210

USCGC 210 FOOT MEDIUM ENDURANCE CUTTERS

(WMEC A&B CLASS)

SPECIFICATIONS FOR DOCKSIDE REPAIRS

Developed By Louis Mikedis (Revision-2, 23 June 2011)

TABLE OF CONTENTS

Work Item Title Page iiRevisions Record

Consolidate List of References iii Consolidated List of Government-furnished Property v Consolidated List of Critical Inspection Items vi Principal Characteristics Principal Characteristics vii General Requirements Work Item 1: Emergency Switchboard Circuit Breakers, Upgrade

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.

3.5.1 Added Travel to cutter’s home pier.

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.

Consolidate 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 of 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 618 WMEC 311-001, Rev N, Emergency Diesel Generator Arrangement, Details, Schematic & Block Wiring Diagram

Coast Guard Drawing 618 WMEC 311-008, Rev C, CAT 3306B, EDG Installation/Replace, Electrical Wiring Diagram Mods

Coast Guard Drawing 627 WMEC 311-001, Rev J, Ship’s Service & Emergency Generator, Arrangements & Details, Block & Schematic Wiring Diagram

Coast Guard Drawing 627 WMEC 311-004, Rev A, Emergency Diesel Generator, Electrical Installation

Coast Guard Drawing 627 WMEC 311-005, Rev A, Emergency Diesel Generator, Electrical Wiring Diagram Coast Guard Publications

Coast Guard Technical Publication (TP) 3233A, Aug 2009, Manufacturer’s Instruction Book, SWBS Group(s) 324, Section F, Switchboard, Emergency Generator 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

Code of Federal Regulations (CFR) Title 33 CFR, Jul 2007, Navigation and Navigable Waters

Code of Federal Regulations (CFR) Title 40, Jul 2007, Environmental Protection Agency

Code of Federal Regulations (CFR) Title 49, Chapter I, Jul 2007, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation 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)

NONE

*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 Service Center

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

This section is not applicable to this package.

Principal Characteristics Principal Characteristics

210' WMEC

Physical Characteristics

Machinery Characteristics

Tank Capacities

00000_PWB_0209_FLT

Commercial Project @ Contractor’ Facility 0209 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 Code of Federal Regulations (CFR) Title 33 CFR, Jul 2007, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Jul 2007, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, Jul 2007, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation

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 extinguishers. The Contractor shall provide portable fire extinguishers.

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

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:

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

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

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

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

3.5 Sewage facilities for vessel personnel – due to disruption of power. The Contractor shall provide vessel-personnel with two portable toilets. Ensure that the toilets are:

· Located as close as possible to the vessel, at a distance not to exceed 100 yards.

· Cleaned and emptied daily, and restocked with consumables.

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 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 coating defects. Perform holiday inspection with a holiday detector for “critical-coated surfaces”.

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: ___________________________________

EC_32410_LNM_0910_210

Work Item 1: Emergency Switchboard Circuit Breakers, Upgrade

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to upgrade the A & B Class 210 Foot WMEC vessel’s emergency switchboard circuit breakers (Qty 2 ea) per vessel.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 618 WMEC 311-001, Rev N, Emergency Diesel Generator Arrangement, Details, Schematic & Block Wiring Diagram

Coast Guard Drawing 618 WMEC 311-008, Rev C, CAT 3306B, EDG Installation/Replace, Electrical Wiring Diagram Modifications

Coast Guard Drawing 627 WMEC 311-001, Rev J, Ship’s Service & Emergency Generator, Arrangements & Details, Block & Schematic Wiring Diagram Coast Guard Drawing 627 WMEC 311-004, Rev A, Emergency Diesel Generator, Electrical Installation

Coast Guard Drawing 627 WMEC 311-005, Rev A, Emergency Diesel Generator, Electrical Wiring Diagram Coast Guard Publications Coast Guard Technical Publication (TP) 3233A, Aug 2009, Manufacturer’s Instruction Book, SWBS Group(s) 324, Section F, Switchboard, Emergency Generator Other References None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of qualified Tech Rep, who is familiar with the Switchboard Equipment and the existing Square-D circuit breakers, to accomplish the following tasks – on site:

· Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system and to the direct replacement of existing circuit breakers with features equal to existing. Ensure the direct replacement circuit breakers are supportable with respect to the availability of spare parts.

· Assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

3.1.2.1 The Contractor shall ensure that the Tech Rep is a certified representative of circuit breaker manufacturer.

3.1.2.2 The Contractor shall submit the name of the Tech Rep to the COTR at the Arrival Conference.

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

3.1.4 Interferences.

· Hatches.

· Vertical ladders.

· Required rigging.

3.1.5 Coordination of work. The Contractor shall coordinate work with the COTR and the Engineering Officer with regards to power outages which may be necessary for the Emergency Circuit Breaker upgrade installations. The Contractor shall submit a written notice of at least 48 hours prior to requesting the securing of power on the vessel.

NOTE!

Coast Guard personnel will be responsible for the actual act of securing power i.e. line side de-energizing, lock-out, tag-out, and grounding of any equipment.

3.2 Emergency switchboard circuit breaker upgrade. The Contractor shall perform the following:

3.2.1 Initial on-site visit. Using Coast Guard Technical Publication (TP) 3233A and Coast Guard Drawing 627 WMEC 311-001 as guidance perform initial onsite visit for the purpose of conducting pre-engineering which shall include collecting information on existing switchgear construction, bussing configuration, cell and frame dimensions, equipment accessibility necessary for the modifications required for circuit breaker upgrade. An initial installation shall be performed on an “A” Class cutter, namely the Confidence and later a “B” Class, namely the Resolute. Upon successful prototype for each class cutter, the Contractor will be required to install remaining emergency switchboard circuit breakers (Qty 2 ea) per vessel.

3.2.1.1 The Contractor shall have a firm understanding of the voltage systems, wiring drawings, mountings and operating/switching procedures of the vessel’s electrical distribution system which includes Main Generators, Emergency Generator and Shore-Power. The replacement circuit breakers shall be a direct replacement of the existing circuit breakers in terms of operating and protective features and shall be able to interface with the vessels main switchboard as the original design features. The Contractor shall ensure that the direct replacement circuit breakers will be supportable with respect to the availability of spare parts for the purposes of repairs and or maintenance.

3.2.2 Existing emergency breaker removals. Provide all labor to include all rigging to remove the two existing 800 AF circuit breakers and dispose of in accordance with Federal, State and local regulations.

3.2.3 Emergency circuit breaker replacement. Provide all labor and rigging necessary to furnish, fit and install two emergency circuit breakers with the following minimum salient characteristics:

· Voltage - 600 VAC, 3-phase

· Continuous current – 800 Amp Frame w/variable Amp trip setting to be determined

· Interrupting capacity – 85,000 Amps

· Electrically Operated Shunt Trip/Shunt Close/Charging Motor : 24-30 VDC

· Micro-logic Trip unit: 5.0 Amps

· Long term, Short Term & Instantaneous Settings

· Push Button Interlock

· Spring Charge Interlock

· Alarm Switches

· Auxiliary Switches

3.2.3.1 Furnish, fit and install all necessary components to integrate the new 800 AF circuit breakers to the existing Emergency Switchboard which shall include but not limited to new copper bus, front door panel, bus supports, breaker mounting plate and all necessary hardware to make electrical and mechanical connections.

3.2.3.2 Install all circuit breaker control wiring necessary to make the breaker perform within the vessel’s existing operating configuration and procedures including (a) bus tie breaker should open upon loss of normal power, and (b) Emergency Diesel Generator (EDG) should start and the EDG breaker should close within a pre-determined period (in seconds).

3.2.4 Written proposal. The Contractor shall provide a written proposal prior to the award of contract for approval by the Coast Guard as follows:

3.2.4.1 Warranty. Written warranty terms and conditions with the vendor quotation. A minimum warranty period of five (5) years from the date of installation for each circuit breaker shall be included for the installation of each ship set.

3.2.4.2 Spare parts list. Provide a list of recommended spare parts based on analysis from similar systems on Navy/Coast Guard ships. The list shall include an estimated lead-time for each spare part listed.

NOTE!

The Coast Guard may decide to purchase spare parts for an undetermined number vessels.

3.2.4.3 Catalogue specification sheet. Provide new equipment specification sheets which can be incorporated into existing Coast Guard Technical Publications.

3.3 Electrical isolation plan. The Coast Guard and the Contractor shall be jointly responsible for securing electrical equipment and providing electrical service to vital loads in accordance with the vessel’s Isolation Plan which will be provided by the Coast Guard. The Contractor shall be responsible for verifying total electrical isolation of the work area prior to commencement of work. If total electrical isolation cannot be obtained, it may be necessary for the Contractor to perform the installation with no power to the vessel. In this instance, the Contractor shall be responsible for providing a portable generator, portable lights, and string lights to ensure at a minimum the work area and main passage way are safely illuminated.

3.4 Emergency circuit breaker upgrade, test. The Contractor shall perform the following to demonstrate that the newly installed circuit breakers operate and integrate as per original ship’s design.

3.4.1 Initial testing. Perform visual inspections, insulation resistance testing of new and existing equipment, check for proper phase rotation when the system is energized.

3.4.2 Operational testing. Demonstrate that the newly installed breakers operate in all modes of operation in accordance with Coast Guard Technical Publication (TP) 3233A. Submit CFR.

NOTE!

Coast Guard personnel will operate all equipment.

3.5 Cutter’s home pier listing.

Name Location Active Port Angeles, WA Alert Warrenton, Oregon Confidence Patrick AFB, Florida Dauntless Galveston, TX Decisive Pascagoula, MS Dependable Cape May, NJ Diligence Wilmington, NC Reliance Kittery, Maine Resolute Saint Petersburg, Florida Steadfast Warrenton, Oregon Valiant Miami Beach, Florida Venturous Saint Petersburg, Florida Vigilant Patrick AFB, Florida Vigorous Cape May, NJ

3.5.1 Travel to cutter’s home pier. The Contractor shall perform an initial on-site visit for both A & B Class cutters for the purpose of conducting pre-engineering as stated previously. Additionally it is estimated that five (5) trips to five (5) cutter home piers shall be required during the first Base Year for a total of seven (7). It is also estimated that the Contractor will be required to travel seven (7) times to seven (7) cutter home piers during the first Option Year. Travel requirements will be subject to the cutter’s schedules and availabilities, and will not be certain at the time of award.

4. NOTES

4.1 Coast Guard responsibilities. The Coast Guard will provide free access to their facilities as appropriate for the work being performed. The Coast Guard will make all equipment available upon arrival of the Contractor’s personnel to permit unimpeded progress of work.