data in the CFR.

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

4. QUALITY ASSURANCE

No additional requirements.

5. NOTES

5.1 Propeller particulars. The propeller is as follows: Nickel Aluminum Bronze , 4 blades, 56" diameter x 46" pitch.

5.2 Definitions.

5.2.1 Conditions for minor repair and reconditioning.

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

5.2.1.2 Minor cracks. Minor cracks are those located within 2 inches of the blade edges and with lengths less than 2 inches. In addition, surface cracks and cracks not exceeding 1/8" in depth or 1/4 of the local thickness, which ever is less, and not greater than 2 inches in length shall be defined as minor.

5.2.1.2 Minor patches. Minor patches are those patches applied to a blade where a small portion of the blade edge is missing (not over 2 square inches) and repairs may be made entirely by added weld metal.

5.2.1.3 Minor cavitation erosion. Weld repair of cavitated or eroded areas less than 2 square inches in surface area and which are less than 1/2-inch deep.

5.2.2 Serviceable condition. Serviceable condition is defined as being capable of functioning and performing in the same manner as an identical new propeller, although it may not have the appearance of newness.

25620A_FLT (08 Aug 2007) 65 WYTL (16 Feb 2007) WORK ITEM 6: Clean, Inspect, and Test Grid Coolers

1.1 Scope. This work item describes the requirements for the Contractor to clean, inspect, and test the following grid coolers (see 5.1 (Term applicability)):

LOCATION

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, 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.)

Coast Guard Drawing 65 WYT 4103-001, Rev -, Engine Cooling System Fernstrum Gridcooler Installation and Maintenance Manual, 2006, Form 165

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:

· 3.3.2 (Inspection.).

3.1.2 Related work item. The Contractor shall accomplish this work item in conjunction with "Routine Drydocking", 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:

· Piping.

3.1.4 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination.

3.1.4.1 The Contractor shall install blanks on the open ends of piping to prevent any contamination or foreign debris from entering the affected systems. Ensure that all cleaning equipment or media used in the cleaning process do not cause any damage to cooler components.

3.1.4.2 Clean all equipment and spaces contaminated due to improper protection to original condition of cleanliness.

3.2 Environmental compliance. The Contractor shall dispose of all waste fluids in accordance with all Federal, state and local regulations. Document a complete chain of custody record of the removed tank contents and generated wastes, from the vessel to the point of final destination or delivery. Submit document to the COR upon completion of work.

3.3 Cleaning, inspection, and testing requirements. The Contractor shall accomplish the following, for each designated cooler, shown on Coast Guard Drawing 65 WYT 4103-001

3.3.1 Preparation.

· Drain and dispose of all existing cooler fluids.

· Disconnect and remove the cooler, if applicable, to a suitable repair shop.

NOTICE!

Ships force will remove and re-install the two main diesel engine thermostats.

3.3.2 Inspection. Perform a visual inspection of all surfaces/components for deterioration or other defects. Visually inspect suction and discharge piping. Submit a CFR.

3.3.3 Cleaning. Clean all cooler interior and exterior surfaces free of all debris or contaminants using industrial standard methods and in accordance with manufacturer's recommendations; or in accordance with Fernstrum Gridcooler Form 165.

3.4 Reassembly. After cleaning and any authorized repairs are complete, the Contractor shall reassemble the cooler. Renew the following components, as applicable, in accordance with cooler manufacturer's recommendations:

· Fasteners (shall be stainless steel).

· Threaded fittings.

· O-rings and seals.

· Hoses between cooler and piping systems, and associated hose clamps.

3.5 Reinstallation. After completion of testing and all authorized repairs, if any, the Contractor shall reinstall each cooler (if previously removed). Where applicable, renew all zinc electrode plates, gaskets, and recessed hex-head bolts in accordance with the manufacturer's specifications. Apply a copper-based anti-seize compound on all bolts; and torque in accordance with manufacturer's specifications, and install lock wire.

3.6 Preservation. The Contractor shall prepare and preserve cooler external surfaces in accordance with Std Spec 0000_STD, paragraph titled "General preservation requirements", and in accordance with COMDTINST M10360.3

3.7 System replenishing. The Contractor shall completely fill the cooling water system with the Government-furnished coolant.

4. QUALITY ASSURANCE

4.1 Clean. The Contractor shall ensure that all cleaned surfaces are one hundred percent free of debris and surface contaminants.

4.2 Hydrostatic test. After all authorized work is complete and prior to reinstalling the cooler(s), the Contractor shall hydrostatically test each cooler in the presence of the COR, in accordance with Std Spec 0740_STD, Appendix C, "Hydrostatic Test". Be aware that no leakage or permanent deformation of pressure-containing parts is permissible. Repair all leaks and discrepancies found.

4.3 Label plates. The Contractor shall attach an anodized aluminum test data plate to each cooler using epoxy resin cement. Ensure that each plate is engraved with ¼-inch high letters, stating the following:

· Hydrostatic test pressure.

· Test date.

· Testing facility.

WARNING!

Do not exceed manufacturer's recommended maximum pressure of 35 psig.

4.4 Leak test. After reinstalling the cooler(s) on the vessel (and prior to undocking), the Contractor shall perform an operational test of the cooler(s) and associated system piping for one hour using the system fluid at normal operating pressure. Be aware that no visible leakage or deformation is acceptable. Repair all leaks and discrepancies found.

5. NOTES

5.1 Term applicability. The term grid cooler is applicable to grid coolers and keel coolers.

5.2 Government-furnished property.

($/UNIT)

5.3 Grid cooler manufacturer:

RW Fernstrum & CO

906/863-5553

5.4 Cooling system capacity. Cooling system approximate gallon capacity is as follows:

5.4.1 Main Diesel Engine: 65 Gallons

5.4.2 #1 S/S Gen.: 17 Gallons.

5.4.3 #2 S/S Gen.: 17 Gallons.

42410O_FLT (13 Aug 2007) 65 WLI (25 Jun 2007) WORK ITEM 7: Remove Transducer and Preserve Transducer Hull Ring

1. SCOPE

1.1 Scope. This work item describes the requirements for the Contractor to remove the transducer, and preserve the transducer hull ring.

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, Jun 2006, Coatings and Color Manual

Coast Guard Drawing FL 6713-203, Rev B, CRP-V850 Transducer (SS505) Adapter Assembly Raytheon V850 Color Echosounder, 2nd Edition, Mar 1993, Operation Manual

3. REQUIREMENTS

3.1 General.

3.1.1 Related work items. The Contractor shall accomplish this work item in conjunction with the…