904_NORTHLAND_DD_FY12_CPP_Paint_Rev-0.pdf

USCGC NORTHLAND (WMEC 904)

270 FOOT "A CLASS" MEDIUM ENDURANCE CUTTER

SPECIFICATION FOR DRYDOCK REPAIRS

01 May thru 31 July 2012

Developed By: Earl F. Allen

(Rev-0, 03 April 2012)

USCGC NORTHLAND (WMEC-270A) DRYDOCK AVAILABILITY 2012

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ....................................................................................................................................... iii Consolidated List of References ................................................................................................................ iv Consolidated List of Government-furnished Property .............................................................................. vii Consolidated List of Critical Inspection Items .......................................................................................... ix Hull Plating, Freeboard, Preserve, 100% Condition-B ( ........................................................................... ix Principal Characteristics ............................................................................................................................. x General Requirements DEFINITE WORK ITEM 01: Inspect Propulsion Shafting CPP Oil Tubes DEFINITE WORK ITEM 02: Controllable Pitch Propeller (CPP) System, Service DEFINITE WORK ITEM 03: U/W Body, Preserve, 100% Condition-B DEFINITE WORK ITEM 04: Hull Plating, Freeboard, Preserve, 100% Condition-B DEFINITE WORK ITEM 05: Drydocking DEFINITE WORK ITEM 06: Temporary Services, Provide DEFINITE WORK ITEM 07: Install One Sea Strainer and Overhaul Two Sea Valves DEFINITE WORK ITEM 08: Sea Trial Performance, Provide Support OPTIONAL WORK ITEM 09: Propulsion Shafting, Remove, Inspect and Reinstall OPTIONAL WORK ITEM 10: Propulsion Intermediate Shaft, Remove, Inspect and Reinstall OPTIONAL WORK ITEM 11: Propulsion Shafting (Thrust Shaft), Remove, Inspect and Reinstall OPTIONAL WORK ITEM 12: Stern Tube Seal Assemblies, Overhaul OPTIONAL WORK ITEM 13: Propeller Shaft Sleeve(s), Renew OPTIONAL WORK ITEM 14: Propulsion Shaft Bearings (External), Check Clearances OPTIONAL WORK ITEM 15: Propulsion Shaft Bearing Housings (External), Inspect OPTIONAL WORK ITEM 16: Controllable Pitch Propeller Hub Assembly, General Maintenance OPTIONAL WORK ITEM 17: U/W Body, Preserve 100% OPTIONAL WORK ITEM 18: Stern Tube Interior Surfaces, Preserve 100% OPTIONAL WORK ITEM 19: Hull Plating Freeboard, Preserve 100%

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.

DATE REV# WORK

ITEM#

CHANGES MADE

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.

iii (Rev-0)

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 901 WMEC 243-001, Rev K, Shafting Arrangement Coast Guard Drawing 901 WMEC 243-002, Rev G, Stern Tubes, Strut Bearing & Seal Arrangement and

Details Coast Guard Drawing 901 WMEC 243-003, Rev F, Shaft Removal Arrangement Coast Guard Drawing 901 WMEC 243-004, Rev E, CPP Shafting Details Coast Guard Drawing 905 WMEC 243-006, Rev C, Shaft Seal Assembly and Details Coast Guard Drawing 901 WMEC 245-001, Rev E, CPCH Propeller Hydraulic System Diagram Coast Guard Drawing 901 WMEC 245-003, Rev E, Propeller Hub Assembly Coast Guard Drawing 901 WMEC 245-004, Rev E, Blade and Palm Coast Guard Drawing 901 WMEC 245-007, Rev B, Special Tools Coast Guard Drawing 901 WMEC 245-008, Rev C, Actuating Unit Coast Guard Drawing 901 WMEC 245-009, Rev L, CPCH Propeller Hydraulic System Diagram Coast Guard Drawing 901 WMEC 256-001, Rev T, Main and Auxiliary Water Cooling Diagrams Coast Guard Drawing 901 WMEC 256-002, Rev L, Main & Aux Sw Cooling Sys A&D Coast Guard Drawing 901 WMEC 256-004, Rev A, Aux Salt Water Mods Coast Guard Drawing 905 WMEC 562-004, Rev D, Rudder Assembly Coast Guard Drawing 901 WMEC 562-005, Rev F, A & B Class Rudder Stock And Steering Gear A & D Coast Guard Drawing 901 WMEC 801-009, Rev J, Outboard Profile Coast Guard Drawing 901 WMEC 801-022, Rev H, Docking Plan iv (Rev-0) http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace

Coast Guard Fleet Drawing FL 2804-11, Rev D, Visual Id Numeral & Letter for Ships Coast Guard Fleet Drawing FL 2804-12, Rev-, U.S.C.G. Emblem Coast Guard Fleet Drawing FL 2804-13, Rev G, Visual Id Kit Sched Coast Guard Fleet Drawing FL 2804-15, Rev-, Draft Figs

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and

Color Manual Coast Guard Technical Publication (TP) 2698, May 2006, Manufacturer’s Instruction Book-SWBS

Group(s) 242-245, Stuffing Box, SWBS 243 Section B Coast Guard Technical Publication (TP) 2699, Mar 2006, Manufacturer’s Instruction Book-SWBS

Group(s) 245, Controllable-Pitch Propeller System Coast Guard Technical Publication (TP) 2816, Mar 1986, SWBS 243, Section B, Technical Manual for

Type MA Mechanical Stern Tube Seal 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 5000 (SFLC Std Spec 5000), Jan 2009, Inspect, Repair, and Test Auxiliary Machine Systems 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 Society of Mechanical Engineers (ASME) B16.34, 2004, Valves-Flanged, Threaded, and

Welding End ASTM International (ASTM) D1330, 2004, Standard Specification for Rubber Sheet Gaskets 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) D4174, Re-approved 1999, Standard Practice for Cleaning, Flushing, and

Purification of Petroleum Fluid Hydraulic Systems ASTM International (ASTM) D4417, 2003, Standard Test Methods for Field Measurement of Surface

Profile of Blast Cleaned Steel ASTM International (ASTM) F992, 2006, Standard Specification for Valve Label Plates 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 International Standard Organization (ISO) 4406, 1999, Hydraulic Fluid Power – Fluids – Method for

Coding Level of Contamination by Solid Particles Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) SP-61, 2003 Edition, Pressure Testing Of Steel Valves v (Rev-0)

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

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

Manufacturers' Standardization Society of the Valve and Fittings Industry (MSS) SP-80, 2008 Edition, Bronze Gate, Globe, Angle and Check Valves

MIL-A-22262, Mar 1996, Abrasive Blasting Media Ship Hull Blast Cleaning MIL-PRF-16173, Sep 2006 Corrosion Preventive Compound, Solvent Cutback, Cold Application MIL-PRF-17672, May 1995, Hydraulic Fluid, Petroleum, Inhibited MIL-PRF-24647, Jun 2006, Paint System, Anticorrosive and Antifouling, Ship Hull NAVSEA Drawing 803-2145807, Rev C, Propulsion Shafting And Components 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) VIS 1, 2004, Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning

The Society for Protective Coatings (SSPC) Surface Preparation Specification No. 1 (SSPC-SP 1), 2004, Solvent Cleaning

The Society for Protective Coatings (SSPC)/NACE-International (NACE) Joint Surface Preparation Standard SSPC-SP 10/NACE No. 2, 2004, Near-White Blast Cleaning

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.11 (SSPC-SP 11), 2004, Power Tool Cleaning to Bare Metal

The Society for Protective Coatings (SSPC)/NACE-International (NACE) Joint Surface Preparation Standard SSPC-SP 12/NACE No. SSPC-SP 12/NACE No.5, Surface Preparation and Cleaning of Steel & Other Hard Materials by High and Ultrahigh Pressure Water Jetting Prior to Recoating

The Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) G-6032, 1999, Grease, Plug Valve, Gasoline and Oil Resistant, NATO Code Number G-363, Metric vi (Rev-0) http://208.233.211.117/cgi-bin/SoftCart.exe/STORE/PAGES/SP10.htm?L+sspcstore+wukd3494+1057295146 vii (Rev-0)

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.

WORK

ITEM MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST EA

D-02 Y **Propeller Blade-LH (Port) NSN: 2010-01-119-3972 1 Set 40,000.00 D-02 Y **Propeller Blade-RH (Stbd) NSN: 2010-01-120-2871 1 Set 40,000.00 D-02 N O-Ring NSN: 5330-01-120-5229 8 ea. 97.00 D-02 N O-Ring NSN: 5330-01-118-8529 8 ea. 96.00 D-02 N Blade Washer NSN: 5310-01-335-4361 48 ea. 112.00 D-02 N O. D. Box Inspection Kit NSN: 3010-01-470-3519 2 ea. 330.00 D-02 N Filter NSN: 4330-01-177-4069 12 ea. 92.00 D-02 Y **Oil Feed Bushing NSN: 3120-12-329-5287 2 ea. 4,811.00 D-02 N **Ball Bearing NSN: 3110-00-156-6745 2 pr. 46.00 D-02 N **Bearing Bushing NSN: 2010-01-469-8639 2 ea. 450.00 D-02 N **Bearing Bushing NSN: 3120-12-198-7607 8 ea. 559.00 D-02 N **Spool valve assembly NSN: 4820-01-513-2509 2 ea. 100.00

D-02 Y Hydraulic Gear Pump, RH, 25 GPM, 1800 RPM, Horizontal Mounted

NSN: 4320-01-130-6252

Pt#: S418-2663 (ZNC) 5 ea 973.96

D-02 Y Hydraulic Gear Pump, LH, 25 GPM NSN: 4320-01-131-6913 Pt#: S418L-2664 (ZNC) 1 ea 997.84

D-02 N RV-1 By-pass to Sump ¾ in, 90 PSI 2 ea 175.00 D-02 N RV-2 Service Pump Discharge ½ in, 600 PSI 6 ea 125.00 D-02 N RV-3 Discharge Pump 1/8 in, 150 PSI 2 ea 100.00 D-02 N RV-4 Head Tank Pump Discharge ¾ in, 150 P SI 2 ea 175.00 D-02 N RV-5 Cooler Discharge to Sump 1-1/2 in, 15 PSI 2 ea 275.00 D-02 N RV-6 Pump Disch Main to Cooler 1-1/2 in, 500 PSI 2 ea 275.00 D-02 N RV-7 Hydraulic oil transfer pump 1-1/2 in, 28 PSI 1 ea 275.00 D-05 Y *Transducer Cover Plate N/A 4 ea. 50.00 D-07 N Simplex Sea Strainer N/A 01 ea $25,000 O-09 Y **Propeller shaft NSN: 2010-01-135-7065 2 ea. 228,555.00 O-10 Y **Intermediate Shaft NSN: 2010-01-364-2026 2 ea. 10,000.00 O-11 Y **Thrust shaft NSN: 2010-01-366-0540 1 ea. 17,150.00 O-11 Y **Shipping pilots N/A 1 set 400.00 O-12 N **Overhaul kit NSN: 5330-01-527-0959 2 ea. 12,894.00 O-12 Y **Stern tube split seal NSN: 5330-01-359-5555 4 ea. 7,763.86 O-13 N **Stern Tube Sleeve (Forward) NSN: 2010-01-340-6083 2 ea. $8,236.00 O-13 N **Stern Tube Sleeve (Aft) NSN: 2010-01-345-2315 2 ea. $10,378.00 O-13 N **Propeller Strut Sleeve (Forward) NSN: 2010-01-345-2314 2 ea. $12,594.33 O-13 N **Propeller Strut Sleeve (Aft) NSN: 2010-01-340-5362 2 ea. $12,725.00 O-16 N **Hub installation kit NSN: 2010-01-470-3258 2 ea. 215.00 O-16 Y **Left hand hub assembly NSN: 2010-01-119-5469 1 ea. 304,313.00 O-16 Y **Right hand hub assembly NSN: 2010-01-118-8538 1 ea. 304,313.00 O-16 N ***CPP Tool Kit ASN: 5180-01-F10-1824 1 set 20,000.00 O-16 N *Special tools (see 4.2 Government- N/A 1 set 1,000.00 loaned installation tools) *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 viii (Rev-0) ix (Rev-0)

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 D-01 Inspect Propulsion Shafting CPP Oil Tubes (3.2.2 Inspect for contamination) D-02 Controllable Pitch Propeller (CPP) System, Service (3.2.2.1 Blade inspections) D-02 Controllable Pitch Propeller (CPP) System, Service (3.2.3.3 Hub interior inspection) D-02 Controllable Pitch Propeller (CPP) System, Service (3.2.7.3 Cooler inspection) D-03 U/W Body, Preserve, 100% Condition-B (3.1.7 Surface inspection) D-04 Hull Plating, Freeboard, Preserve, 100% Condition-B (3.2.2.1 Surface inspection) O-09 Propulsion Shafting; Remove, Inspect, and Reinstall (3.2.2 Inspections) O-10 Propulsion Intermediate Shaft; Remove, Inspect, and Reinstall (3.4 Inspections) O-11 Propulsion Shafting (Thrust Shaft); Remove, Inspect and Reinstall (3.3 Inspections) O-14 Propulsion Shaft Bearings (External), Check Clearances (3.2.2 Bearing clearances)

Principal Characteristics

PC_270A_WMEC_0909

270' WMEC (A Class)

PHYSICAL CHARACTERISTICS

Length Overall 270' 0" Depth 33' 3" Maximum Beam 37' 9-3/8" Frame Spacing 1' 0" Full Load Draft 13.85' Full Load Displacement 1825.64 long tons Shore Tie Voltage Requirements 450 vac, 400A, 3 phase cables

HULL CHARACTERISTICS

MACHINERY CHARACTERISTICS

Number of Propellers 2 Number of Blades 4 Diameter of Propeller 9' Pitch Controllable

RPM 260

Shaft Diameter 10.55" at exit of hull

TANK CAPACITIES

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This page was left blank intentionally. Do not delete.

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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 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

1 (Rev-0)

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 for Coast Guard fire watch personnel.

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.

2 (Rev-0)

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.

3 (Rev-0)

• 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.

4 (Rev-0) http://www.uscg.mil/directives/cim.asp

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

Vessel Name Hull # Work Item # Work Item Title

Location of Work (incl. frame #’s) Area (sqft)

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.

Name of QP-1/NACE Inspector Signature Cert. # Date / Time

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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.

DATE &

TIME

ACTIVITY (Surface preparation, primer coat, barrier coat, top coat, etc…)

LOCATION

(Frame &

Deck, relation to equipment, etc.)

TEMPERATURE % REL.

HUMID-

ITY DEW PT. SURFACE AMBIENT ΔT

| DP - Surface |

6 (Rev-0)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

Location of Work (Frame References) Area (sqft)

SURFACE PREPARATION METHOD PROFILE ACHIEVED (mils) Min Max Mean

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

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Reading:__________ mils

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Reading:__________ mils

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Reading:__________ mils

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

7 (Rev-0)

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

SURFACE PREPARATION METHOD PROFILE ACHIEVED (mils) Min Max Mean

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.

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

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

_____ mils _____ mils _____ mils _____ mils _____ mils

8 (Rev-0)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15

DATE TEST LOCATIONS CONDUCTIVITY

(microsiemens/cm)

9 (Rev-0)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

Coating Mfg Product Name Batch # Induction Time

Coating System Sequence (Primer/Touchup/3rd Coat, etc.)

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

SPOT 1 2 3 4 5 AVERAGE

VALUE

*BASE METAL

READING (BMR)

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

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation 3 Before

Adjustments After Adjustments

Avg.

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation 3 Before

Adjustments After Adjustments

Avg.

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation 3 Before

Adjustments After Adjustments

Avg.

Application Method (Airless, Conventional Spray, Rolled) Average DFT

10 (Rev-0)

11 (Rev-0)

24310_0210_FLT

REC_24310_FLT_270A WMEC (ALL) (0310)

DEFINITE WORK ITEM 01: Inspect Propulsion Shafting CPP Oil Tubes

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect the port and starboard controllable pitch propeller (CPP) oil tubes contained within the propulsion shafting.

1.2 Government-furnished property.

None

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 901 WMEC 243-001, Rev K, Shafting Arrangement Coast Guard Drawing 901 WMEC 243-002, Rev G, Stern Tubes, Strut Bearing & Seal Arrangement and

Details Coast Guard Drawing 901 WMEC 243-003, Rev F, Shaft Removal Arrangement Coast Guard Drawing 901 WMEC 243-004, Rev E, CPP Shafting Details

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 2699, Mar 2006, Manufacturer’s Instruction Book-SWBS

Group(s) 245, Controllable-Pitch Propeller System 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(s):

• 3.2.2 (Inspections).

3.1.2 Tech Rep. The Surface Forces Logistics Center will provide the services of a qualified Tech Rep, who is familiar with the Escher-Wyss CPP system, to accomplish the following tasks – on site:

• Provide information, software, and tools pertinent to the equipment/system.

• 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.

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

• Rope guard.

• Fairwaters.

3.2 Work to be accomplished. Using Coast Guard Drawings 901 WMEC 243-001, 901 WMEC 243-002, 901 WMEC 243-003, and 901 WMEC 243-004 as guidance, as applicable, the Contractor shall accomplish the following for port and starboard propeller shafts:

3.2.1 Removals. Move both tail shafts back (aftward) approx 12 inches to facilitate inspection of CPP oil tubes.

• Mark existing shaft position, and match-mark shaft coupling bolts to their respective holes, to facilitate reinstallation procedures.

• Both shaft seals shall be partially disassembled to allow propeller shaft movement.

• Ensure shaft is properly protected and supported at all bearing journals, at all times, until reinstallation.

3.2.2 Inspect for Contamination. Under direction of the Tech Rep visually inspect both shafts and CPP systems to determine the extent of contamination (Submit CIR).

3.2.3 Reinstallation. Reinstall the propeller shaft to its original configuration and accomplish the following, using Coast Guard Drawings 901 WMEC 243-001, 901 WMEC 243-002, 901 WMEC 243-003, and 901 WMEC 243-004, as applicable.

3.2.3.1 Renew all O-rings for the CPP oil tube connections and coupling flanges during reinstallation.

3.2.3.2 Take care not to damage the sleeves, fiberglass coating, the taper and threads during installation.

3.2.3.3 Ensure the propeller shaft is properly aligned to its original position using the reference marks established prior to its removal.

3.3 Operational test – post repairs. After completion of work, the Contractor shall witness an operational test (by Coast Guard personnel) of the shafting system, for a minimum of 4 hours, to prove satisfactory operating condition. Submit a CFR.

4. NOTES

This section is not applicable to this work item

12 (Rev-0)

13 (Rev-0)

24510_0911_210_270 REC_24510_210_270_270’ WMEC ‘A’ Class (ALL) (0911)

DEFINITE WORK ITEM 02: Controllable Pitch Propeller (CPP) System, Service

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to service both port and starboard CPP systems.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST EACH

Y **Propeller Blade-LH (Port) NSN: 2010-01-119-3972 1 Set 40,000.00 Y **Propeller Blade-RH (Stbd) NSN: 2010-01-120-2871 1 Set 40,000.00 N O-Ring NSN: 5330-01-120-5229 8 ea. 97.00 N O-Ring NSN: 5330-01-118-8529 8 ea. 96.00 N Blade Washer NSN: 5310-01-335-4361 48 ea. 112.00 N O. D. Box Inspection Kit NSN: 3010-01470-3519 2 ea. 330.00 N Filter NSN: 4330-01-177-4069 12 ea. 92.00 Y **Oil Feed Bushing NSN: 3120-12-329-5287 2 ea. 4,811.00 N **Ball Bearing NSN: 3110-00-156-6745 2 pr. 46.00 N **Bearing Bushing NSN: 2010-01-469-8639 2 ea. 450.00 N **Bearing Bushing NSN: 3120-12-198-7607 8 ea. 559.00 N **Spool valve assembly NSN: 4820-01-513-2509 2 ea. 100.00

Y Hydraulic Gear Pump, RH, 25 GPM, 1800 RPM, Horizontal Mounted

NSN: 4320-01-130-6252

Part No: S418-2663 5 ea 973.96

Y Hydraulic Gear Pump, LH, 25 GPM NSN: 4320-01-131-6913 Part No: S418L-2664 1 ea 997.84

N RV-1 By-pass to Sump ¾ in, 90 PSI 2 ea 175.00 N RV-2 Service Pump Discharge ½ in, 600 PSI 6 ea 125.00 N RV-3 Discharge Pump 1/8 in, 150 PSI 2 ea 100.00 N RV-4 Head Tank Pump Discharge ¾ in, 150 PSI 2 ea 175.00 N RV-5 Cooler Discharge to Sump 1-1/2 in, 15 PSI 2 ea 275.00 N RV-6 Pump Discharge Main to Cooler 1-1/2 in, 500 PSI 2ea 275.00 N RV-7 Hydraulic oil transfer pump 1-1/2 in, 28 PSI 1 ea 275.00

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

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 901 WMEC 243-001, Rev K, Shafting Arrangement Coast Guard Drawing 901 WMEC 245-001, Rev E, CPCH Propeller Hydraulic System Diagram Coast Guard Drawing 901 WMEC 245-003, Rev E, Propeller Hub Assembly Coast Guard Drawing 901 WMEC 245-004, Rev E, Blade and Palm Coast Guard Drawing 901 WMEC 245-007, Rev B, Special Tools Coast Guard Drawing 901 WMEC 245-008, Rev C, Actuating Unit Coast Guard Drawing 901 WMEC 245-009, Rev L, CPCH Propeller Hydraulic System Diagram

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 2699, Mar 2006, Manufacturer’s Instruction Book-SWBS

Group(s) 245, Controllable-Pitch Propeller System Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), Jan 2009, Auxiliary

Machine Systems

OTHER REFERENCES

ASTM International (ASTM) D4174, Re-approved 1999, Standard Practice for Cleaning, Flushing, and

Purification of Petroleum Fluid Hydraulic Systems International Standard Organization (ISO) 4406, 1999, Hydraulic Fluid Power – Fluids – Method for

Coding Level of Contamination by Solid Particles MIL-PRF-17672, May 1995, Hydraulic Fluid, Petroleum, Inhibited

3. REQUIREMENTS

3.1 General.

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

• 3.2.2.1 Blade inspections.

• 3.2.3.3 Hub interior inspection

• 3.2.7.3 Cooler inspection.

3.1.2 Tech Rep. The Surface Forces Logistics Center will provide the services of a qualified Tech Rep, who is familiar with the Escher-Wyss CPP system, to accomplish the following tasks – on site:

• Provide information, software, and tools pertinent to the equipment/system.

• 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.

14 (Rev-0)

3.1.3 Protective measures - hydraulic system(s). 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).

NOTE

Plastic bags may be used only when arrangement or configuration prevents the use of the other sealing methods specified above.

3.1.4 Interferences.

None.

3.1.5 Personnel and equipment safety. The Contractor shall ensure that only personnel experienced with the existing CPP system may take part in the removal and reinstallation of the hub, if required.

3.1.6 Hydraulic fluid sampling and testing. Prior to and immediately following the work herein, the Contractor shall sample and test the system hydraulic fluid in accordance with SFLC Std Spec 5000, Appendix C, Paragraph C2.1 (Fluids).

3.1.7 CPP service particulars. The Contractor shall accomplish all work specified herein under the supervision of the Tech Rep, using the Coast Guard drawings referenced in Section 2 and TP-2699.

3.1.8 Operational test - initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of the CPP system, to demonstrate existing operational condition. Submit a CFR.

3.1.9 Pitch checks. Check pitch of blades against indicated pitch scale in accordance with TP-2699 to ensure synchronization. Check the time for pitch to advance from zero to full pitch ahead and full pitch astern. Submit a

CFR.

NOTE

Seals must be water-lubricated during pitch checks.

3.1.10 System fluid drainage and disposal. The Contractor shall drain all hydraulic oil from the CPP systems (approximately 800 gallons each) into a suitable container; dispose of removed fluids in accordance with all applicable Federal, state and local regulations.

3.2 General maintenance.

3.2.1 Tanks. The Contractor shall clean the existing Oil System Sumps (4-162-1-F and 4-162-2-F), Head Tanks, and Storage Tank (4-162-0-F) free of all oil residues and all other surface contaminants.

CAUTION!

Ensure extreme care is exercised to prevent damage to the tank level indicator sensors, during the cleaning process.

15 (Rev-0)

Ship’s Force is given 48 hours to calibrate the tank level indicator sensors and to renew and test the CPP sump heatin elements after cleaning process has been completed.

3.2.2 Propeller blades. The Contractor shall accomplish the following for the propeller blades using Coast Guard Drawings 901 WMEC 245-003 and 901 WMEC 245-004 as guidance:

3.2.2.1 Blade inspections. Perform the following inspections. Submit CIR:

3.2.2.2.1 Visually inspect the port and starboard propeller blades for damage and defects.

3.2.2.2.2 Conduct non-destructive inspection of blade surfaces, from the palms to 0.7 radius, and all blade bolts, in accordance with SFLC Std Spec 0740, Appendix C.

3.2.3 Propeller hub and shaft inspections. The Contractor shall perform the following inspections for the propeller hubs and shafts using Coast Guard Drawings 901 WMEC 243-001 and 901 WMEC 245-003 as guidance; submit a CFR:

3.2.3.1 Visually inspect the in-place installation of the propeller hubs and shafts.

3.2.3.2 Take trunnion-to-bushing clearances and thrusts and compare to manufacturer’s specifications.

3.2.3.3 Visually inspect interior surfaces of port and starboard hubs to detreremine the extent of contamination.

Submit CIR.

3.2.4 CPP system hydraulic pressure relief valves. The Contractor shall renew the below-listed pressure relief valves, using Coast Guard Drawing 901 WMEC 245-009 and TP-2699, Chapter 4, Section 4-8 (Annual Preventive Maintenance Actions) as guidance.

3.2.4.1 After renewal, reset the relief valves to their set pressure and test.

3.2.4.2 Furnish and tag each relief valve with data plates that include the test pressure, test date, and the name of test facility.

TABLE 1 - PRESSURE RELIEF VALVES

NUMBER QTY SIZE SET PSI SERVICE

RV-1 2 3/4 90 By-pass to Sump RV-2 6 1/2 600 Service Pump Discharge RV-3 2 1/8 150 Discharge Pump RV-4 2 3/4 150 Head Tank Pump Discharge RV-5 2 1-1/2 15 Cooler Discharge to Sump RV-6 2 1-1/2 500 Pump Discharge Main to Cooler RV-7 1 1-1/2 28 Hydraulic oil transfer pump

3.2.5 Hydraulic controls and pressure filter manifolds. The Contractor shall accomplish the following task for the hydraulic controls and pressure filter manifolds, using TP-2699, Appendix "D" (Pressure Filter Manifold) and the hydraulic control manifolds shown in TP-2699, Appendix "E" (Control Manifold) as guidance:

3.2.5.1 Dispose of the filter elements.

16 (Rev-0)

3.2.5.2 Clean and inspect the pressure filter manifold. Submit a CFR.

3.2.5.3 Reassemble and reinstall the pressure filter manifolds, with Contractor-furnished check valves, seals, gaskets and "O" rings and Government-furnished filter elements.

3.2.6 Actuating units. The Contractor shall accomplish the following tasks for the actuating units, including the oil distribution (OD) boxes, using TP-2699, Chapter 8 (Removal/Installation) and Coast Guard Drawing 901 WMEC 245-008 as guidance:

3.2.6.1 Disassemble and clean the units free of all surface contaminants.

3.2.6.2 Visually inspect all components for signs of wear and deterioration. Submit a CFR.

3.2.6.3 Reassemble and reinstall each actuating unit in accordance with TP-2699, Chapter 8 (Removal/Installation) and Coast Guard Drawing 901 WMEC 245-008.

3.2.6.4 Clean the interior surfaces of the OD box free of all dirt, rust, and all other surface contaminants, using lint-free rags; coat the surfaces with new 2135TH oil.

3.2.7 CPP hydraulic oil coolers. The Contractor shall accomplish the following tasks for the oil coolers using Coast Guard Drawing 901 WMEC 245-009 and TP 2699, Appendix F (Heat Exchangers), Section C (Operator’s Maintenance), paragraph 2.1 (Disassembly of Unit), paragraph 2.2 (Cleaning Outside Surface of Tubes and Support Plates), and paragraph 3 (Locating Leaking Tubes in Single Tube-Sheet Units) as guidance.

3.2.7.1 Removal and disassembly. Remove the hydraulic oil coolers and take to a facility that is qualified to repair hydraulic oil coolers and disassemble.

3.2.7.2 Cleaning. Clean all components, including water and oil sides of the hydraulic oil coolers, with the manufacturer recommended cleaning solution. Flush clean the coolers with fresh water to remove all residual cleaning solution. Air dry all cleaned surfaces.

WARNING!

Ensure that the drain valves are cracked slowly, to relieve pressure gradually!

3.2.7.3 Cooler inspection. Inspect the tube sheet units. Submit CIR.

3.2.7.4 Reassembly and reinstallation. Reassemble the hydraulic oil coolers in accordance with TP-2699, Appendix F (Heat Exchangers), Section C (Operator's Maintenance), Paragraph 6 (Reassembly) and reinstall the hydraulic coolers to original configurations. Renew all O-rings, lantern rings, and gaskets.

3.2.8 Hydraulic oil pumps. The contractor shall renew all six hydraulic pumps with Government furnished pumps.

3.2.8.1 The Port and Starboards CPP systems each have two electrically driven pumps and one gear driven pump.

3.2.9 System flushing. After completion of all authorized system work, the Contractor shall flush the hydraulic system using the system's operating fluid in accordance with the requirements specified in Section 9 (Flushing Program) of ASTM D4174. Contractor shall notify the COTR at least 24 hours prior to beginning flushing operation.

17 (Rev-0)

3.2.9.1 Continue flushing until the fluid entering temporary filters reaches the minimum cleanliness standard specified by the system manufacturer.

NOTE

In the absence of manufacturer’s specifications, hydraulic fluid with a particulate count of -/18/15 or better (per ISO 4406) and a water content no greater than 500 ppm (0.05% by volume) is acceptable.

3.2.9.2 Submit a detailed report to the COTR within 24 hours. Report shall include:

• Method used to obtain the particulate contamination reading.

• Method used to determine particle size.

• Final contamination level readings.

3.2.9.3 Drain and retain the flushing fluid for reuse (see 3.2.9 (Re-servicing of CPP oil systems)).

3.2.9.4 After flushing, remove and dispose of temporary filters and mesh screens. Renew all system hydraulic filters.

WARNING!

Do not operate the system hydraulic pumps, motors and other components while filled with flushing fluid.

3.2.10 Re-servicing of CPP oil systems. After all authorized repairs, the Contractor shall accomplish the following:

3.2.10.1 Storage tank. Replenish the system with hydraulic oil conforming to MIL-PRF-17672, Symbol 2135 TH to top-off the storage tank, filtered, through a 10-micron absolute, non-bypass type filter designed specifically for filtering oils and other lubricants.

3.2.10.2 Sump tanks. Replenish the Sump Tanks from the ship's storage tank via the hydraulic purifier for both CPP systems. Before refilling hydraulic oil tanks, install new Government-furnished filter elements in place of the existing elements.

3.2.10.2.1 When the sump tank level is correct, put the main hydraulic pump on line for each system.

NOTE

Vent system by opening the filter gauge ports. If accessible, the hub plugs should also be opened.

3.2.10.2.2 Continue filling the Sump Tanks as the system is filling with oil. Do not allow the oil level in the tank to drop below 45-inches.

3.2.10.2.3 After each Head Tank is full, pitch system ahead and astern twice.

3.2.10.2.4 After thirty minutes, start the other hydraulic pump and cycle the pitch ahead and astern again.

NOTE

Each system should be completely void of air after cycling; oil level must be monitored after the…