HICKORY_Repair_January_2009_Rev 1.doc

Specifications for the

Repair of

USCGC HICKORY (WLB-212)

January 2009

Rev 1

UNITED STATES COAST GUARD

MAINTENANCE AND LOGISTICS COMMAND PACIFIC

NAVAL ENGINEERING DIVISION

RONALD V. DELLUMS FEDERAL BUILDING

1301 CLAY STREET, SUITE 807N

OAKLAND, CALIFORNIA 94612-5249

Table of Contents

Definite work items are identified by a “D” preceding the item number in the table above. Optional work items are designated by an “O” and shall be individually priced for possible performance.

CUTTER DESCRIPTION — USCGC HICKORY (WLB 212)

[Design Class: 225B-WLB]

Hull Characteristics:

Length Overall 225’ 0” Length, Between Perpendiculars 206’ 0” Beam, Molded 46’ 0” Designed Draft 13’ 0” Displacement, Full Load 2,000 L. tons

Displacement, Light Ship 1523 L. tons

Displacement, Minimum Operating 1800 L. tons

Frame Spacing

Frames 0-12:

21”

Frames 12-30:

22”

Frames 30-102 24” Hull Material Steel

Mast Height (Above 12’ Waterline) 67’5” (Approximately)

Bilge Keels (Port & Starboard) Frames 42 to 79

Rudder One

Ground Tackle Two 4000 lb Standard Navy Stockless Anchors, 8 shots each, port and starboard, 1-3/8 Die-lock chain

Machinery Characteristics:

Main Propulsion Diesel Reduction

Diesel Engines Two Caterpillar 3608, TA, 3100 BHP each, at 900 RPM

Propeller One 10’ diameter, reversible pitch, 4 blade

Ship’s Service Diesel Generators Two Caterpillar 3508 TA rated at 450 kW

Emergency Diesel Generator One Caterpillar 3406 DITA rated at 280 kW

Shore Tie Two 450 VAC, 400 Amp, 3-wire

Shaft Bearing, Forward Cooper Bearing 01-BCP-1400-EX-TL

Shaft Bearing, Aft Water Lubricated Cutless Bearing E2-2934

Tank Capacities:

Diesel Oil Capacity 76,498 gallons

Fresh Water Capacity 8,056 gallons

Hydraulic Oil Capacity 2,785 gallons

Lube Oil Storage 764 gallons

Grey Water Tank 2700 gallons

Sewage Holding Tank 1700 gallons

Crew Size:

Number Of Crew

Number Of Officers

Number of Females

CONSOLIDATED LIST OF REFERENCES

Drawings

225-WLB 573-206, Rev B; Integrated Buoy Handling Control System

225-WLB 573-7, Rev B; Cargo Hatch Control Block and Schematic

225-WLB 601-001, Rev J; General Arrangement Inboard & Outboard Profiles

225B-WLB 437-1, Rev B; Tank Level Ind Systems Block, Wiring Deck Plan & E

225B-WLB 506-1, Rev F; Overflows, Air Escapes & Sndg Tubes Diagram

225B-WLB 561-1, Rev B; Steering Gear Hydraulics Diagram

225B-WLB 561-3, Rev A; Steering Gear Arrangement

225B-WLB 562-1, Rev D; Steering Components Arrangement and Detail

225B-WLB 597-2, Rev B; Oily Recovery System Diagram

225B-WLB 259-001, Rev C; Combustion Intake & Exhaust Diagram

225B-WLB 259-005, Rev C; Combustion Intak & Exhaust A&D Hull Block 940

225B-WLB 259-006, Rev B; Combustion Intake & Exhaust A&D Hull Block 970 & 975

225B-WLB 259-1, Rev C; Combustion Intake & Exhaust Diagram

225B-WLB 259-5, Rev C; Combustion Intake & Exhaust A&D Hull Block 940

225B-WLB 259-6, Rev B; Combustion Intake & Exhaust A & D Hull Block 970 & 975

225B-WLB 320-001, Rev A; Electrical One-Line Diagram

225B-WLB 528-1, Rev C, Plumber & Interior Deck Drains

225B-WLB 593-1, Rev C, Sewage and Waste Water System Diagram

225B-WLB 593-9, Rev A, Sewage Holding Tank

225B-WLB 601-2, Rev A, Booklet of General Drawings

225B-WLB-644-1, Rev C, Sanitary Facilities & Laundry Space Arrgt & Dets

Applicable Documents

15 USC §2601 to 2692, Toxic Substance Control Act (TSCA)

16 CFR §1303, Ban of Lead-Containing Paint and Certain Consumer Products Bearing Lead-Containing Paint

29 CFR §1910, Occupational Safety and Health Standards

29 CFR §1915, Occupational Health and Safety Standards for Shipyard Employment

29 CFR §1926, Safety and Health Regulations for Construction

29CFR1910.401; Commercial Diving Operations

33 CFR §154, Facilities Transferring Oil or Hazardous Materials in Bulk

33 USC §1251 to 1387, Federal Water Pollution Control Act

33 USC §1342, National Pollutant Discharge Elimination System

33 USC §2701 to 2761, Oil Pollution Control Act of 1990

40 CFR §112, Oil Pollution Prevention

40 CFR §204, Noise Emission Standards for Construction Equipment

40 CFR §261, Identification and Listing of Hazardous Waste

40 CFR §262, Standards Applicable to Generators of Hazardous Waste

40 CFR §263, Standards Applicable to Transporters of Hazardous Waste

40 CFR §279, Used Oil Management Standards

40 CFR §300, National Oil and Hazardous Substances Pollution Contingency Plan

40 CFR §61, National Emission Standards for Hazardous Air Pollutants

40 CFR §761, Polychlorinated Biphenyls (PCB) Manufacturing, Processing, Distribution in Commerce, And Use Prohibitions

42 USC §4851 to 4852, Residential Lead-Based Paint Hazard Reduction Act

42 USC §4901 to 4918, Noise Control Act (NCA)

42 USC §6901 to 6991(i), Resource Conservation and Recovery Act (RCRA)

42 USC §7401 to 7671(q), Clean Air Act

42 USC §9601 to 9675, Comprehensive Environmental Response, Compensation, And Liability Act (CERCLA)

49 CFR §100-199, Hazardous Materials Transportation, Handling, And Storage Regulations

7 USC §136 to 136(y), Federal Insecticide, Fungicide, And Rodenticide Act (FIFRA)

American National Standards Institute (ANSI/NCSL) Z540.1, Rev 1994 (R2002), 8/1/1994; General Requirements for Calibration and Measuring and Test Equipment

American Society of Mechanical Engineers (ASME) B16.11, Forged Steel Fittings, Socket-Welding and Threaded, 2001

American Society of Mechanical Engineers (ASME) B16.9, Factory-Made Wrought Buttwelding Fittings , 2003

CG Tech Pub 3524, 1/7/1997; Manufacturer’s Instruction Book-SWBS Group(s) 243-262

CG Tech Pub 3534A, 1, Manufacturer’s Instruction Book–SWBS Group(s) 324, 3/9/2000

CG Tech Pub 3555, 5/21/1996; Steering Gear Systems

CG Tech Pub 3557, 1/7/1997; Manufacturer’s Instruction Book-SWBS Group(s) 568-573

CG Tech Pub 3564, 4/21/1997; Manufacturer’s Instruction Book-SWBS Group(s) 593

COMDTINST 6260.21, Hazard Communications for Work Place Materials

COMDTINST 9077.1, Equipment Tag-Out Procedure, Revision C

COMDTINST M10360.3, Coatings and Colors Manual, Revision C

COMDTINST M10360.3B, B, Coatings and Colors Manual, 11/24/2003

COMDTINST M10360.3C, Coatings and Colors Manual, C

COMDTINST M16478.1, Hazardous Waste Management Manual

COMDTINST M16478.2, Procurement, Handling and Disposal of Polychlorinated Biphenyls

COMDTINST M6260.16A, Asbestos Exposure Control Manual, Ch-1

COMDTINST M9000.6, Rev E; Naval Engineering Manual (NEM)

California Code of Regulations, Title 22, Division 4, Environmental Health and 4.5, Environmental Health Standards for the Management of Hazardous Waste

California Code of Regulations, Title 23, Waters

California Health and Safety Code, Divisions 20, Miscellaneous Health and Safety Provisions, 26, Air Resources, 37, Regulation of Environmental Protection, 103, Disease Prevention and Health Promotion, 104, Environmental Health.

Chapter 173-303, WASHINGTON Administrative Code

Chapter 340, Oregon Administrative Rules

Federal Standard FED-STD-595B(1), Rev B, Not 1; Color Used in Government Procurement

MIL-A-22262, Rev B, Amd 2; Abrasive Blasting Media Ship Hull Blast Cleaning

MIL-DTL-24643, Rev B, Sup 1A; Cables and Cords, Electric, Low Smoke, For Shipboard Use, General Specification for

MIL-DTL-5624, Rev U; Turbine Fuel, Aviation, Grades JP-4 and JP-5

MIL-F-1183J SUP 1, Fittings, Pipe, Cast Bronze, Silver-Brazing, General Specifications for, 5/5/1987

MIL-G-18458, Rev B, Amd 5; Grease, Wire Rope and Exposed Gear

MIL-PRF-1149, Rev D, 6/10/1998; Gasket Materials, Synthetic Rubber, 50 and 65 Durometer Hardness

MIL-PRF-16884, Rev L; Fuel, Naval Distillate

MIL-PRF-24613, Amd 2, Not 1; Deck Covering Materials, Interior, Cosmetic Polymeric

MIL-STD-1625, Rev C, Chg Not 1; Safety Certification Program for Drydocking Facilities and Shipbuilding Ways for U.S. Navy Ships

MIL-STD-1627C, Bending of Pipe or Tube for Ship Piping System, 9/30/1994

MIL-STD-1689A, Fabrication, Welding and Inspection of Ships Structure, 11/23/1990

MIL-STD-2035A, Nondestructive Testing Acceptance Criteria, 5/15/1995

MIL-STD-22D NOT 3, Welded Joint Design, 3/21/1991

MIL-T-16420K(1), Tube, Copper-Nickel Alloy, Seamless and Welded (Copper Alloy Numbers 715 and 706), 9/16/1988

MLCPAC Standard Specification 041, 1/1/2000; Production Control, Gantt Bar Chart

MLCPAC Standard Specification 074, Welding and Allied Processes, 3/21/2003

MLCPAC Standard Specification 085.1, General Requirements for Drawing Preparation, 3/1/2000

MLCPAC Standard Specification 304.1, 3/1/2000; Shipboard Electrical Cable Test

MLCPAC Standard Specification 304.2, 3/1/2000; Shipboard Electrical Cable Removal, Relocation, Splice, Repair and Installation

MLCPAC Standard Specification 634, 3/1/2000; Deck Covering Renewal

MLCPAC Standard Specification 074, Welding and Allied Processes, 3/21/2003

NAVSEA 0900-LP-001-7000, Fabrication and Inspection of Brazed Piping Systems

NAVSEA Dwg 804-1385781, Pipe Hangers for Surface Ships (Superseding NAVSEA Dwg. 810-1385781), E

NAVSEA Dwg 810-1385880, Fittings, Cu-Ni Alloy, Slip on Sleeve, D

NAVSEA S9074-AR-GIB-010/278, Requirements for Fabrication Welding & Inspection & Casting Inspection & Repair for Machinery, Piping & Pressure Vessels

NAVSEA T9074-AS-GIB-010/271, Requirements for Non-Destructive Testing Methods, 97

NSTM S9086-RK-STM-010/CH-505R2, Naval Ships’ Technical Manual, Chapter 505, Piping Systems, 2

NSTM S9086-T8-STM-010/CH-593R4, Naval Ships’ Technical Manual, Chapter 593, Pollution Control, 4

NSTM S9086-VH-STM-010/CH-635R2, Naval Ships’ Technical Manual, Chapter 635, Thermal, Fire and Acoustic Insulation, 2

National Electrical Manufacturers Association (NEMA) AB4, 1/1/2003; Guidelines for Inspection and Preventive Maintenance of Molded Case Circuit Breakers Used in Commercial and Industrial Applications

National Fire Protection Association NFPA 51 Standard for the Design and Installation of Oxygen-Fuel Gas Systems for Welding, Cutting, And Allied Processes

Naval Ships’ Technical Manual, Chapter 074, Volume 1, Chg 5, Welding and Allied Processes Rev 4, 8/1/1999

Naval Ships’ Technical Manual, Chapter 491, Electrical Measuring and Test Instruments, 9/1/1999

Naval Ships’ Technical Manual, Chapter 504, Pressure, Temperature and Other Mechanical and Electrical Measuring Instruments, 12/1/2001

Naval Ships’ Technical Manual, Chapter 505, Piping Systems, 12/1/2001

Naval Ships’ Technical Manual, Chapter 593, Pollution Control

Naval Ship’s Technical Manual (NSTM) Chapter 245, Propellers, Rev 5

Naval Ship’s Technical Manual (NSTM) Chapter 613, Wire and Fiber Rope and Rigging, Rev 3

Nondestructive Testing Handbook, American Society for Non-Destructive Testing, Volume 1, Section 7

The Society for Protective Coatings SSPC-SP 11, Power Tool Cleaning to Bare Metal

The Society for Protective Coatings SSPC-SP 3, Power Tool Cleaning

Title 11, Hawaii Administrative Code

Title 18, Alaska Administrative Code

Underwriters Laboratories Inc. (UL) 489, Rev Edition 10, 5/25/2002; Molded Case Circuit Breaker

CONSOLIDATED LIST OF GOVERNMENT FURNISHED PROPERTY

ITEM 11: SHOWER DECK DRAIN REPLACEMENT

ITEM 13: BUOY AND CARGO HANDELING CRANE WIRE ROPE RENEWAL

GENERAL REQUIREMENTS — DOCKSIDE, HOME PORT

GR_00000_JMS_0308_Fleet

1 Intent

This document invokes general requirements applicable to ship repair contracts for work performed at a cutter’s home port pier. The items discussed in the General Requirements are an amplification of, or are in addition to, the specific items of the Specification. Other sections of the contract establish requirements for work on Coast Guard cutters. The General Requirements are a part of the contract and, as such, compliance is a contractual requirement. The Contractor is responsible for understanding and complying with all requirements established in the Specifications.

Government Furnished Property: NONE

2 REFERENCES

Coast Guard Drawings: NONE

Applicable Documents:

COMDTINST M6260.16A, Asbestos Exposure Control Manual, Ch-1 COMDTINST 6260.21, Hazard Communications for Work Place Materials COMDTINST 9077.1, Equipment Tag-Out Procedure, Revision C COMDTINST M16478.1, Hazardous Waste Management Manual COMDTINST M16478.2, Procurement, Handling and Disposal of Polychlorinated Biphenyls COMDTINST M10360.3, Coatings and Colors Manual, Revision C Federal Standard FED-STD-595B(1), Rev B, Not 1; Color Used in Government Procurement MIL-A-22262, Rev B, Amd 2; Abrasive Blasting Media Ship Hull Blast Cleaning MIL-DTL-5624, Rev U; Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-PRF-16884, Rev L; Fuel, Naval Distillate MIL-STD-1625, Rev C, Chg Not 1; Safety Certification Program for Drydocking Facilities and Shipbuilding Ways for U.S. Navy Ships MLCPAC Standard Specification 997, 3/29/2004; DrydockingMLCPAC Standard Specification 074, Welding and Allied Processes, 3/21/2003 MLCPAC Standard Specification 085.1, General Requirements for Drawing Preparation, 3/1/2000 National Fire Protection Association NFPA 51 Standard for the Design and Installation of Oxygen-Fuel Gas Systems for Welding, Cutting, And Allied Processes Naval Ships’ Technical Manual, Chapter 074, Volume 1, Chg 5, Welding and Allied Processes Rev 4 (Aug 99)

Naval Ships’ Technical Manual, Chapter 074, Volume 1, Chg 5, Welding and Allied Processes Rev 4, 8/1/1999

Nondestructive Testing Handbook, American Society for Non-Destructive Testing, Volume 1, Section 7 7 USC §136 to 136(y), Federal Insecticide, Fungicide, And Rodenticide Act (FIFRA) 15 USC §2601 to 2692, Toxic Substance Control Act (TSCA) 33 USC §1251 to 1387, Federal Water Pollution Control Act 33 USC §1342, National Pollutant Discharge Elimination System 33 USC §2701 to 2761, Oil Pollution Control Act of 1990 42 USC §4851 to 4852, Residential Lead-Based Paint Hazard Reduction Act 42 USC §4901 to 4918, Noise Control Act (NCA) 42 USC §6901 to 6991(i), Resource Conservation and Recovery Act (RCRA) 42 USC §7401 to 7671(q), Clean Air Act 42 USC §9601 to 9675, Comprehensive Environmental Response, Compensation, And Liability Act (CERCLA) 16 CFR §1303, Ban of Lead-Containing Paint and Certain Consumer Products Bearing Lead-Containing Paint 29 CFR §1910, Occupational Safety and Health Standards 29 CFR §1926, Safety and Health Regulations for Construction 29 CFR §1915, Occupational Health and Safety Standards for Shipyard Employment 33 CFR §154, Facilities Transferring Oil or Hazardous Materials in Bulk 40 CFR §61, National Emission Standards for Hazardous Air Pollutants 40 CFR §112, Oil Pollution Prevention 40 CFR §204, Noise Emission Standards for Construction Equipment 40 CFR §261, Identification and Listing of Hazardous Waste 40 CFR §262, Standards Applicable to Generators of Hazardous Waste 40 CFR §263, Standards Applicable to Transporters of Hazardous Waste 40 CFR §279, Used Oil Management Standards 40 CFR §300, National Oil and Hazardous Substances Pollution Contingency Plan 40 CFR §761, Polychlorinated Biphenyls (PCB) Manufacturing, Processing, Distribution in Commerce, And Use Prohibitions 49 CFR §100-199, Hazardous Materials Transportation, Handling, And Storage Regulations California Code of Regulations, Title 22, Division 4, Environmental Health and 4.5, Environmental Health Standards for the Management of Hazardous Waste California Code of Regulations, Title 23, Waters California Health and Safety Code, Divisions 20, Miscellaneous Health and Safety Provisions, 26, Air Resources, 37, Regulation of Environmental Protection, 103, Disease Prevention and Health Promotion, 104, Environmental Health.

Chapter 173-303, WASHINGTON Administrative Code Chapter 340, Oregon Administrative Rules Title 18, Alaska Administrative Code Title 11, Hawaii Administrative Code 3 Administration

3.1 Definitions

3.1.1 Unless otherwise stated, the phrase as shown, as indicated, as detailed, or words of similar import refer to the contractual documents including drawings referenced in the specification.

3.1.2 The phrase as directed, as required, as permitted, approved, acceptance, or words of similar import refer to the direction, requirements, permission, approval, or acceptance by the Contracting Officer or a properly designated Contracting Officer’s Representative (COR).

3.1.3 Remove/Reinstall – To remove the original item and then later install the same original item back in its place after performing specified work on it.

3.1.4 Renew or renewal–To remove the original item and to install a new item in new condition, identical or of like size, material and quality to that removed (i.e. “Renew-in-Kind”).

3.1.5 Replace – To remove the original item and to install in its place a different item as described in the specification.

3.1.6 Restore – To bring back to the former, original or normal condition before alteration or removal.

3.1.7 Underwater body includes the external hull, all appendages, and sea chests from the keel up to and including the upper edge of the boot-top area.

3.1.8 The Contracting Officer’s Representative (COR) is the person delegated by the Contracting Officer as the on-scene representative for matters concerning performance of work. This includes technical correctness, timeliness, and quality of the Contractor’s work. Normally the Commanding Officer of the vessel is designated as the COR.

3.1.9 The Coast Guard Inspector is the COR or the individual designated by the COR to perform Coast Guard Inspector duties.

3.1.10 Condition Found Report (CFR) – See paragraph 3.8 below.

3.1.11 Vessel – Either a Coast Guard cutter (sixty-five feet or greater) or a Coast Guard boat (less than sixty-five feet.)

3.2 References

3.2.1 All references shall be of the issue and/or revision indicated in the consolidated list of references. It is incumbent on the Contractor to maintain current MLCPAC Standard Specifications. In many instances, the references will be available for review locally aboard the vessel or at the cognizant Naval Engineering Support Unit (NESU). U. S. Government issued Standardization Documents can be found at: http://stinet.dtic.mil/str/dodiss4_fields.html.

3.2.2 Detail and dimensioned drawings for precision equipment are generally accurate and will give sufficient information for estimating. However, allowance for changes in dimensions should be taken into consideration due to changes of equipment and to the structure and arrangement of the vessel. Actual installations shall conform to the specifications. When it is required that drawings or sketches be prepared, the Contractor shall meet the requirements of MLCPAC Standard Specification 085.1.

3.2.3 All referenced drawings and each piece or page of data that is marked with a Limited Rights Legend is a part of this specification and shall not be used for any purpose other than that contemplated by the specifications or item of work. The Contractor is prohibited from further use, release, or disclosure of this information.

3.2.4 Unless otherwise noted within this specification, hierarchy, priority, or order of precedence of requirements shall be as follows:

Specification Definite Item or Optional Item Specification General Requirements Coast Guard Drawings Coast Guard Technical Manuals Commercial Drawings Commercial Technical Manuals Coast Guard Standards and Instructions Military and Navy Standards, Specifications, and Technical Manuals Commercial or Industrial Standards Commercial practices

3.2.5 Drawing discrepancies found in performance of work associated with this specification which may adversely affect work in this or future specifications shall be reported using “DRAWING DEFICIENCY ACTION FORM.” This drawing feedback form, designed to be used by Contractor and Coast Guard personnel alike, may be downloaded from the Procurement section of the following Coast Guard web site: http://www.uscg.mil/mlcpac/mlcp/Eng%20Support/mlcpv/files/procurement/Drawing_Deficiency_Action_Form_editable.pdf. The form shall be downloaded, duplicated and completed, as necessary, to inform MLCP(vs) technical personnel of drawing & configuration problems, as well as, suggested recommendations which may correct them.

3.3 Arrival Conference

3.3.1 Within two days of the arrival of the vessel, and usually prior to the start of work, the Contracting Officer or the Contracting Officer’s designated representative will meet with the Contractor at either the Contractor’s conference facilities near the vessel or aboard the vessel (location to be at the sole discretion of the COR).

3.3.2 Normally this conference will be attended by the COR, designated Coast Guard Inspectors, representatives of the cognizant MLCPAC Naval Engineering Support Unit (NESU) and MLCPAC Support Branch (vr). For availabilities at Coast Guard facilities, the facility Hazardous Waste Coordinator will be invited to attend. A sample Arrival Conference Agenda can be found at http://www.uscg.mil/mlcpac/mlcp/Eng%20Support/mlcpv/files/platform_support/Arrival_Agenda_Pkg_Form.doc

3.4 Contractor’s Submittals

3.4.1 The Contractor shall provide the following at the arrival conference:

Subcontractor List

Technical Representatives List

Marine Chemist & “Competent Persons” List

Welders’ Qualification List

List of Qualified Sil-Brazers

Material Safety Data Sheets

List of Key Personnel

List of Emergency Phone Numbers

Contractor’s Inspection And Quality Control System

Contractor’s Property Administration System for GFE

Certificate of Insurance

Sample Copy of the Condition Found Report

Contractor’s Fire Emergency Response Plan

Contractor’s Oil Spill Response Plan

Environmental Submittals (See Section 6)

Contractor Security Requirements

3.5 Vessel’s Submittals

3.5.1 The vessel will provide the following at the arrival conference:

List of Key Personnel

List of Emergency Phone Numbers

List of designated Coast Guard Inspectors

3.6 Working Hours

3.6.1 Except for items specifically authorized by COR, Contractor work shall normally be accomplished between the hours of 7:30 a.m. to 10 p.m. Monday through Friday, except Federal Holidays.

3.6.2 If the Contractor desires to accomplish work outside of normal working hours, request shall be made to the COR at least 24 hours in advance. Approval will be the sole discretion of the Contracting Officer or the COR.

3.7 Progress Meetings

3.7.1 Weekly progress meetings will be held at either the Contractor’s conference facilities near the vessel or aboard the vessel, at the sole discretion of the COR. The day of the week and time of day for the weekly progress meeting will be set by the COR at the arrival conference. Representatives for the COR and the Contractor will meet before each progress meeting to review the percentage of completion for each work item and change. Each progress meeting will result in the COR producing a Contract Status Report documenting the percentage completion and documenting areas needing attention by the Contractor in order to complete the contract on time. The COR will transmit the Contract Status Report to the Contracting Officer, the NESU Representative, and MLCPAC(vr) the same day. Additional reports/charts shall be presented at each meeting as required by Definite Item “Production Control, Gantt Bar Chart Provide”.

3.8 Reports/Readings/As Found Conditions

3.8.1 All readings and inspections are to be taken within twenty-four hours after the machinery or system is opened. The Contractor shall notify the COR of the time and location of inspections requiring Coast Guard verification 24 hours prior to such inspections, unless such inspections need to be conducted more than 50 road miles from the primary place of contact performance, in which case 3 working days notice is required, in order to make travel arrangements for the Coast Guard inspectors. Measurements and readings shall be taken with calibrated measurement and test instrumentation. All reports of readings, operational tests and inspections required by the specifications shall be submitted to the COR in writing, using a “Condition Found Report (CFR)”, within twenty-four hours after the readings and/or inspections are made. Promptness in taking and reporting readings is particularly important for underbody work items such as shaft bearing or rudder bearing clearances. Often during the progress of a work item, conditions are discovered by the Contractor which are considered abnormal for reasons of safety, expected reliability, health, or habitability. These conditions must be brought to the attention of the Coast Guard using a CFR. Details provided by the Contractor in a CFR are important because the CFR may result in a contract change. To speed the contract change process, the Contractor should include in the CFR the following details as a minimum:

3.8.1.1 A sequential number.

3.8.1.2 The contract item which the “CFR” relates to (i.e. D-XX).

3.8.1.3 A clear statement, definition, and description of the condition found, including but not limited to frame numbers, part numbers, materials, and dimensions as appropriate.

3.8.1.4 A proposed or recommended repair to correct the defective condition, including but not limited to frame numbers, part numbers, materials, and dimensions as appropriate.

3.8.1.5 Indicate whether the report requires Coast Guard action or if it is provided “for info” only. If action is required, indicate the time and date when the Coast Guard response is required in order to complete the action within the specified contract performance period. If the action cannot be completed within the specified contract period, so state.

3.8.1.6 A space on the form for the Coast Guard designated representative to make comments.

3.8.1.7 All CFRs shall be signed, dated and submitted by the Contractor’s Ship Superintendent.

3.9 Government Furnished Material/Equipment

3.9.1 The Contractor shall furnish all equipment, staging, materials, fittings, tools, etc., necessary for proper completion of each item of work unless the specifications indicate the Coast Guard will provide GFM/GFE.

3.9.2 If GFM/GFE is to be furnished by the Coast Guard, it will be indicated in the specification for the specified work item. Unless otherwise noted in the specifications, GFM/GFE will be delivered by the Government to pierside/dockside of the vessel (at the place the vessel is located for the performance of work under this contract). Unless otherwise noted in the specifications, delivery date will be at the Coast Guard’s discretion between the start of the contract and up to 5 working days after the start of the contract.

3.9.3 The Contractor shall perform sufficient receipt inspection of the GFM/GFE and then sign for custody of the GFM/GFE by a Coast Guard form DD1149 or comparable Contractor’s form. The Contractor assumes the risk of, and shall be responsible for, any loss or destruction of, or damage to Government property upon its delivery to the Contractor. However, the Contractor is not responsible for reasonable wear and tear to Government property properly consumed in performing this work.

3.9.4 It shall be the Contractor’s responsibility to move or rig all GFM/GFE from the point of delivery to the point of storage (if necessary) and then to the point of use.

3.9.5 At the end of the contract, the Contractor shall turn over to the Coast Guard any and all GFM/GFE which was not installed under the terms of the contract.

3.10 Sanitary Facilities

3.10.1 Sanitary facilities for Contractor personnel shall be Contractor’s responsibility; Contractor’s sanitary facilities shall be separate & distinct from sanitary facilities used by vessel personnel. During any period that any or all of the vessel’s head facilities are unavailable for use due to Contractor’s performance under this contract, the Contractor shall provide clean, sanitary replacement facilities.

3.10.2 If at any time during the performance of the contract, Contractor work will place vessel sanitary facilities out of service, the Contractor shall provide temporary replacement facilities. The minimum replacement facility for up to 18 crew members displaced shall be hot and cold running water with a minimum of 2 showers, 2 sinks, 2 toilets, and 1 urinal located no further than two hundred feet from the vessel’s gangway. Facility shall be equipped with electrical lighting and power outlets (110 VAC with ground fault circuit interrupters, GFCI’s) for powering of electrical appliances (e.g., blow dryers). If more crew members are displaced, the replacement facilities shall be increased in direct proportion to this ratio. If the crew contains members of both sexes, suitable separate facilities shall be provided for men and women in proportion to their numbers in the crew. The Contractor shall maintain the facilities in a clean and sanitary condition at all times.

3.11 Smoking and Tobacco Products

3.11.1 Smoking and use of tobacco products aboard the Vessel or in Vessel office space is prohibited. Exceptions may be permitted if in strict compliance with Vessel rules and regulations (which may include designated smoking time/area).

3.12 Contractor Services

3.12.1 The Contractor shall provide all services required by the Contractor for the completion of work. These services include but are not limited to electrical power, compressed air, steam, crane services, garbage and refuse, phones, office space, and portable toilet facilities. These services are for the Contractor’s use only. Services required by the vessel are found in the “Temporary Services” item of the specification. Regarding crane services, several Coast Guard facilities have weight restrictions at some piers or berths. Notify the COTR seven days in advance of desired lift to coordinate lift, crane size, rigger locations, etc.

4 Work Control

4.1 Tag-out Procedures

4.1.1 To prevent injury to personnel and/or damage to ship systems equipment tag-outs must be properly conducted. Ship’s force will work closely with the Contractor to ensure tag-outs are done in a thorough and efficient manner as outlined below and in more detail in COMDTINST 9077.1, Equipment Tag-out Procedure.

4.1.2 Tag-Out Establishment

4.1.2.1 Prior to start of work on this Item, notify the Coast Guard Inspector in writing of equipment, systems, circuits, components, piping, and valves that require isolation so that tag-outs can be accomplished as required by COMDTINST 9077.1, Equipment Tag-out Procedure.

4.1.2.2 Ship’s Force personnel will position equipment and install tags when tag-out of equipment, systems, circuits, components, piping, or valves as required.

4.1.2.3 The Ship’s Authorizing Officer (normally the Engineer of the Watch) and the Repair Activity (Contractor’s) Representative shall each verify that the tag-out is sufficient to prevent operation of equipment, systems, circuits, components, piping, or valves from all stations that could exercise control. Tags shall also be hung as required by COMDTINST 9077.1, Equipment Tag-out Procedure, paragraph 1.d to control the status of non-permanent jumpers, locking devices, seals, blank flanges, relief valve gags, or similar safety devices.

4.1.2.4 A Contractor’s representative shall also verify that each tag is attached to the proper component and that it is in the condition required by the tag-out record sheet. This verification shall be made by witnessing the actions of the Ship’s Force member posting or checking the tags and observing devices such as valve position indicators, operating handles, etc.

4.1.2.5 A Contractor’s designated representative shall sign and identify his company on each ship’s tag-out record sheet and tag prepared to support the Contractor’s work.

4.1.3 Tag-Out Clearance

4.1.3.1 To facilitate prompt removal of tags, the Contractor shall notify the Coast Guard Inspector immediately when the Contractor’s work is complete and the affected system, piping, or circuit is ready for activation.

4.1.3.2 Tags shall be cleared and removed in accordance with COMDTINST 9077.1, Equipment Tag-out Procedure, before the equipment is operationally tested or operated.

4.1.3.3 The Ship’s Authorizing Officer and the Repair Activity (Contractor’s) Representative shall each verify that the work necessary to clear a tag-out has been completed prior to authorizing removal of the tags. Both parties shall concur to clearing the tag-out by signing the ship’s tag-out record sheet.

4.1.3.4 Ship’s Force personnel will remove the tags so authorized for clearance.

4.2 Safety Requirements

4.2.1 The Contractor shall comply with and ensure compliance to the following for operations which may affect Government personnel or property: 29 CFR Part 1915, “Occupational Safety and Health Standards for Shipyard Employment”, 29 CFR Part 1910, “Occupational Safety and Health Standards”, and 29 CFR Part 1926 “Safety and Health Requirements for Construction”.

4.2.2 The following are deficiencies commonly encountered on safety inspections and are therefore emphasized here:

4.2.2.1 Anti-backflash control valves are required on all welding rigs (NFPA 51).

4.2.2.2 Scaffolds and/or lifelines are required when working above five feet. 29 CFR 1910 and 1915 cover this in detail. The following are commonly encountered problem areas:

4.2.2.2.1 Scaffolds require standard 42” high rails & midrails and 4” toeboards.

4.2.2.2.2 Planking must be scaffold-grade and completely cover the area between the railings and the ship.

4.2.2.3 Lifelines, body harnesses and lanyards are required wherever standard rails are not feasible. Lines must be kept taut, never allowing a fall of greater than six feet.

4.2.2.4 Lifelines must be attached above the worker.

4.2.3 Gear and equipment for rigging and lifting shall be in good working condition and operated according to the regulations set forth in 29 CFR 1915.111-116 and 29 CFR 1910.184. Proper safety precautions shall be practiced in the use of tag lines, mousing of hooks, and moving loads. In addition to the above requirements, all cranes used for work on the vessel or for handling GFM/GFE shall have a current weight handling certification in accordance with local, state and federal laws.

4.2.4 Tools and related equipment are addressed in 29 CFR 1915 Subpart H. Of particular concern is the use of ground fault circuit interrupters (GFCI) with power tools and the use of double insulated power tools. All shore supplied power circuits shall be protected by GFCI’S and have a grounding circuit back to shore. In addition, all power tools shall be approved by Underwriters’ Laboratories, or by other testing laboratories approved by the Contracting Officer and either be double insulated or have a grounded circuit.

4.2.5 Personnel protective equipment must be maintained and used in accordance with 29 CFR 1915.151-160.

4.2.5.1 Where personnel exposures can not be maintained below the PEL using appropriate engineering controls, the Contractor shall provide all Contractor personnel with appropriate respiratory protective equipment or other protective equipment specified by the manufacture or where the Contractor/Contractor’s industrial hygienist has determined that exposures could exceed the PEL. The Contractor shall also ensure personnel are properly protected from sensitizing agents/conditions reported by the manufacturer in the Material Safety Data Sheets. These operations include, but are not limited to spray painting and grinding. Selection of respiratory protective equipment should be based on sound industrial hygiene sampling data for the material being worked. Airline hose masks or Self Contained Breathing Apparatus (SCBA) shall be provided to all personnel conducting abrasive blasting or confined space operations, unless an industrial hygienist has determined that exposures can be maintained below the PEL. In addition, respiratory protection for all work which could be immediately dangerous to life and health must consist of either an SCBA or a airline hose mask with an escape bottle as a designed component of the mask assembly.

4.2.5.2 Air line respirators shall be fitted with a pressure regulating valve, a filter which will remove oil, water, and rust particles, and a carbon monoxide alarm. The air intake shall be from a source free from all contaminants, such as the exhaust from internal combustion engines, and air must meet Grade D.

4.2.5.3 Safety harnesses shall be equipped with lifelines which are secured with a minimum of slack when in use. Lifelines must not permit a drop of greater than six feet or contact with any lower level.

4.2.6 Confined space entry requires initial gas free certification by a Marine Chemist in accordance with 29 CFR 1915. The Contractor shall be responsible for monitoring and maintaining the “safe” condition during the entire time work is being performed. Monitoring shall be conducted by a NFPA certified Marine Chemist or a Competent Person. As a minimum, test/certification shall be made before each work shift or daily, whichever is more frequent, and duly recorded on all required certificates.

4.2.7 The Contractor shall provide to the vessel Material Safety Data Sheets for all hazardous materials used under this contract (including petroleum products), at least two working days prior to its use, if not previously submitted per paragraph 3.3. These include, but are not limited to, paints, solvents, cleaners, and abrasive blasting grits.

4.2.8 The Contractor shall ensure paints, solvents, etc., used in, on or around the vessel are used in a manner which prevents personnel exposure to concentrations of vapors exceeding Permissible Exposure Limits (PELs), or Threshold Limit Values (TLVs) for chemicals for which PELs are not listed in OSHA standards.

4.2.9 Each fuel and gas system supplied from shore shall be arranged to be secured by a valve located off the ship and marked to show its purpose. When not in use, fuel and gas hose valves shall be secured at the manifolds and the hoses pulled back to the open deck. Unused manifold valves shall be capped.

4.2.10 The Contractor shall control abrasive blast grit sufficiently to prevent exposure to personnel at or greater than Permissible Exposure Limits (as defined by OSHA). Ensure abrasive blast grit does not contain free silica.

4.2.11 Diving operations must be accomplished in accordance with the requirements of 29 CFR 1910.401 to 440 including appendices. No person may fill more than one assignment if it an emergency response or other incident may require complete dedication to one of the tasks.

4.3 Quality Control

4.3.1 The Contractor shall implement the quality control (QC) program submitted in paragraph 3.4.9. Quality assurance is the sole responsibility of the Contractor. The COR may delegate inspection responsibilities to members of the vessel’s crew. The designated inspectors monitor the progress of work done by the Contractor. If, during the performance of work the Coast Guard Inspectors witness work that fails to meet the specifications, work that is otherwise unsatisfactory, or conditions which may lead to an unsatisfactory end product, the inspectors will alert the COR who will advise the Contractor informally of the deficiency. If the deficient work is not corrected within a reasonable period of time (as approved by the COR), the COR will officially alert the Contractor via a Contract Deficiency Report. The COR will initiate the report (a sample report may be found at http://www.uscg.mil/mlcpac/mlcp/Eng%20Support/mlcpv/files/platform_support/Arrival_Agenda_Pkg_Form.doc) and submit it to the Contracting Officer with copies to the cognizant NESU and MLCPAC(vr). The Contracting Officer will forward the original to the Contractor.

4.4 Interferences

4.4.1 The prices offered shall include the cost of performing all the necessary removal, relocation, and/or reinstallation of ship’s structure, materials, and equipment in connection with the work. The fact that an interference is not shown on a plan or specifically identified in the specification item is not justification for a contract change. A physical check of each job aboard the vessel prior to bidding is strongly encouraged.

4.4.2 Removal and Reinstallation of Interferences. The Contractor shall remove and reinstall all interferences and obstructions necessary to complete the required work without regard to whether interferences are indicated under specification work items. This may include the removal of machinery, piping, ducts, wiring, insulation, structure and anything else which interferes with the proper accomplishment of a work item. Prior to being disturbed or removed and in the presence of the Coast Guard Inspector, the Contractor shall operationally test each interference reporting by Condition Found Report any existing operational defects or deficiencies. While awaiting reinstallation and restoration, the Contractor shall maintain and protect interferences. When determined to be in the best interest of the Coast Guard & the Contractor and upon Coast Guard approval, interferences may be modified or altered and returned to essentially the same configuration and condition. They are then to be retested in the presence of the Coast Guard Inspector to verify proper operation. Otherwise, upon completion of required work, the Contractor shall restore interferences to their original configuration and condition, and in the presence of the Coast Guard Inspector retest for proper operation.

4.5 exterior/Compartment Preservation/Protection

4.5.1 To prevent damage arising from the performance of the contracted work, it shall be the responsibility of the Contractor to provide adequate protection to the vessel or any government property in areas where the work under items of these specifications is to be accomplished. Any damage resulting from the Contractor’s failure to adequately protect the vessel or government property shall be repaired by the Contractor at no charge to the government.

4.5.2 Compartment Cleaning and Finishing – When the Contractor enters a compartment for the accomplishment of work, the Contractor is to notify the Coast Guard Inspector and jointly inspect the compartment prior to starting the work. All areas in way of the Contractor’s work, whether or not directly repaired or altered, are to be restored to as clean and ship shape condition on completion of the work as when work was started. For example, the decks leading to work areas are to be cleaned and, if required due to unusual wear by the Contractor’s crew, the work sections are to be either refinished or renewed so that they match the original condition of the decks.

4.5.3 Protective Coverings – All machinery, equipment, deck covering, insulation, and open vent terminals exposed to dust or drifting particles resulting from work under this contract shall be adequately protected. Methods of protection include, but are not limited to fire-retardant blanket (if required due to sparks or slag), canvas, or plastic coverings. All open vent intakes shall be completely covered with air intake screens fitted with 20 pores per inch polyester or polyurethane foam filtering material and shall be maintained by the Contractor to prevent excessive air restriction and/or damage to ventilation motors. Any damage resulting from failure by the Contractor to provide adequate coverings shall be repaired at the Contractor’s expense. It shall be the responsibility of the Contractor to provide adequate protection to all deck covering in areas where the work under items of these specifications is being accomplished and on all main access routes to these areas. Acceptable protective covering will be either heavy cardboard, masonite (fiberboard), or plywood installed in sufficient quantities to adequately protect existing deck covering. Any protective coverings which are damaged during the course of work shall be immediately repaired or renewed by the Contractor.

4.5.4 Glass – All glass (port lights, windows, etc.) adjacent to areas interior and exterior where abrasive blasting, burning, or welding is required or accomplished shall be covered to prevent scarring and damage.

4.5.5 Ragged Edges – Care is to be taken to smooth off all ragged edges or burned off edges by grinding or filing to leave a smooth surface. Removal of fixtures, equipment, plating, piping, and fittings shall be made clean to the root and finished off. Where pipes, cables, and fittings are removed, the hole shall be blanked off flush with welded plates of like material and thickness.

4.5.6 Bracket and Supports – All pipes, cables, duct work, installed furniture, and equipment shall be bracketed, supported, and/or secured so as to carry the weight, prevent excessive vibration, and withstand inertia forces resulting from rolling and pitching.

4.5.7 Dirt/Debris/Trash – At the end of the work day, the Contractor shall remove all dirt, debris, trash, grinding dust and excess material from the vessel in areas and access to areas where work is being accomplished. The standard for this daily clean up is that the decks will be broom/vacuum clean, no liquids will be left standing on decks, and items which will not be further used for the work will be removed from the vessel. The goals behind this requirement are to remove fire hazards, to improve access within the vessel for routine and emergency movement of personnel, and to preserve the material condition of the vessel.

4.5.8 Painting

4.5.8.1 All burned or scarred areas, new structure, or plating resulting from any work performed by the Contractor shall be cleaned and repainted in accordance with this specification, the Coatings and Color Manual (Commandant Instruction M10360.3), or vessel paint schedule in that order of priority. The Coast Guard Inspector will inspect surface preparation prior to painting to assure conformance with specifications and COMDTINST M10360.3. Prime bare metal to prevent rusting. Re-preparation due to rust bloom shall be the responsibility of the Contractor at no charge to the Government.

NOTE: Local VOC restrictions may reduce number of paint system options permitted by the Coatings and Color Manual (Commandant Instruction M10360.3). Ensure VOC limits of painting systems used comply with local (where work is performed) requirements.

4.5.8.2 All steel and aluminum installed under this contract shall, prior to installation, be free of mill scale and corrosion. Except where otherwise specified, all steel shall be properly primed with one liberal coat of high build epoxy primer in accordance with the Coast Guard Coatings and Color Manual (COMDTINST M10360.3).

NOTE: Apply all coatings in strict compliance with manufacturer’s application instructions.

4.5.8.3 Where new paint is to be merged into the existing paint system, feather into the surrounding paint. Apply paint to surfaces only if they are dry and free of sand, dust, grease, or any foreign material. Apply paint only if surface is five or more degrees F. above the dew point.

4.5.8.4 Paint must have an age less than the manufacturer’s recommended shelf life. The Contractor shall supply certified laboratory reports showing product, batch number, and date of manufacture for each batch of paint to the designated Coast Guard Inspector.

4.5.8.5 Store paint for at least 48 hours prior to painting so it is maintained between 65 and 85 degrees F. Issue paint from storage so that it is applied before the paint temperature drops below 50 degrees F. Do not apply paint if the paint temperature is below 50 degrees. When ambient temperature drops below 50 degrees F. or wet weather is encountered, the Contractor shall ascertain whether the paint manufacturer recommends any substitutions of paint, alteration of paint formulas, or modified application instructions. Any substitution of paint is subject to approval of COR. Adhere to all of the manufacturer’s recommendations.

4.5.8.6 All paints shall meet the environmental standards for the locale at which they are applied. This includes, but may not be limited to, meeting volatile organic compound (VOC) limits for coating systems.

4.5.8.7 Quality assurance inspections are required for all painting done in accordance with individual work items, and are to be recorded the Paint Log. The Paint Log will be filled out by the Contractor, verified by the Coast Guard Inspector and retained by the vessel for hull history. The forms may be downloaded from the Procurement section of the following Coast Guard web site: http://www.uscg.mil/mlcpac/mlcp/Eng%20Support/mlcpv/index.htm.

4.5.9 Fluid Containers & Piping. The Contractor is responsible for containment, clean up, and disposal of any fluid spilled during course of their efforts (e.g., includes spills resulting from mishandling, disassembly & piping removal).

4.6 Hotwork/Welding

4.6.1 The Contractor and Coast Guard Inspectors shall comply with the hot work, atmospheric testing, ventilation, and safety precaution requirements contained in 29 CFR Part 1915, “Occupational Safety and Health Standards for Shipyard Employment”, and Naval Ships’ Technical Manual, Chapter 074, Volume 3, Gas Free Engineering.

4.6.1.1 The Contractor shall certify that a safe atmosphere exists in and about a compartment before starting any work which may produce the heat of ignition, sparks, or flames. The Contractor shall pump down, wipe up, ventilate, or take any other action required to make the compartment safe for personnel and the work to be performed.