Spec Revision 2 TYBEE

USCGC TYBEE (WPB-110B) DRYDOCK AVAILABILITY 2012

USCGC TYBEE (WPB 1330)

110 FOOT "B CLASS" PATROL BOAT (USCG)

SPECIFICATION FOR DRYDOCK REPAIRS

Developed By: Donnie R Boyer and Tim O’Brien (Rev-2, 12 January 2012)

TABLE OF CONTENTS

iiiRevisions Record ivConsolidated List of References viiConsolidated List of Government-furnished Property viiiConsolidated List of Critical Inspection Items

1Principal Characteristics

3General Requirements

13WORK ITEM 1: Perform Ultrasonic Thickness Measurements (D)

16WORK ITEM 2: Appendages (U/W), Leak Test (D)

18WORK ITEM 3: Tanks (Potable Water), Clean and Inspect (D)

21WORK ITEM 4: Rudder Assembly, Remove, Inspect and Reinstall (D)

26WORK ITEM 5: Grey Water Holding Tanks , Clean and Inspect (D)

29WORK ITEM 6: Sewage Holding Tanks , Clean and Inspect (D)

32WORK ITEM 7: Aft Steering Compartment, Preserve and Insulate (D)

35WORK ITEM 8: Battery Space, Preserve and Insulate (D)

38WORK ITEM 9: Main Mast , Preserve, 100% (D)

43WORK ITEM 10: U/W Body, Preserve “Partial – Condition A ”(O)

47WORK ITEM 11: U/W Body, Preserve “Partial - Condition B” (O)

51WORK ITEM 12: U/W Body, Preserve “Partial - Condition C ” (O)

55WORK ITEM 13: U/W Body, Preserve “100%” (O)

58WORK ITEM 14: Drydocking (D)

61WORK ITEM 15: Temporary Services, Provide (D)

63WORK ITEM 16: Data Service , Provide (D)

65WORK ITEM 17: Sea Trial Performance, Provide Support (D)

68WORK ITEM 18: Tanks (MP Fuel Service), Clean and Inspect (D)

71WORK ITEM 19: Tanks (MP Fuel Stowage and Overflow), Clean and Inspect (D)

74WORK ITEM 20: Fathometer Transducer, Renew (D)

77WORK ITEM 21: Speed Doppler, Doppler Valve, Clean and Inspect (D)

80WORK ITEM 22: Tanks (Potable Water), Preserve “ 100% ” (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

A-Team Note: For vessels going to the Coast Guard Yard, the Yard may submit an alternate plan that accounts for specific CG Yard facility characteristics. However, the drawing above does not need to be changed in the specification. DELETE THIS NOTE BEFORE RELEASE OF REV 0.

Coast Guard Drawing 110 WPB 085-002, Rev -, Docking Plan Coast Guard Drawing 110 WPB 085-010, Rev B, Docking Plan, Docking/Lifting Cradle (‘A’, ‘B’ & ‘C’ Classes) Coast Guard Drawing 110 WPB 085-010, Rev B, Docking Plan Coast Guard Drawing 110 WPB 114-001, Rev B, Stern Flap Coast Guard Drawing 110 WPB 114-002, Rev A, Spray Rail Arrangement and Details Coast Guard Drawing 110 WPB 243-006, Rev C, Propulsion Shaft Details (Partially supercedes 110 WPB 243-002, 110B WPB 243-002, and 110C WPB 243-002) Coast Guard Drawing 110 WPB 601-002, Rev D, Outboard Profile and Weather Decks Coast Guard Drawing 110B WPB 085-001, Rev A, Tank CAPACITY - 95% Curves Coast Guard Drawing 110B WPB 085-010, Rev-, Docking Plan Coast Guard Drawing 110B WPB 085-012, Rev A, Booklet of General Plans Coast Guard Drawing 110B WPB 085-012, Rev A, Booklets of General Plans Coast Guard Drawing 110B WPB 111-003, Rev G, Shell Expansion Coast Guard Drawing 110B WPB 113-001, Rev J, Inner Bottom Plating Coast Guard Drawing 110B WPB 117-001, Rev H, Transverse Sections Coast Guard Drawing 110B WPB 121-001, Rev D, Longitudinal Bulkheads Coast Guard Drawing 110B WPB 161-001, Rev C, Main Shaft Strut Details Coast Guard Drawing 110B WPB 161-002, Rev D, Main Shaft Strut Installation Coast Guard Drawing 110B WPB 161-003, Rev B, Intermediate Shaft Strut Details Coast Guard Drawing 110B WPB 528-002, Rev E, Sewage Piping Arrangement & Details Coast Guard Drawing 110B WPB 561-004, Rev B, Steering System Details – Piping Coast Guard Drawing 110B WPB 635-001, Rev C, Linings And Insulation Plan And Details Coast Guard Drawing 110B WPB 636-001, Rev C, Noise Damping Details Coast Guard Drawing 110B WPB 85-012, Rev A, Booklet of General Plans (Supersedes 110B-WPB-085-7) Coast Guard Drawing 110C WPB 161-005, Rev D, Stern Tube Installation Details Coast Guard Drawing 110C WPB 562-001, Rev G, Rudder Details (Stock & Blade Details) Coast Guard Drawing 110C WPB 562-001, Rev G, Rudder Details (superceded 110B WPB 562-001) Coast Guard Drawing 110C WPB 565-001, Rev D, Fin Stabilizer System Coast Guard Drawing FL 6713-20 3, Rev - , CRP -V850, SST XDCR (SS505 ) Adapter Assembly

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Change 1, Jun 2006, Coatings and Color Manual Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual Coast Guard Technical Manual (TP) 3223, May 1985, SWBS 420, Section G, Doppler Service Manual Coast Guard Technical Manual (TP) 3990, Aug 2002, SWBS 426, Section A , NAVIKNOT 400 - SINGLE-AXIS DOPPLER SPEED LOG Service Manual Coast Guard Technical Publication (TP) 3100, Nov 1989, Chapter 561, Vosper-Thornycroft Steering Manual Coast Guard Technical Publication (TP) 3906, Oct 2002, Ship’s Steering Gear System Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0740, Jan 2009, Welding and Allied Processes 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 Surface Forces Logistics Center Standard Specification 8636 (SFLC Std Spec 8636), Jan 2009, Temporary Hull Accesses

OTHER REFERENCES

American National Standards Institute/American Water Works Association (ANSI/AWWA) C652, 2002, Disinfection of Water-Storage Facilities American National Standards Institute/NSF International (ANSI/NSF) 61, 2008, Drinking Water System Components - Health Effects ASTM International (ASTM) D 4138, 2007, Standard Practices for Measurement of Dry Film Thickness of Protective Coating Systems by Destructive, Cross-Sectioning Means ASTM International (ASTM) D1330, 2004, Standard Specification for Rubber Sheet Gaskets 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) 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 Federal Specification (Fed Spec) HH-P-151, Mar 1991, Packing; Rubber-Sheet, Cloth-Insert Federal Specification (Fed Spec) QQ-N-281, Oct 1985, Nickel-Copper Alloy Bar, Rod, Plate, Sheet, Strip, Wire, Forgings, and Structural and Special Shaped Sections Furuno Operators Manual RDP-139/148/149 HYPERLINK "http://www.assistdocs.com" MIL-A-22262, Mar 1996, Abrasive Blasting Media Ship Hull Blast Cleaning MIL-A-22262, Mar 1996, Abrasive Blasting Media Ship Hull Blast Cleaning MIL-A-24456, Jun 1979, Adhesive for Plastic-Vibration Damping Tile 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-2148, Oct 1989, Vibration Damping Materials, Procedures for Installation, Maintenance, and Repairs Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) C6183, 2007, Cork and Rubber Composition Sheet; For Aromatic Fuel And Oil Resistant Gaskets 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 10/NACE No.2, 2007, Near-White Blast Cleaning The Society for Protective Coatings (SSPC)/NACE International (NACE) Joint Surface Preparation Standard SSPC-SP 12/NACE No.5, 2007, Surface Preparation and Cleaning of Steel & Other Hard Materials by High and Ultrahigh Pressure Water Jetting The Society for Protective Coatings (SSPC)/NACE International (NACE) Joint Surface Preparation Standard SSPC-SP 7/NACE No.4, 2007, Brush-Off 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)

*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_110B_WPB_0909

110’ WPB (“B”-CLASS) PATROL BOAT

Pysical Characteristics

Hull Characteristics

110’ WPB (“B”-CLASS) PATROL BOAT

Machinery Characteristics

Tank CAPACITIES

00000_PWB_0211_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 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.

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:

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 fact that the requirements 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.).”

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.

11001 _JLW_1210_87WPB

WORK ITEM 1: Perform Ultrasonic Thickness Measurements (D)

· 1. SCOPE

· 1.1 Intent. This work item describes the requirements for the Contractor to perform Ultrasonic Thickness (UT) measurements in lots of 100 shots (measurements) as directed by the COTR.

· 1.2 Government-furnished property.

· None.

· 2. REFERENCES

· Coast Guard Drawings

· Coast Guard Drawing 110 WPB 085-002, Rev B, Docking Plan

· Coast Guard Drawing 87 WPB 111-001, Rev E, Shell Expansion

· Coast Guard Publications

· None.

· Other References

· None.

· 3. REQUIREMENTS

· 3.1 General.

· 3.1.1 CIR.

· Not applicable.

· 3.1.2 Technical Representative.

· Not applicable.

· 3.1.3 Protective measures.

· Not applicable.

· 3.1.4.1 If UT measurements cannot be obtained due to interferences, the Contractor shall submit a CFR that details all necessary interference removal/reinstallation work. After the KO has released a CR, remove the interferences and reinstall after completion of associated work.

· 3.2 UT measurements. The Contractor shall perform up to 250 UT measurements in locations designated by the Coast Guard Inspector, in accordance with SFLC Std Spec 0740, Appendix C. Create a sketch to show all locations selected for measurement and record all measurements in Table 1 (UT Measurements Summary Sheet - Port/Stbd Shell) provided at the end of this item. Submit a CFR that contains the sketch and completed Table I.

· 4. NOTES

· This section is not applicable to this work item.

Table I - UT MEASUREMENTS SUMMARY SHEET PORT/STBD SHELL

11400_UW_Appendages_0610_FLT REC_11400_UW_Appendages_FLT_110’ WPB ‘B’ Class (ALL) (0310)

WORK ITEM 2: Appendages (U/W), Leak Test (D)

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform leak test of the U/W appendages (see Table I).

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 110 WPB 085-010, Rev B, Docking Plan Coast Guard Drawing 110 WPB 114-001, Rev B, Stern Flap Coast Guard Drawing 110 WPB 114-002, Rev A, Spray Rail Arrangement and Details Coast Guard Drawing 110B WPB 111-003, Rev G, Shell Expansion Coast Guard Drawing 110C WPB 562-001, Rev G, Rudder Details (Stock & Blade Details) Coast Guard Drawing 110C WPB 565-001, Rev D, Fin Stabilizer System Coast Guard Publications Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Other References ASTM International (ASTM) D5363, 2008; Standard Specification for Anaerobic Single-Component Adhesives (An) MIL-S-45180, 1998; Sealing Compound, Gasket, Hydrocarbon Fluid and Water Resistant

3. REQUIREMENTS

3.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph:

· 3.2 (Leak test particulars).

3.2 Leak test particulars. In the presence of the Coast Guard Inspector, the Contractor shall accomplish the following tasks for all appendages as designated in paragraph 1.1(Intent) and Table 1 below, using the Coast Guard drawings listed in Section 2 (References) as guidance:

· Remove and dispose of the existing drain plugs.

· Submit a CIR noting any liquids draining from any of the appendages – indicating the presence of a leak.

· Dispose of any drained liquids in accordance with all Federal, state, and local laws and regulations.

CAUTION!

Some liquids that are drained may be may be classified as hazardous materials or hazardous waste depending on state and local regulations. The vessel environmental coordinator may assist with determination of waste category.

3.3 Plug renewal. Upon completion of all work on appendages, the Contractor shall accomplish the following tasks:

· Chase the hull insert threads of all plugs.

· Renew stainless steel, Type 316 and Monel drain plugs (as applicable) in place of those removed.

· Coat new plugs prior to installation with a sealing and locking compound conforming to ASTM D5363-AN0123 or a flexible joint compound conforming to MIL-S-45180, Type II.

TABLE I – DRAIN PLUGS FOR U/W APPENDAGES

3.4 Appendage air test. If a Change Request has been authorized and released, the Contractor shall accomplish the following tasks, for each appendage designated by the Coast Guard Inspector:

· Apply a vacuum or pressure of 2 psig to the void, in accordance with SFLC Std Spec 0740, Appendix C.

· Submit a CFR.

4. NOTES

This section is not applicable to this work item.

12314_DLA_0209_FLT

REC_12314_FLT/110’ WPB ‘B’ Class (ALL) (0310)

WORK ITEM 3: Tanks (Potable Water), Clean and Inspect (D)

1.1 Intent. This work item describes the requirements for the Contractor to clean and inspect the following tank(s):

(gallons)

LOW SUCTION

(gallons)

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 110B WPB 85-012, Rev A, Booklet of General Plans (Supersedes 110B-WPB-085-7)

Coast Guard Publications None.

Other References American National Standards Institute/NSF International (ANSI/NSF) 61, 2008, Drinking Water System Components - Health Effects American National Standards Institute/American Water Works Association (ANSI/AWWA) C652, 2002, Disinfection of Water-Storage Facilities

3. REQUIREMENTS

3.1 General. The Contractor shall refer to Coast Guard Drawing 110B WPB 85-012 for guidance. The Contractor shall notify the Dockmaster prior to filling or draining the potable water tank(s), when this item is being executed in a drydock availability. The Contractor shall accomplish the following for the tank(s) designated in paragraph 1.1 (Intent):

3.1.1 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.

3.1.2 Tank content removal. Remove and dispose of all fluids and/or residues in accordance with all applicable Federal, state, and local regulations.

3.1.3 Tank cleaning. Remove tank cover(s); clean tank interior surfaces free of all foreign materials, such as sediment or 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.

3.1.4 Inspection. Visually inspect all tank 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, if any.

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

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

· Sounding tube and striker plate condition.

· Suction and discharge piping condition.

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

3.2 Tank closing. The Contractor shall ensure that the tank(s) remain open for approximately 24 hours after completion of the tasks specified above. Notify the COTR at least 24 hours prior to closing the tank(s). After satisfactory inspection by the Coast Guard Inspector, and completion of all authorized repairs, close tank manhole cover(s) with new gasket material conforming to ANSI/NSF 61. Renew all stud cotton grommets (as applicable) upon reinstallation of manhole cover(s).

3.3 Tank disinfecting. After all other work involving the potable water system and tank closing have been completed, the Contractor shall disinfect and treat the affected potable water tank(s) and associated disturbed piping and components, as necessary, to meet or exceed the requirements of AWWA C652. After tank disinfecting; remove and dispose of all treated water in accordance with all Federal, state and local regulations.

NOTE

Ensure that no one enters the tanks once disinfection is completed.

3.4 Operational test – post repairs. After completion of work, the Contractor shall witness an operational test (by Coast Guard personnel) of all designated tank TLIs to prove satisfactory operating condition. Submit a CFR.

4. NOTES

This section is not applicable to this work item.

56200_0110_FLT

REC_56200_FLT_110’ WPB ‘B’ Class (ALL) (0210)

WORK ITEM 4: Rudder Assembly, Remove, Inspect and Reinstall (D)

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

($/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 or the C4IT Service Center.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 110B WPB 561-004, Rev B, Steering System Details – Piping Coast Guard Drawing 110C WPB 562-001, Rev G, Rudder Details (superceded 110B WPB 562-001) Coast Guard Publications Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Coast Guard Technical Publication (TP) 3906, Oct 2002, Ship’s Steering Gear System Coast Guard Technical Publication (TP) 3100, Nov 1989, Chapter 561, Vosper-Thornycroft Steering 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 None.

3. REQUIREMENTS

3.1 General.

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

· 3.3 (Inspections).

3.1.2 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.

· Provide suitable covering to protect all exposed rudder and vessel components against contamination during the performance of the work specified herein.

· Ensure that rudder stock/shaft surfaces are supported in a minimum of two locations, at all times, until reinstallation.

3.1.3 Hydraulic system cleanliness requirements. The Contractor shall maintain existing hydraulic system cleanliness; take all necessary precautions to prevent the introduction of contaminants into the hydraulic system. Whenever disconnecting or removing components from the hydraulic system, completely seal all openings to the rest of the system, immediately, using either caps (for externally threaded connection points), bolt-on blanks, or taped-on discs/covers (durable plastic or sheet-metal no less than 1/16-inch thick).

3.1.4 Initial inspection. After the cutter has been dry-docked, the Contractor shall perform the following inspections before disassembling the rudder assemblies. Submit a CIR.

Within 24-hours of dry-docking the vessel, remove the countersunk threaded plugs from the bottom of the rudder blades and note the type, volume, and color of any effluent.

Measure the rudder alignment and compare to the specifications detailed on Coast Guard Drawing 110C WPB 562-001.

Operate the rudders over the full range of motion and verify that the full range of motion is available per Coast Guard Drawing 110C WPB 562-001.

Center the rudders, compare the rudder angle indicator reading on the bridge to the actual rudder angle in aft steering, and document the readings.

Inspect the tie bar adjustment nut for the presence of (2) flat bar lock tabs welded across the adjusting nut, see Coast Guard Drawing 110C WPB 562-001, sheet 5 for guidance.

Inspect the threaded rods and associated fasteners on the rudder packing gland tension system for signs of defects or mechanical derangement. Verify the configuration and materials against the configuration specified on Coast Guard Drawing 110C WPB 562-001, sheet 3.

3.2 Removal. The Contractor shall remove, unship and disassemble each rudder assembly. Separate and uninstall the hydraulic actuators from the tiller heads. In the presence of a CG Inspector, perform a freedom of motion check utilizing the emergency manual steering system. Take note of the bearing action for signs of binding, clicking, or any other quality that would indicate a mechanical fault.

3.3 Inspections. The Contractor shall clean all rudder components, and accomplish the below-specified inspections (Submit CIR for rudder blade and stock only, and a CFR for all other component inspections):

3.3.1 Visual. Clean and visually inspect all components, including but not limited to, rudder stock/shaft and blade surfaces, bearings, bearing housing, seals, and grease passages for signs of excessive wear and other mechanical defects such as nicks, cracks, and corrosion, as applicable.

3.3.1.1 Visually inspect the grease lines, fittings, and securing clamps, from the final threaded connection at the service end points back to the bulkhead connections at the hand operated grease pump. Inspect for corrosion, age and environmental degradation, chaffing, or any other mechanical discrepancy. Compare the configuration, materials, and route of the grease lines against Coast Guard Drawing 561-004.

3.3.1.2 Visually inspect the hydraulic lines (flexible rubber and hard pipes), fittings, compression glands and seals, and securing clamps from the final threaded connection at the service end points to the bulkhead connections on the hydraulic power unit. Inspect for corrosion, age and environmental degradation, chaffing, or any other mechanical discrepancy. Compare the configuration and route of the hydraulic lines against Coast Guard Drawing 110B WPB 561-004.

3.3.1.3 Void the packing boxes of packing material. Power tool clean the packing gland pusher and packing box to remove any marine growth or contaminants. Leave the packing gland pusher bare metal. Inspect the packing boxes and gland for signs of corrosion, wear, or mechanical fault.

3.3.1.4 Visually inspect the upper rudder bearing mounting plate, mounting holes, and adjacent framing for corrosion, cracks, hole elongation, or any other mechanical fault.

3.3.2 Measurements. Conduct the following measurements:

· Check rudder stock runout for straightness.

· Measure the outside diameter of the rudder stock where the upper and lower bearings sit.

· Measure the lower rudder bearing inside diameter.

· Measure the diameters of the tie bar pins, hydraulic ram pins, tie bar pin and hydraulic ram pin bushings, the tie bar rod eye bores, and hydraulic ram rod eye bores.

· Measure and record all bearing housing inside diameters at forward, aft, and middle positions. Compare measurements to the dimensions in Table I and tolerances per ANSI/ASTM B4.1, Class FN3 Force. Submit CFR.

Table 1 – SLEEVE DIAMETERS

Areas Sleeve Inside Diameters (inches)

Check the concentricity/alignment between the upper bearing housing and lower bearing housing bores.

3.3.3 NDI. The Contractor shall perform NDI of the following components in accordance with SFLC Std Spec 0740, Appendix C. Submit a CFR.

· Keys.

· Keyways.

3.4 Reassembly and reinstallation. Upon completion of all inspections and authorized repairs, the Contractor shall reassemble and reinstall the port and starboard rudder assemblies, using Coast Guard Drawings 110B WPB 561-004 and 110C WPB 562-001, TP-3906 and TP 3100 as guidance, and accomplish the following:

3.4.1 Bearing housing seal renewal. Renew the upper and lower seals of the upper bearing housings.

3.4.2 Packing renewal. Furnish and install new packing material as shown on Coast Guard Drawing 110C WPB 562-001, following manufacturer’s installation instructions.

3.4.3 Bearing renewal. If a change request has been released and authorized by the KO, the Contractor shall accomplish the following, for a designated rudder stock:

3.4.3.1 Upper bearing. Furnish and install a new upper roller bearing.

3.4.3.2 Lower bearing. Furnish and install a new lower bearing (see 4.7 (Sources for packing material and lower bearing)).

3.4.3.2.1 Measure and record rudder tube inside diameter (ID) bearing inner diameter (ID), at six points (two at the top, two in the middle, and two at the bottom).

3.4.3.2.2 Measure and machine the outer diameter (OD) of the bearing, as necessary to achieve a 0.003” interference fit. Install the new bearing.

3.4.3.2.3 Measure and record the inner diameter of the bearing at the same locations listed above, after bearing has been installed.

3.4.3.3 Submit a written CFR of all bearing measurements taken.

3.5 Alignment. Upon completion of reinstallation, the Contractor shall check the rudder alignment with the pilothouse rudder angle indicator. Ensure that alignment is adjusted to within plus or minus 1/2 degree.

3.6 Government’s right for changing out the rudder. The Contractor shall be aware that the Government reserves the right to furnish a new rudder for installation in place of each existing rudder. If the Government exercises this right, the Contractor shall accomplish the following:

3.6.1 Turn over the removed rudder to the Coast Guard PA as a MTI item.

3.6.2 Prior to installation of the new rudder(s), prepare and coat the new rudder(s) surfaces using the system specified for "Underwater (U/W) Body Appendages (U/W Appendages: High Turbulent Areas (i.e. Rudders, Struts, Fins for 110WPBs))" in COMDTINST M10360.3, Appendix A (Cutter and Boat Exterior Paint Systems), with the exception of the following:

3.6.2.1 Roughen the existing Belzona-coated surface to facilitate paint adhesion, taking care not to remove the existing Belzona coating. Solvent clean the abraded surface.

3.6.2.2 Apply one coat (2-3 mils DFT) of high turbulence coating, followed by two coats of antifouling paint, while the high turbulence coating is still tacky.

3.7 Government’s right for changing out the bearing housing. The Contractor shall be aware that the Government reserves the right to furnish a spare bearing housing or housings to be installed in place of the existing housing(s). If the Government exercises this right, the Contractor shall use the existing housing(s) to template the flange bolt, bearing set screw holes, and alignment pin holes to the new housing(s), as applicable.

3.8 Operational test – post repairs. After completion of work, the Contractor shall witness an operational test (by Coast Guard personnel) of the rudder system to prove satisfactory operating condition. Test the steering and rudder system to ensure the rudders travel smoothly throughout the full range of travel without chattering or binding and at the required rate of train. The steering shall be operated in all modes of control. Submit a CFR.

4. NOTES

4.1 Rudder details. Rudder details are shown on Coast Guard Drawing 110B WPB 562-001 (all sheets).

4.2 Rudder stock data. The rudder stock outside diameter should be 5.000".

4.3 Seal particulars. Both seals are press fitted; the outside diameter of the upper seal is 4.506 inch and lower seal is 5.256 inch.

4.4 Lower bearing data. The inside diameter of bearing should be in between 5.0093" and 5.0084". Clearance between the ID of the bearing and the stock should be in between 0.0109" and 0.0116". Installation of lower bearing may require machining to obtain a proper fit.

4.5 Upper bearing data. Bearing data for this bearing is as follows: SKF No. 21319CC, Spherical roller bearing, 3.7482 inch bore x 7.8740 inch O.D.

4.6 Sources for lower bearing. Sources for procuring lower bearing specified herein include, but are not limited to the following:

59301_0310_FLT

REC_59301_FLT_110’ WPB ‘B’ Class (ALL) (1209)

WORK ITEM 5: Grey Water Holding Tanks , Clean and Inspect (D)1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to clean and inspect the following tank(s):

(Gallons) LOW SUCTION (Gallons)

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 110B WPB 528-002, Rev E, Sewage Piping Arrangement &…