SPEC REV2 SAWFISH

USCGC SAWFISH (WPB-87) EMERGENCY DRYDOCK AVAILABILITY 2012

USCGC SAWFISH (WPB 87357)

87 FOOT COASTAL PATROL BOAT (USCG)

SPECIFICATION FOR EMERGENCY DRYDOCK REPAIRS

Developed By: Paul M Walukewicz (REV-2, 28 February 2012)

TABLE OF CONTENTS

iiiRevisions Record ivConsolidated List of References viConsolidated List of Government-furnished Property viiiConsolidated List of Critical Inspection Items ixPrincipal Characteristics

1General Requirements

12WORK ITEM 1: Main Engine/Reduction Gear, Realign ( O )

14WORK ITEM 2: Propulsion Shaft, Repair (O)

16WORK ITEM 3: Propulsion Shaft, Straighten (O)

18WORK ITEM 4: Intermediate Water-Lubricated Propulsion Shaft Bearing , Renew (O)

20WORK ITEM 5: Aft Water-Lubricated Propulsion Shaft Bearing , Renew (O)

22WORK ITEM 6: Intermediate Bearing Carrier, Renew (O)

23WORK ITEM 7: Aft Bearing Carrier, Renew (O)

24WORK ITEM 8: Propellers, Remove, Inspect, and Reinstall (D)

27WORK ITEM 9: Propeller, Minor Reconditioning and Repairs, Perform (O)

30WORK ITEM 10: Rudder Assemblies, Remove, Inspect and Reinstall (D)

34WORK ITEM 11: U/W Body, Preserve (“100%”) (O)

37WORK ITEM 12: Drydocking (D)

42WORK ITEM 13: Temporary Services, Provide (D)

44WORK ITEM 14: Telephone Service, Provide (D)

45WORK ITEM 15: Reduction Gear/Shafting System, Inspect and Repair (D)

57WORK ITEM 16: U/W Body, Preserve (“Partial – 33%”) (O)

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 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 87 WPB 085-010, Rev D, Docking Plan

Coast Guard Drawing 87 WPB 085-011, Rev B, Lifting Slings

Coast Guard Drawing 87 WPB 085-012, Rev -, Lifting Cradle

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

Coast Guard Drawing 87 WPB 161-001, Rev C, Skeg Construction

Coast Guard Drawing 87 WPB 163-001, Rev G, Sea Chest Details

Coast Guard Drawing 87 WPB 182-001, Rev A, Main Engine and Generator Foundations

Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details

Coast Guard Drawing 87 WPB 243-050, Rev -, Propulsion Shaft Single Sheet Detail 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 J, Steering System Details

Coast Guard Drawing 87 WPB 562-001, Rev A, Rudder Details

Coast Guard Drawing 87 WPB 583-001, Rev T, RIB Deployment Structure

Coast Guard Drawing 87 WPB 601-001, Rev G; Outboard Profile And General Arrangement

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Jun 2006, Coatings and Colors 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 (SFLC Std Spec) 0000, Jan 2009, General Requirements

Surface Forces Logistics Center Standard Specification (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

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) D 4138, 2007, Standard Practices for Measurement of Dry Film Thickness of Protective Coating Systems by Destructive, Cross-Sectioning Means

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

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)

(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

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

*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_1111_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 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 portable fire extinguishers for Coast Guard fire watch personnel. Coast Guard fire watch is in lieu of contractor personnel during the hours of 0800-1600, Monday through Friday, and limited to two Coast Guard fire watch personnel.

· 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.

23320_JLW_1210_87WPB

WORK ITEM 1: Main Engine/Reduction Gear, Realign ( O )

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to realign a designated main diesel engine and its corresponding reduction gear assembly to the propeller shaft.

1.2 Government-furnished property.

($/UNIT)

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 87 WPB 182-001, Rev A, Main Engine and Generator Foundations Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details Coast Guard Publications None.

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.

Not applicable.

3.1.2 Technical Representative.

Not applicable.

3.1.3 Protective measures.

Not applicable.

3.1.4 Interferences.

None.

3.2 Alignment. The Contractor shall use USCG CPB Project MTU-FA 771903 as a guide.

3.2.1 Personnel qualification. The Contractor shall ensure that the shaft alignment is performed under the direct supervision of personnel experienced in and regularly engaged in shaft and engine alignment. Personnel performing alignment work shall be familiar with manufacturer's installation techniques, be able to assist with proper bearing and shaft alignment, be able to analyze shaft and bearing clearances, and be able to ensure compliance with engine/reduction gear manufacturer's installation standards. Personnel engaged in the supervision of the alignment work shall possess a résumé of demonstrated experience with engine and reduction gear systems. Submit a copy of the supervisor’s résumé and any applicable references to the COTR at the Arrival Conference.

3.3 Alignment preparation. Prior to shaft realignment, the Contractor shall ensure the following conditions are met for at least 24 hours before the alignment check:

· The vessel is waterborne with fuel and water filled to normal operating levels, a minimum of three-quarters capacity.

· All major equipment and machinery weighing over 1,000 pounds (450 kilograms) are either installed or simulated by equivalent weights appropriately located.

3.4 Shaft realignment. The Contractor shall accomplish the shaft realignment using Coast Guard Drawings 87 WPB 182-001, 87 WPB 243-001, and Engine/Gearbox Plant Alignment Instructions (USCG CPB Project MTU-FA 771903) as guidance.

3.4.1 Alignment adjustment. Correct any misalignment by repositioning the propulsion engine/reduction gear. Shim the engine foundations in place as necessary.

3.4.2 Final readings. Recheck all alignment readings, insert the bolts in the flanges, and tighten to the proper torque for the size and type. Submit a CFR for all final readings.

NOTE

The tightening torque for the flange bolts shall be 430 Nm according to Engine/Gearbox Plant Alignment Instructions (USCG CPB Project MTU-FA 771903).

3.5 Operational test. The Contractor shall demonstrate proper operation of the propeller shaft without binding during sea trials. Inspect and correct any abnormal noise and vibration generated from the shaft or bearings (see 4.1, Equipment operation).

4. NOTES

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

24301_MWS_0112_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 in four cubic inch increments.

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 Drawing 87 WPB 243-050, Rev -, Propulsion Shaft: Single Sheet Detail 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 in four cubic inch increments. First remove 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. Dye penetrant inspect (NDI) all welds and submit a CFR.

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.

3.2.4 Final surface finish. The repaired area surface finish shall be brought to within specification of the affected area.

3.3 Post-repair inspection. Following all repair work, the Contractor shall inspect and demonstrate that the requirements as shown on Coast Guard Drawing 87 WPB 243-050 have been met. Submit a CFR.

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_MWS_1111_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 243-050, Rev -, Propulsion Shaft: Single Sheet Detail 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.

3.2 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.

3.3 Pre-straightening preparation. Prior to initiating straightening processes, slowly spin the shaft on the lathe for approximately two hours to eliminate any sagging that may have occurred during handling and storage.

3.4 Straightening procedures. Straighten the shaft to equal or less than 0.005" total indicator runout, using the cold straightening methods in accordance with MIL-STD-2191, Section 11.2.2.3 and sub-paragraphs.

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

· Conduct non-destructive inspection of all straightened areas in accordance with SFLC Std Spec 0740.

· Recheck the shaft surfaces, as specified in paragraph 3.1.2.1 (Pre-straightening inspection).

4. NOTES

This section is not applicable to this work item.

24303_JLW_1210_87WPB

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

1.1 Intent. This work item describes the requirements for the Contractor to renew the intermediate water-lubricated bearing for the designated shaft.

NOTICE!

The work performed on one shaft is equivalent to one job.

1.2 Government-furnished property.

($/UNIT)

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

PN: F54615-02-8-1

NSN: 3120-21-914-2012

Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details Coast Guard Publications None Other References None

3. REQUIREMENTS

3.1 Bearing renewal. The Contractor shall perform the following. Refer to Coast Guard Drawing 87 WPB 243-001. All measurments shall be to the nearest thousandth inch unless otherwise specified.

3.1.1 Remove and dispose of existing bearing. Inspect intermediate carrier for damage, excessive wear, etc. Measure and record bearing carrier inner diameter dimensions at the 3-9 and 6-12 o’clock positions in three locations (forward end, middle, and aft end of carrier). Submit CFR.

3.1.2 Skim cut new Government-furnished bearing, as required, to suit carrier and shaft dimensions (i.e. as specified on Coast Guard Drawing 87 WPB 243-001, cut bearing to maintain interference fit tolerance between bearing and carrier, and maintain clearance tolerance between shaft and bearing). Measure and record final bearing dimensions. Submit CFR.

NOTICE

Find “Target Points” that designate CL of stern tube.

Alignment method/rig, reused from shaft rmv/inspect/reinstl item, shall be accurate to within 0.001 inch (e.g. piano wire, optical, laser, etc.)

3.1.3 Remove and dispose of exiting chock-fast bed. Align the center line of the intermediate carrier to the center line of the stern tube. Measure and record alignment data. Submit CFR.

3.1.4 Renew chock fast bed. Prior to pouring, seal or dam-off all joints and seams to prevent leakage. After chock-fast has set, re-verify alignment of carrier with the centerline of the stern tube; measure and record alignment data. Submit CFR.

3.1.5 Install new Government-furnished bearing. Renew all disturbed fasteners (Monel or type 316 stainless steel). Verify final alignment of centerline of bearing with centerline of the stern tube; measure and record alignment data. Submit CFR.

3.2 Testing. During sea trials verify no unusual noise, binding, abnormal vibration. Submit CFR.

4. NOTES

24304_JLW_1210_87WPB

WORK ITEM 5: Aft Water-Lubricated Propulsion Shaft Bearing , Renew (O) 1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew the aft water-lubricated bearing for the designated shaft.

NOTE

The work performed on one shaft is equivalent to one job.

1.2 Government-furnished property.

($/UNIT)

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

PN: F54615-02-8-0

NSN: 3120-21-914-2011

Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details Coast Guard Publications None Other References None

3. REQUIREMENTS

3.1 Bearing renewal. The Contractor shall perform the following. Refer to Coast Guard Drawing 87 WPB 243-001. All measurments shall be to the nearest thousandth inch unless otherwise specified.

3.1.1 Remove and dispose of existing bearing. Inspect aft carrier for damage, excessive wear, etc. Measure the bearing carrier position relative to stern tube centerline. Measure and record bearing carrier inner diameter dimensions at the 3-9 and 6-12 o’clock positions in three locations (forward end, middle, and aft end of carrier). Submit CFR.

3.1.2 Skim cut new Government-furnished bearing, as required, to suit carrier and shaft dimensions (i.e. as specified on Coast Guard Drawing 87 WPB 243-001, cut bearing to maintain interference fit tolerance between bearing and carrier, and maintain clearance tolerance between shaft and bearing). Measure and record final bearing dimensions. Submit CFR.

NOTE

Find “Target Points” that designate CL of stern tube.

Alignment method/rig, reused from shaft rmv/inspect/reinstl item, shall be accurate to within 0.001 inch (e.g. piano wire, optical, laser, etc.)

3.1.3 Install new Government-furnished bearing. Renew all disturbed fasteners (Monel or type 316 stainless steel). Verify final position of bearing centerline relative to the stern tube centerline; measure and record alignment data. Submit CFR.

3.2 Testing. During sea trials verify no unusual shaft noise, binding, abnormal vibration. Submit CFR.

4. NOTES

24305_JLW_1210_87WPB

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

1.1 Intent. This work item describes the requirements for the Contractor to renew the designated bearing carrier.

NOTE

Perform this item in conjunction with associated bearing renewal work item and shaft rmv/inspect/reinstl item.

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 None.

Other References None.

3. REQUIREMENTS

3.1 Bearing carrier renewal. The Contractor shall fabricate and install a new stainless steel bearing carrier as shown on Coast Guard Drawing 87 WPB 243-001. Measure and record all final dimensions of the new bearing carrier. Submit CFR.

CAUTION!

DO NOT cut into the skeg while performing this work.

4. NOTES

24306_JLW_1210_87WPB

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

1.1 Intent. This work item describes the requirements for the Contractor to renew the designated bearing carrier.

NOTICE

Perform this item in conjunction with associated bearing renewal work item and shaft rmv/inspect/reinstl item.

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 None.

Other References None.

3. REQUIREMENTS

3.1 Bearing carrier renewal. The Contractor shall fabricate and install a new stainless steel bearing carrier as shown on Coast Guard Drawing 87 WPB 243-001. Measure and record all final dimensions of the new bearing carrier. Submit CFR.

CAUTION!

DO NOT cut into the skeg while performing this work.

4. NOTES

24500_JLW_1210_87WPB

WORK ITEM 8: Propellers, Remove, Inspect, and Reinstall (D)

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

1.2 Government-furnished property.

NSN: 2010-01-457-0573

NSN: 2010-01-459-0421

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 Publications Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Other References 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-PRF-16173, 2006, Corrosive Preventive Compound, Solvent Cutback, Cold Application

3. REQUIREMENTS

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

· 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 245-003.

3.2.1 Removal. Remove the propeller.

NOTE

If heating is required to remove a propeller, ensure that the hub temperature never exceeds 500 degrees Fahrenheit. Remove gland, packing ring, and fill & vent plugs. Protect adjacent components from flames.

3.2.2 Inspection. Visually inspect the propeller for any damage, cracks, and other defects. Examine and record the suction and pressure face thickness, blade tip profiles, leading and trailing edges, contours, track, width, diameter, taper, pitch, and keyway of the propeller in accordance with ISO 484/2, Class I. Submit a written CFR.

3.2.2.1 NDI. Perform NDI of the entire surface area of each propeller, with particular attention to the propeller hub, blade roots, blade tips, blade leading and trailing edges, keyways and bolt-holes, in accordance with SFLC Std Spec 0740, Appendix C. Submit a CFR.

3.2.3 Polishing. Polish the propellers to meet a minimum surface texture finish of 6 micrometers from the radius 0.3R in accordance with ISO 484/2, Class I.

3.2.4 Propeller hub fitting check. Verify hub fit in the presence of the Coast Guard Inspector. and with the key in place, carefully check the fit of the propeller hub bore to the shaft taper by applying Prussian blue to the shaft taper.

3.2.4.1 Uniform fit. 80 percent contact over the taper area, with a slightly heavier fit on the larger end, is required. Do not heat the shaft taper to compensate for a poor fit.

3.2.4.2 Propeller fit. If the fit is less than 80 percent, hand grind/stone the propeller hub bore, as required, to achieve 80 percent contact over taper surfaces.

WARNING!

Do not machine the shaft taper.

3.2.4.3 Location inscription. When 80 percent fit has been obtained, make a small inscription on the shaft to mark the propeller location. Use this mark as a reference in final assembly.

3.3 Propeller Installation. The Contractor shall clean the propeller hub bore and shaft taper to remove all bluing, lubricants, dirt, and all other foreign particles. Install the propeller with dry metal-to-metal contact to obtain the maximum frictional force for torque transmission. Renew the rubber O-rings and packing before reassembly, as applicable. After the propeller is installed on the taper (in the same position as when fitted), install the propeller nut. Using the nut, drive the propeller up the taper approximately 1/16" past the inscribed mark as specified in 3.2.4.3 (Location inscription). Lock the nut in place.

NOTE

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

3.3.1 Void filling. As required, fill all internal voids in the propeller hub and cap with rust preventive compound conforming to MIL-PRF-16173, Class II, Grade 3. Renew all brass plugs.

3.3.2 Adhere to the following:

· Do…