GANNET

USCGC GANNET (WPB-87) EMERGENCY DRYDOCK AVAILABILITY 2012

USCGC GANNET (WPB 87334)

87 FOOT COASTAL PATROL BOAT (USCG)

SPECIFICATION FOR EMERGENCY DRYDOCK REPAIRS

Developed By: Paul M Walukewicz (Draft-0, 02 September 2011)

TABLE OF CONTENTS

iiiRevisions Record ivConsolidated List of References viiConsolidated List of Government-furnished Property ixConsolidated List of Critical Inspection Items xPrincipal Characteristics

1General Requirements

12WORK ITEM 1: Propulsion Shafts, Remove, Inspect, and Reinstall (D)

23WORK ITEM 2: Propulsion Shaft, Repair (O)

25WORK ITEM 3: Propulsion Shaft, Straighten (O)

27WORK ITEM 4: Intermediate Water-Lubricated Propulsion Shaft Bearing , Renew (O)

29WORK ITEM 5: Aft Water-Lubricated Propulsion Shaft Bearing , Renew (O)

31WORK ITEM 6: Intermediate Bearing Carrier, Renew (O)

32WORK ITEM 7: Aft Bearing Carrier, Renew (O)

33WORK ITEM 8: Stern Tube s , Interior Surfaces , Preserve 100% (O)

36WORK ITEM 9: Stern Tube s , Interior Surfaces , Repair (O)

38WORK ITEM 10: Propellers, Remove, Inspect, and Reinstall (D)

41WORK ITEM 11: Rudder Assemblies, Remove, Inspect and Reinstall (D)

45WORK ITEM 12: Drydocking (D)

50WORK ITEM 13: Temporary Services, Provide (D)

53WORK ITEM 14: Telephone Service, Provide (D)

54WORK ITEM 15: Propeller, Minor Reconditioning and Repairs, Perform (D)

57WORK ITEM 16Propulsion Shaft Strain (Strain Gage Alignment), Measure(D)

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.

Consolidated List of 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.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free or charge. Other Government documents may be accessed – free of charge – as follows:

· MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

· Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

· Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws:: www.gpoaccess.gov The Government is aware of the following internet web links where contractors may procure commercial specifications:

· American Welding Society (AWS): http://www.awspubs.com/index.php

· ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

· NFPA: http://www.nfpa.org

· SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 085-010, Rev C, Docking Plan Coast Guard Drawing 87 WPB 085-012, Rev -, Lifting Cradle Coast Guard Drawing 87 WPB 085-11, Rev B, Lifting Slings Coast Guard Drawing 87 WPB 111-001, Rev D, Shell Expansion Coast Guard Drawing 87 WPB 161-001, Rev C, Skeg Construction Coast Guard Drawing 87 WPB 163-1, Rev F, Sea Chest Details Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details Coast Guard Drawing 87 WPB 245-002, Rev-, Propeller Details Coast Guard Drawing 87 WPB 245-003, Rev A, Propeller Details Coast Guard Drawing 87 WPB 561-001, Rev H, Steering System Details Coast Guard Drawing 87 WPB 562-001, Rev A, Rudder Details

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual Coast Guard Technical Publication (TP) 4506, Wartsila TM-EL-68839, Issue A, Mar 2005, Rudderstock Seal Type EL Coast Guard Technical Publication (TP) 4593B, Mar 2003, SWBS 562, Rudderstock Seal-Type EJ Coast Guard Technical Publication (TP) 4593C, Feb 2002, SWBS 243, Manufacturer's Instruction Book, 87' WPB Propulsion Shaft Seals, John Crane Type F.S.E.

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 8634 (SFLC Std Spec 8634), Jan 2009, Drydocking Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), Jan 2009, Provide Temporary Services

OTHER REFERENCES

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

American Bureau of Shipping (ABS), 2, Rules for Survey After Construction, 2008, Part 7, Appendix Section 10, Guide for Bronze and Stainless Steel Propeller Castings ASTM International (ASTM) D4417, 2003, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel ASTM International (ASTM) D5363, 2008; Standard Specification for Anaerobic Single-Component Adhesives (An) ASTM International (ASTM), D3951, Re-approved 2004, Standard Practice for Commercial Packaging Bollinger Shipyard, USCG CPB Project MTU-FA 771903, 07 Feb 2000, Engine/Gearbox Plant Alignment Instructions 8V396 TE94/Flange mounted BW 255 Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation Commercial Item Description (CID) A-A-59316, Nov 2003, Abrasive Materials for Blasting International Organization for Standardization (ISO), 484/2, First Edition, 1981, Shipbuilding - Ship Screw Propeller - Manufacturing tolerances - Part 2: Propellers of diameter between 0.80 and 2.50 m inclusive International Standard For Organization (ISO) 484/2, 1981, Shipbuilding - Ship Screw Propeller - Manufacturing Tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50 m, Inclusive MIL-A-22262, Mar 1996; Abrasive Blasting Media Ship Hull Blast Cleaning MIL-PRF-16173, 2006, Corrosive Preventive Compound, Solvent Cutback, Cold Application MIL-PRF-24647, Jun 2006, Paint System, Anticorrosive and Antifouling, Ship Hull MIL-S-45180, 1998; Sealing Compound, Gasket, Hydrocarbon Fluid and Water Resistant MIL-STD-167-1, Nov 2005, Mechanical Vibrations of Shipboard Equipment (Type I - Environmental and Type II - Internally Excited) MIL-STD-1687, Sep 1994, Thermal Spray Processes For Naval Ship Machinery Application MIL-STD-2191, Nov 1992, Repair Welding, Weld Cladding, Straightening, and Cold Rolling of Main Propulsion Shafting NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), May 1997, Requirements for Fabrication, Welding, and Inspection of Submarine Structure Prevent shock transmission to reduction gear. Prior to removing propeller nut fit a shore from the dock floor to one propeller blade near the root, to, as necessary. Protect propeller blade edges and blade roots with suitable covers, at all times until reinstallation. 3.2 Work to be accomplished . The Contractor shall perform the tasks specified below to both propellers. Refer to Coast Guard Drawings 87 WPB 243-001, 87 WPB 245-002, and 87 WPB 245-00 The Society for Protective Coatings (SSPC) Surface Preparation Specification No.11 (SSPC-SP 11), 2004, Power Tool Cleaning to Bare Metal The Society for Protective Coatings (SSPC) VIS 1, 2004, Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning The Society for Protective Coatings (SSPC)/NACE International (NACE) Joint Surface Preparation Standard SSPC-SP 12/NACE No.5, 2002, Surface Preparation and Cleaning of Metals by Waterjetting Prior to Recoating The Society for Protective Coatings (SSPC)/NACE-International (NACE) Joint Surface Preparation Standard SSPC-SP 10/NACE No. 2, 2004, Near-White Blast Cleaning

Consolidated List of Government-furnished Property

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

($/Unit)

NSN: 5330-01-521-3559

NSN: 2040-01-521-2654

NSN: 3120-01-521-2390

NSN: 3120-01-521-2268

NSN: 5330-01-521-4855

NSN: 5340-01-521-3573

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

PN: F54615-02-8-1

NSN: 3120-21-914-2012

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

PN: F54615-02-8-0

NSN: 3120-21-914-2011

NSN: 2010-01-457-0573

NSN: 2010-01-459-0421

*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 or the C4IT ServiceCenter

Consolidated 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 SFLC Std Spec 0000_STD, paragraph 3.2.6.5 (Inspection report particulars)):

Work Item Title

Principal Characteristics

PC_87_WPB_0511

87' WPB

Physical Characteristics

Hull Characteristics

Machinery Characteristics

Tank Capacities

00000_PWB_0811_FLT

REC_0000_FLT_ Commercial Project @ Contractor’ Facility (0211) General Requirements

1. SCOPE

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

2. REFERENCES

Coast Guard Drawings None.

Coast Guard Publications Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Other References ASTM International (ASTM) D4417, 2003, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel Commercial Item Description (CID) A-A-59316, Nov 2003, Abrasive Materials for Blasting Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation MIL-A-22262, Mar 1996, Abrasive Blasting Media Ship Hull Blast Cleaning NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), May 1997, Requirements for Fabrication, Welding, and Inspection of Submarine Structure The Society for Protective Coatings (SSPC) VIS 1, 2004, Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning

3. REQUIREMENTS

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

NOTE

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.

Or

3.2 Contractor-provided fire extinguishers. The Contractor shall provide portable fire extinguishers.

Or

3.2 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

· Provide fire watch personnel and fire extinguishers for the duration of the availability period, during and beyond noted Coast Guard fire watch support.

3.3 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740.

NOTE

NAVSEA approval is NOT required for welding procedures submitted but the procedures must be reviewed and shown to satisfy the requirements set forth in NAVSEA TP 1688, by a welding regulatory agency. The requirements for welding Weldox 900 shall be considered the same as those for welding HY-130

3.4 HW disposal. The Contractor is considered as the generator of all contract-generated hazardous wastes and shall use its facility’s EPA generator ID number for management, transportation, and disposal of said hazardous wastes. Ensure the following:

3.4.1 Contractor’s hazardous waste handlers shall comply with applicable requirements of 40 CFR 262.

3.4.2 All contract generated hazardous wastes shall be packaged in 49 CFR-compliant containers.

3.4.3 The designated wastes shall be disposed of at a state or Federally-approved and permitted HW TSDF.

3.4.4 Name of destination TSDF shall be submitted to the KO at the Arrival Conference.

3.5 Pre-surface preparation test coupon. In order to ensure production of required surface profile, the Contractor shall accomplish the following tasks, whenever abrasive-blasting is required in a work item that is deemed a ”critical-coated’ surface:

3.5.1 Coupon material and test set-up particulars.

3.5.1.1 Conduct a performance test on all abrasive blasting operations on a Contractor- provided test coupon, prior to starting abrasive blasting operations on the vessel. Ensure the following:

· The coupon shall be a new metal plate, of the same metal type and material properties as the vessel area to be blasted - steel or aluminum plate, as applicable, and shall have no existing anchor profile - other than the surface irregularities from the manufacturing process.

· The test coupon shall be flat, with nothing welded to the side used for the anchor profile test, no thinner than a 1/8-inch plate and measuring no smaller than 1-foot by 1-foot.

· For steel substrates, the coupon shall have the mill scale intact, and be in a Rust Grade "A" condition, in accordance with SSPC-VIS 1.

· The test coupon shall be affixed so as to not permit excessive movement during the performance test, but shall not be affixed to the vessel.

3.5.1.2 Ensure that the abrasive-blasting operation for the test coupon is conducted with the identical setup and parameters that will be used blasting the designated vessel surfaces – including, but not limited to:

· The abrasive media type and media size selected to achieve the anchor profile range, as specified in the applicable work items.

· Nozzle size and type (straight bore, high velocity nozzle, angle nozzle...).

· Delivery rate and pressure settings.

3.5.1.3 Blast a one-square foot area on one side of the test coupon to the abrasive surface preparation standard specified in the work item, and perform an anchor profile test of the blasted surface in accordance with ASTM D4417, Method B or C. Notify the COTR in advance of the abrasive blasting operation test, to permit the witnessing of the test by the COTR. Submit a CFR documenting the results of the abrasive blasting operation test. The CFR shall include at a minimum, the following:

· Area of the vessel for which the verified setup will be used to abrasive blast.

· The selected abrasive media type and size.

· The nozzle size and type.

· The delivery rate and pressure.

· The test coupon starting properties (material type and surface conditions).

· The resultant anchor profile readings from the test (a minimum of 3 locations, separated by a minimum of 2 inches shall be recorded).

NOTES

1. A performance test of the abrasive blasting operations on a test coupon and measuring the resultant anchor profile prior to performing the abrasive blasting operation on the cutter is required. The test coupon will be used to evaluate the anchor profile produced by the equipment setup and selected abrasive media.

2. The reverse side of the test coupon may be used for the subsequent test, provided that the conditions in paragraph 3.5.1 (Coupon material and test set-up particulars) are met.

3. Ultra high pressure water jetting does not create an anchor profile and is exempt from the anchor profile test coupon check.

3.5.1.4 Repeat the abrasive blasting operation test in the following instances:

· The equipment setup, that was evaluated during the test coupon abrasive blasting performance test in paragraph 3.5.1 (Coupon material and test set-up particulars), has changed.

· The resultant anchor profile readings observed on the vessel are outside the specified anchor profile range.

· Media is changed from MIL-A-22262 to CID A-A-59316 or vice versa.

· The supplier of the abrasive blasting media changes, regardless if the new source for the media has the same specifications.

· When Directed by the COTR.

CAUTION!

Ensure that blast media from the performance test does not strike the vessel during the test.

3.6 Interim changes to SFLC Std Spec 0000. The Contractor shall be aware of the following interim changes to the SFLC Std Spec 0000:

3.6.1 Contents of paragraph 3.3.2.1.1 (Water depth) have been revised to read as follows:

“3.3.2.1.1 Water depth. Ensure that water depth is sufficient at the pier to allow the vessel's lowest underwater appendage to clear the bottom by at least two feet at:

· Ordinary low water mark on non-tidal rivers.

· At all tide conditions predicted during the availability for tidal rivers and other navigable waterways (Bay, Lake, etc.).”

3.6.2 Paragraph 3.2.11.1 (Sanitary facilities for vessel-personnel – due to disruption of grey water system) has been revised as follows:

“3.2.11.1 Sanitary facilities for vessel-personnel – due to disruption of grey water and sewage systems. When the shipboard grey water and sewage systems are disrupted due to repairs required by contract work, the Contractor shall provide vessel-personnel with a sanitary facility, within a five minute walking distance from the vessel, to include the amenities listed in Table II (Sanitary Facility Amenities). Ensure the following:

· Shower stalls are equipped with privacy screens.

· Sinks are provided with fresh hot and cold water.

· Electrical convenience GFI receptacles, in accordance with NFPA 70, National Electric Code (NEC), are located in vicinity of sinks.

· Toilets have doors or privacy dividers.

· Lockers are capable of being locked.”

4. NOTES

4.1 Access to COMDTINST M10360.3. The COMDTINST M10360.3 may be accessed at the following URL address: http://www.uscg.mil/directives/cim.asp

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

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 mfgr.

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 mfgr.

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.

Verify equipment setup, blast media, and surface preparation methods match designated test coupon.

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 using ASTM D4417-Methods B or C against COMDTINST M10360.3. Conduct profile readings at a minimum of 5 locations for the first 1000-sqft area, and 2 locations for each succeeding 1000-sqft area.

Measure soluble salt conductivity in accordance with SSPC-Guide 15. Conduct 5 measurements per each 1000-sqft area (max. threshold: 70 microsiemens/cm for non-submerged surfaces, 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 (WFT) at random, to prevent under or over application. Verify final DFT.

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. Conduct 5 sets of 3 readings for each of the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area.

Ensure that system cure is in accordance with manufacturer's recommendation for intended service.

Ensure potable water tank exhaust ventilation is maintained continuously from and during coating application through final system cure, to exhaust all solvent to the atmosphere and to prevent solvent entrapment.

For immersion coatings (including tank U/W body), record date and time of the following events:

Final coat application: _____/_____; Return to service or removal from environment controls: _____/_____

CHECKPOINT 10 – RECORD KEEPING

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

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.

| DP - Surface |

QA-3a - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-C)

SSPC-SP-10/NACE No. 2

SSPC-SP-12/NACE No. 5

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area)

Brush-blasting (non-metallic substrate)

Abrasive Manufacturer and Sieve Size: _________________________________ Place surface profile replica tapes in the spaces provided below, to serve as permanent QA record. Maintain a separate log for each location. When an area is divided into separate sections, maintain a separate log for each section.

Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils

Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils

Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils

Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils

Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils Place Surface Profile Replica Tape Here Reading:__________ mils

Mean Mil Reading (IAW ASTM D4417-Method C) for above 15 readings: ______________

QA-3b - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-B)

SSPC-SP-10/NACE No. 2

SSPC-SP-12/NACE No. 5

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area)

Brush-blasting (non-metallic substrate)

Abrasive Manufacturer and Sieve Size: _________________________________ Record measurements taken in the spaces provided below, to serve as permanent QA record. Maintain separate log for each location. When an area is divided into separate sections, maintain a separate log for each section.

Mean Mil Reading (IAW ASTM D4417-Method B) for above 10 readings (by column):

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY Measurements IAW SSPC-GUIDE 15

(microsiemens/cm)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

Dry Film Thickness (DFT) Measurements IAW SSPC-PA 2

*BASE METAL READING (BMR)

*Required, If Magnetic Pull-Off (Type I/Banana) Gauge Is Used.

Location (Frame Reference): ___________________

Overall Avg. DFT

ADJUSTMENTS

Avg.

Overall Avg. DFT

ADJUSTMENTS

Avg.

Overall Avg. DFT

ADJUSTMENTS

Avg.

24300_JLW_0311_87WPB

WORK ITEM 1: Propulsion Shafts, Remove, Inspect, and Reinstall (D)

1. SCOPE

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

1.2 Government-furnished property.

NSN: 5330-01-521-3559

NSN: 2040-01-521-2654

NSN: 3120-01-521-2390

NSN: 3120-01-521-2268

NSN: 5330-01-521-4855

NSN: 5340-01-521-3573

1.3 Technical representative for shaft seal work. If an “X” appears in the blank below, then the Contractor shall provide a technical representative to supervise the installation of the shaft seal. Otherwise, when no “X” appears in the blank, the Contractor may provide the services of a shaft seal technical representative, at the Contractor’s discretion (see paragraph 3.1.6 below).

__X__ Technical Representative required.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details Coast Guard Publications Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Coast Guard Technical Publication (TP) 4593C, Feb 2002, SWBS 243, Manufacturer's Instruction Book, 87' WPB Propulsion Shaft Seals, John Crane Type F.S.E.

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

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph(s):

· 3.2 (Pre-docking waterborne coupling hub alignment check).

· 3.4 (Shaft inspections).

· 3.5.1 (Visual inspection and bearing ID check)

· 3.5.2 Alignment (concentricity) check

3.1.2 Interferences. The Contractor shall be aware that interferences in way of work may include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences):

· Deck plates.

· Deck plate framing.

· Stern tube mid bearing access hatch.

· Stern tube aft bearing access hatch.

· Stern tube forward access hatch.

3.1.3 Tolerances. Unless otherwise specified, all measurements shall be accurate to within the nearest 0.001 inch.

NOTE

The following methods for obtaining coupling hub alignment measurements are acceptable: 1) Dial indicator to obtain total indicator run-out, 2) Straight-edge/feeler gage.

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

3.2 Pre-docking waterborne coupling hub alignment check. The Contractor shall perform the following prior to docking the vessel. Remove and retain shaft coupling for reinstallation. Using the Government-furnished alignment kit (shaft support) to center the shaft in the seal bore, measure and record shaft and reduction gear coupling hub alignment data: 1) parallel misalignment between hub ODs, 2) angular misalignment between hub faces, and 3) hub to hub gap. Measure and record the thickness of shims beneath each engine mount. Submit CIR.

CAUTION!

If the CL of a stern tube points away from the CL of its engine/reduction-gear foundation by a significant amount then stern tube relocation may be appropriate. If this is the case, make recommendations in the inspection report. COTR will notify AMS3 prior to taking corrective action.

CAUTION!

Thickness of laminated shim stock istalled between engine mounts and engine foundation shall not exceed 0.250 inches. Shim stock shall be stainless steel, brass shim stock not allowed. If more than 0.250 inches of shim are required then stainless steel liners shall be fabricated and installed to limit the amount of laminated shim stock used.

If machined liners are fabricated and installed they shall be tack welded in place after final installation.

3.2.1 Major structural misalignment. Determine if major MDE related structural components (stern tube, engine foundation) are severely misaligned, evaluate, and include recommendations for corrective measures in the above CIR. Major structural misalignment may exist if any of the following conditions exist:

· Shims between engine/red-gear foundation exceed 0.750 inch.

· Gap between raw water suction inlet and outlet pipe flanges (for expansion joints) exceeds 6-1/2 inches or is less than 5-5/8 inches.

3.3 Remove shafts. The Contractor shall remove each shaft seal and shaft. Refer to Coast Guard Drawing 87 WPB 243-001. Protect each shaft from damage during removal, storage, and reinstallation.

3.3.1 Shaft support requirements. When lifting, suspend the shaft from at least 2 supports spaced approximately 7 feet apart and from each end. Lift with a spreader bar, or similar device, to minimize bending stress on the shaft. When storing, rest the shaft on a minimum of 3 supports spaced approximately 5 feet apart and 5 feet from each end. Each support shall extend a minimum of 6 inches along the shaft. Prevent all possible damage to shaft surfaces in support areas (i.e. install padding between shaft and support, as required.).

NOTE

Bearing journal wear must be repaired to an "as-new" condition. All damage (e.g. pits, cracks, areas showing excessive wear, etc) shall be removed from each bearing journal. Renew the shaft if any pit or wear area exceeds 0.125 inches depth.

3.4 Shaft inspections. The Contractor shall determine if each shaft can be reused. Then, for each shaft being reused, determine extent of repairs required. Clean each shaft of all surface contaminants and accomplish the following in-shop inspections. Visually inspect each shaft, and all associated components (e.g. propeller nut, gear nut, keys, locking fasteners, coupling, etc.), for corrosion, pitting, surface cracks, and other defects. Perform non-destructive inspection (NDI) of the shaft taper, shaft coupling, coupling bolts, keys and keyways at both shaft ends, in accordance with SFLC Std Spec 0740. Prior to measuring shaft machined surfaces, eliminate all temporary/non-permanent bending/sagging effects induced into each shaft during handling and storage; spin each shaft on the lathe for approximately two hours at a slow speed. Measure and record shaft dimensions as described below. Submit CIR.

3.4.1 Shaft measurements. Prior to taking shaft dimensions place the shaft on two precision rollers 24 inches from each end of the shaft. No additional supports shall be used. Measure and record all shaft, shaft key, keyway, and journal dimensions described on the forms provided at the end of this work item. Also measure and record shaft coupling face and coupling OD runouts.

3.4.2 Shaft renewal at Govt. discretion. The Contractor shall be aware that the Government reserves the right to furnish one or more new propeller shafts in lieu of working and reinstalling the existing shafts. When the Government exercises this right, the Contractor shall perform all checks on the new shafts specified herein, prior to installation; submit CFR.

3.5 Stern tube and bearing inspections. Within 72 hours after shaft removal, the Contractor shall determine the extent of repairs required to each stern tube assembly (i.e. stern tube, bearings, bearing housings and carriers, chock-fast, shaft seal flange, etc). Perform the following and submit reports (CIRs and CFRs) as described; in the reports include descriptions of methods used to obtain the measurements.

3.5.1 Visual inspection and bearing ID check. Visually inspect both stern tube assemblies for damage, corrosion, unusual wear patterns, and all other symptoms that indicate that repairs are required. For each bearing, measure and record bearing inner diameter dimensions at the 3-9 and 6-12 o’clock positions in three locations (forward end, middle, and aft end of bearing). Submit CIR.

NOTE

Compare shaft bearing journal dimensions to bearing ID dimensions. Final journal-to-bearing diametrical clearance shall be 0.030” minimum and 0.120" maximum (these dimensions take precedent over dimensions specified on Coast Guard Drawing 87 WPB 243-001). If clearances are outside of this range contact PBPL ENG AMS3 for further evaluation. Otherwise, renew bearings, repair shafts, or both, as applicable, to obtain the specified clearance.

3.5.2 Alignment (concentricity) check. Minimize thermal effects by performing the following late in the evening or before sunrise. Find the “Target Points” shown on Coast Guard Drawing 87 WPB 243-001, determining the center line of each stern tube. Measure and record the concentricity of the centerlines of each bearing, relative to the stern tube centerline, at the 3-9 and 6-12 o’clock positions in three locations (forward end, middle, and aft end of each bearing). Measure and record offset between the stern tube centerline and the center of the reduction gear hub flange. Measure and record offset between the stern tube centerline and the center of the shaft seal flange. Note all discernable bearing wear patterns; identify wear patterns inconsistent with measured offset positions. Submit CIR.

NOTE

Concentricity checks may be performed using optical, laser, or piano wire methods. Due to higher precision, optical and laser methods are preferred.

CAUTION!

If the CL of a stern tube points away from the CL of its engine/reduction-gear foundation by a significant amount then stern tube relocation may be appropriate. If this is the case, make recommendations in the inspection report. COTR will notify AMS3 prior to taking corrective action.

3.5.3 Post repair checks. Perform the “Alignment (concentricity) check” again after completion of all authorized repairs, and prior to reinstalling shafts. Submit CFR.

3.5.4 Shaft coupling hub fit check. Prior to reinstalling shafts, the Contractor shall blue check the shaft-to-coupling-hub taper fit. With the key in place, perform minor grinding or hand-stoning of the coupling hub ID, as required, to achieve a minimum of 80 percent uniform contact. After all bluing/fitting, and with hub installed, measure and record hub OD radial runout; verify measurement is in tolerance. Submit CFR.

3.6 Reinstall shaft assemblies. The Contractor shall reinstall shaft assemblies and perform the following.

3.6.1 Bearing clearance checks. Measure and record shaft journal to bearing diametrical clearance (max 0.120 inches allowed) for each bearing. Submit CFR.

3.6.2 New shaft seal installation. Measure and record flatness of shaft seal flange face with straight edge (evaluate if flange not flat to within 0.003"). Submit CFR. Install new Government-furnished shaft seal assemblies; refer to TP-4593C. Test the inflatable emergency shaft seal prior to undocking and during sea trials.

3.6.2.1 Technical Representative for shaft seal installation. If the blank beneath paragraph 1.3 above contains an “X” then the Contractor shall provide the services of an on-site Technical Representative (Tech Rep) who 1) is experienced with the FSE-type seal system who shall assist with proper installation of the seal and ensure compliance with manufacturer's procedures and standards during installation, and 2) possesses a résumé of demonstrated experience (submit a copy of the Tech Rep’s résumé and a list of references to the COTR at the Arrival Conference). If the blank beneath paragraph 1.3, above, contains no “X” then the Contractor may provide the services of a shaft seal technical representative, at the Contractor’s discretion.

3.6.3 Waterborne shaft coupling hub alignment check. After vessel is undocked, determine if engine/reduction-gear alignment is required; using the Government-furnished alignment kit (shaft support) to center the shaft in the seal bore, measure and record shaft and reduction gear coupling hub alignment data: 1) parallel misalignment between hub ODs, 2) angular misalignment between hub faces, and 3) hub to hub air gap. Submit CFR

3.7 Operational test. The Contractor shall demonstrate proper operation of both propeller shaft assemblies. During sea trials verify no unusual noise, vibrations, binding, etc. Correct all discrepancies. Submit a CFR.

4. NOTES

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

Shaft Keyway and Key Measurement Form Vessel Name and Hull Number: _______________________

C

A

B

Shaft Keyway and Key

Port Shaft Keyway and Key Measurements (inch)

Starboard Shaft Keyway and Key Measurements (inch)

Inspection Facility:

Inspector Signature:

Date and Time:

Shaft Journal Measurement Form Vessel Name and Hull Number: _______________________ Shaft and Stern Tube

L

Aft

Fwd

Forward Port Shaft Journal OD in Stern Tube (inch)

Forward Stbd Shaft Journal OD in Stern Tube (inch)

Aft Port Shaft Journal OD in Stern Tube (inch)

Aft Stbd Shaft Journal OD in Stern Tube (inch)

Date and Time:

Port Shaft Runout Measurement Form Vessel Name and Hull Number: _______________________

C

A

D

Port Shaft Runout Measurements (inch)

Shaft Location1

Aft Taper

Aft Bearing Journal 1

Aft Bearing Journal 2

Fwd Bearing Journal 1

Fwd Bearing Journal 2

Shaft Seal

Fwd Taper

1Measurements are to be taken at a minimum of 6 locations along the shaft.

Date and Time:

Starboard Shaft Runout Measurement Form Vessel Name and Hull Number: _______________________

C

A

D

Starboard Shaft Runout Measurements (inch)

Shaft Location1

Aft Taper

Aft Bearing Journal 1

Aft Bearing Journal 2

Fwd Bearing Journal 1

Fwd Bearing Journal 2

Shaft Seal

Fwd Taper

1Measurements are to be taken at a minimum of 6 locations along the shaft.

Date and Time: ___________________________________________________

24301_JLW_1210_87WPB

WORK ITEM 2: Propulsion Shaft, Repair (O)

1.1 Intent. This work item describes the requirements for the Contractor to repair the designated propeller shaft.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details Coast Guard Publications Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Other References MIL-STD-1687, Sep 1994, Thermal Spray Processes For Naval Ship Machinery Application

3. REQUIREMENTS

3.1 General.

NOTE

The Contractor must have craftsmen experienced in performing weld repairs to stainless steel shafts.

3.1.1 Personnel qualification. The Contractor shall ensure that the weld fusion overlay process, specified herein, shall be performed under the direct supervision of personnel experienced in and regularly engaged in weld repairing of stainless steel shafts. The qualified personnel shall be familiar with stainless steel shaft repair techniques and ensure compliance with propeller shaft manufacturer's standards. The personnel must have a resume of previously demonstrated weld fusion overlay of stainless steel shaft experience as described within this work item. The qualified personnel must be able to provide a list of references upon request to the COTR.

NOTE

The grade of stainless steel shaft shall be in accordance with the Bill of Materials in Coast Guard Drawing 87 WPB 243-001.

3.2 Shaft repairs. The Contractor shall repair the designated shaft by first removing all cracks on the shaft bearing journal surfaces. The Contractor shall then machine and build up the affected bearing journal areas of the stainless steel shaft, using Coast Guard Drawing 87 WPB 243-001 as guidance, back to a reusable condition with the following process:

3.2.1 Weld overlay fusion process. Obtain a metallurgically sound bond by using the Nitronic 5Ow, in accordance with SFLC Std Spec 0740, as matching filler with qualified personnel for weld overlay and fully welded joints.

NOTE

To minimize distortion, a semi-automated process (gas metal-arc) is preferred by clamping a welding torch to a lathe tool holder for indexing as the shaft rotates in the lathe under the weld head. If this cannot be accomplished, longitudinal overlay weld beads may be deposited alternatively 180 degrees opposite the previous overlay.

3.2.2 High Velocity Oxy Fuel (HVOF) thermal spray process. Alternatively, the Contractor may opt to employ the HVOF thermal spray process in lieu of the weld overlay fusion process to repair the worn propulsion shaft areas. The HVOF is thermal sprayed onto the affect shaft areas by applying tungsten carbide coating in accordance with MIL-STD-1687.

3.2.3 Machining. When the repaired shaft is fully cured, machine the built-up areas to a diameter of four inches.

NOTE

The Contractor may build up to a diametrical thickness up to 0.080" along the propulsion shaft bearing journal areas.

4. NOTES

4.1 Bearing journal areas. The propeller shaft bearing journal areas for this vessel may be worn up to 0.125" of the shaft diameter before condemnation. Historically, the bearing journal areas have not been worn beyond 0.050" and this work item allows for build-up up to 0.080" diametrical thickness. Submit a change request for any amount of bearing journal build-up more exceeding 0.080" diametrical thickness.

24302_JLW_1210_87WPB

WORK ITEM 3: Propulsion Shaft, Straighten (O)

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

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details Coast Guard Publications Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Other References MIL-STD-2191, Nov 1992, Repair Welding, Weld Cladding, Straightening, and Cold Rolling of Main Propulsion Shafting

3. REQUIREMENTS

3.1 General.

3.1.1 Shaft straightening requirements. Based on inspection results obtained from a related shaft work item in this specification package, or provided by the Coast Guard Inspector, the Contractor shall straighten the designated shaft, using Coast Guard Drawing 87 WPB 243-001, and MIL-STD-2191 as guidance and as specified herein.

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

· Before taking shaft runout readings, spin the shaft on the lathe for approximately two hours at a high rate of speed, as close as practicable to 800 RPMs, 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.

3.1.1.2 Straightening procedures. Straighten the shaft to equal or less than 0.005"…