MARIA BRAY REVISED SPEC.pdf

USCGC MARIA BRAY (WLM 562)

175 FOOT COASTAL BUOY TENDER

SPECIFICATION FOR EMERGENCY DRYDOCK REPAIRS

Developed By: Paul W. Beausejour

(Rev-1, 25 March 2010)

USCGC MARIA BRAY (WLM-175) EMERGENCY DRYDOCK AVAILABILITY 2010

ii (Rev-1)

TABLE OF CONTENTS

Revisions Record ....................................................................................................................................... iii Consolidated List of References ................................................................................................................ iv Consolidated List of Government-furnished Property ............................................................................... vi Consolidated List of Critical Inspection Items ......................................................................................... vii Principal Characteristics .......................................................................................................................... viii General Requirements WORK ITEM 1: Z-Drive Propulsion Unit Seals, Renew (In Drydock) WORK ITEM 2: Drydocking WORK ITEM 3: Temporary Services, Provide WORK ITEM 4: Z-Drive Propulsion Unit Seal oil Tank , Relocate iii (Rev-1)

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

3/25/2010 1 1 Deleted GFP – all components will be provided by the Contractor. Added additional parts, as per feedback from Rolls Royce.

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.

iv (Rev-1)

Consolidated List of References

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free or charge. Other Government documents may be accessed – free of charge – as follows:

• MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

• Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

• Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws::

www.gpoaccess.gov

The Government is aware of the following internet web links where contractors may procure commercial specifications:

• American Welding Society (AWS): http://www.awspubs.com/index.php

• ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

• NFPA: http://www.nfpa.org

• SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS

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

C oast Guard Drawing 175 WLM 245-1, Rev A, Propeller Coast Guard Drawing 175 WLM 243-2, Rev E, Propulsion Shaft Arrangement Coast Guard Drawing 175 WLM 245-1, Rev A, Propeller Coast Guard Drawing 175 WLM 561-1, Rev J, Z-Drive Hydraulic System Diagram Coast Guard Drawing 175 WLM 635-1, Rev F, Hull Thermal & Acoustic Insulation Schedule Coast Guard Drawing 175 WLM 801-006, Rev H, Docking Drawing

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual Coast Guard Technical Publication (TP) 3613, Dec 2002; SWBS 245, Section A; Z-Drive Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0000, Jan 2009; General Requirements Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 085, Jan 2009, General Requirements for Drawing Preparation 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 v (Rev-1)

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

Coast Guard Technical Publication (TP) 3613 , Jan 1997, Manufacturers Instruction Book-SWBS Group(s) 242-262 Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation Commercial Item Description (CID) A-A-59323, Rev A, Cloths, Cleaning, Low-Lint DOD-STD-1399 Section 301A, Jul 1986, Ship Motion and Attitude Manufacturers Standardization Society of the Valve and Fittings Industry (MSS), SP-69, 2003, Pipe Hangers and Supports - Selection and Application Manufacturers Standardization Society of the Valve and Fittings Industry (MSS), SP-89, 2003, Pipe Hangers and Supports – Fabrication and Installation Practices MIL- F-24402, May 1995, Filters (Hydraulic), Filter Elements (High Efficiency), and Filter Differential Pressure Indicators, General Specification MIL-F-1183, Rev J; Fittings, Pipe Cast Bronze Silver-Brazing MIL-T-24107, Oct 1987, Tube, Copper (Seamless) (Copper Alloy Numbers C10100, C10200, C10300, C10800, C12000, C12200, a nd C14200) vi (Rev-1)

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

($/UNIT)

2 Y *Transducer Cover

Plate N/A 3 ea. 50.00

*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 vii (Rev-1)

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 1 Z-Drive Propulsion Unit Seals, Renew (In Drydock) viii (Rev-1)

PC_175_WLM_0909

Principal Characteristics

175' WLM BUOY TENDER

PHYSICAL CHARACTERISTICS

Length Overall 174' 8" Length between Perpendiculars 155' 1" Depth 14' 8" Maximum Beam 36' 0" Designed Draft 8' 0" Mast Height (Above 8' Waterline) 58' 8" Frame Spacing 20" Full Load Displacement 906.42 long tons Light Load Displacement 840 long tons Minimum Op Condition Displ 870 long tons

MACHINERY CHARACTERISTICS

Main Propulsion

Two Caterpillar 3508 DITA V-8 diesel; 999 BHP ea

@ 1500 RPM

Two Ulstein 360 degree steerable Z-Drives, 403

SRPM @ 1600 ERPM

Reduction Gears Two Z-Drive units, Cardan shafting; 3.973:1 gear ratio

Shaft Seal John Crane Type ND

Shaft Bearings Five pedestal mounted, Cooper split roller bearings

Number of Propellers 2 Number of Blades 4 Diameter 57.1" Rudders None; Z-drive

Ship's Service Generators Three Caterpillar Model 3406 DITA Turbocharged;

285KW, 450V, 60 Hz, 1800 RPM

Emergency Diesel Generator One Caterpillar Model 3406 DIT 210 KW, 24V, 60 Hz, 1800 RPM

TANK CAPACITIES

Diesel Oil Capacity (100%) 16,385 gal Fresh Water Capacity (100%) 7,339 gal Lubricating Oil (100%) 86 gal

1 (Rev-1)

00000_0110_FLT

REC_0000_FLT_ Commercial Project @ Contractor’ Facility (0110)

General Requirements

1. SCOPE

1.1 Intent. This item describes the general requirements to be followed by the Contractor while conducting this availability.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

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

Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 33 CFR, 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

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and also to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.2 Contractor-provided fire watch personnel. The Contractor shall provide fire watch personnel and equipment.

3.3 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI

2 (Rev-1) 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.

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.

3 (Rev-1)

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________ Specific Area Being Preserved: ___________________________________________________________

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

Ensure all coatings are in compliance with COMDTINST M10360.3, Appendix C.

CHECKPOINT 2 - PAINT STORAGE

Ensure all coatings are kept at a temperature of 65 to 85°F at all times, unless otherwise specified by the coating manufacturer(s).

CHECKPOINT 3 - AMBIENT CONDITIONS

Ensure surface and surrounding temperatures are each between 50 and 90°F for water-based coatings, and 35 and 95°F for other coatings, unless otherwise specified by the coating manufacturer(s).

Ensure maximum relative humidity (RH) is as follows, from surface preparations through final curing of topcoat: 50% for tanks, voids, and vent plenum; and 85% for all other areas, unless otherwise specified by manufacturer(s).

Ensure surface temperature is at least 5°F above the dew point, unless otherwise specified by the coating manufacturer(s).

CHECKPOINT 4 - PRE-SURFACE PREPARATION

Remove surface contaminants (soluble salts, loose rust, mud, and marine growth) with low pressure fresh water wash down (maximum 5,000 psi). If oil and grease are present, perform solvent cleaning, as per SSPC SP-1.

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure cleanliness of prepared surface is as per specification (i.e.: SSPC SP-12, SP-11, SP-10…).

Verify surface anchor profile (1.5-3.5 mils for abrasive-blasted steel surfaces; 1.0 mil (minimum) for power-tool cleaned surfaces; 1.0-1.5 mils for abrasive-blasted aluminum surfaces); and 1.5 –2.5 for surfaces to be coated w/single coat of inorganic zinc). Conduct 5 sets of 3 readings for the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area.

Measure soluble salt conductivity (5 measurements per 1000 sqft) – maximum threshold: 70 microsiemens/cm for non-submerged surfaces and 30 microsiemens/cm for submerged surfaces.

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Verify proper mixing and stand-in (induction) times.

Ensure no paint is applied when the temperature is expected to drop to freezing before the paint has dried.

Ensure surfaces are completely dry, unless otherwise allowed by the coating manufacturer(s).

Verify wet film thickness (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.

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 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

4 (Rev-1)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________

(Use one sheet for each activity. Record conditions every four hours from before surface preparation to application of final coating system coat)

DATE &

TIME

ENTER ACTIVITY

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

LOCATION

TEMPERATURE

% REL.

HUMIDITY

SIGNATURE

OF

INSPECTOR DEW

POINT SURFACE AMBIENT

?T | DP - Surface

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

5 (Rev-1)

QA-3 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG)

Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________ Location of Surface Profile Measurements: ___________________________________________________________

SURFACE PREPARATION METHOD PROFILE

(mils)

Min Max Avg.

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 separate log for each area/location. When an Area Is Divided Into Separate Sections, Maintain A Separate Log for Each Section.

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

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

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

6 (Rev-1)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________

Location of Work (including frame numbers): _______________________________________ Area (square feet): ____________

DATE TEST LOCATIONS CONDUCTIVITY

(microsiemens/cm)

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

7 (Rev-1)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence) Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________

Coating Manufacturer: ___________________Product Name: _______________________Batch Number: ____________ Induction Time: _______________________________________________________________ Coating System Sequence (Indicate Whether: Primer, Touch-Up Primer, Barrier Coat, 3rd Coat…): __________________

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-Of (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: __________________________________________________________

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

8 (Rev-1)

24503_Z-DrvSl_Rnwl(DD)_0310_175

WORK ITEM 1: Z-Drive Propulsion Unit Seals, Renew (In Drydock)

1. SCOPE

1.1 Intent. The intent of this work item is for the Contractor to renew the port and starboard z-drive’s propeller shaft seals as well as the steering tube seals, in drydock. Contractor shall procure and furnish all parts required, Government will not provide any parts for this specification.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 175 WLM 243-2, Rev E, Propulsion Shaft Arrangement Coast Guard Drawing 175 WLM 245-1, Rev A, Propeller

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Coast Guard Technical Publication (TP) 3613, Dec 2002; SWBS 245, Section A; Z-Drive Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0000, Jan 2009; General

Requirements

OTHER REFERENCES

Commercial Item Description (CID) A-A-59323, Rev A, Cloths, Cleaning, Low-Lint MIL-F-24402, May 1995, Filters (Hydraulic), Filter Elements (High Efficiency), and Filter Differential

Pressure Indicators, General Specification

9 (Rev-1)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a critical inspection report (CIR) for the inspections listed in the following paragraphs:

• 3.4.1 (Z-drive initial inspection).

3.1.2 Tech Rep. The Contractor shall provide the services of qualified Tech Rep who is familiar with the Ulstein Z-drive propulsion unit, model number 1350-H, to accomplish the following tasks - on site:

• Provide manufacturer's proprietary 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.

3.1.2.1 The Contractor shall ensure that the Tech Rep is a certified representative of Rolls-Royce.

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

3.1.3 Protective measures. The Contractor shall take the following protective measures, to prevent contamination of the Z-drive, during the performance of the work specified herein:

• Ensure that all lifting equipment, chain blocks, rope, nylon slings, and other equipment/tools shall be washed clean prior to use on the Z-drive propulsion units to prevent dirt from falling into the system.

• When not actually working on the Z-drive propulsion units and at the end of each working day, it shall be wrapped with plastic sheeting, then taped closed to exclude dirt and moisture.

• Process any new oil added to the Z-drive propulsion units or hydraulic system through a non-bypass filter assembly prior to its introduction into the hydraulic system. Filter assembly shall utilize new clean disposable filter elements with a minimum Beta 10 = 75 ratio rating. Do not exceed filter assembly and/or element flow ratings or pressure ratings (both maximum collapse as well as delta across) during filling.

• Coordinate the progress of this item with other hull work to avoid abrasive blasting while the Z-drive propulsion units are open.

• Furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

10 (Rev-1)

3.1.4 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):

• Electrical boxes.

• Control panels.

3.2 Operational test - initial. Prior to drydocking the vessel, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR.

3.2.1 The system shall be inspected for oil leaks prior to disassembly and while Z-drive propulsion units are operationally tested.

3.2.2 Operational testing shall be performed under the supervision of the Tech Rep.

NOTE

The purpose of this test is to document pre-work condition of the Z-drive propulsion units and as a baseline to compare the post-work operational tests against.

3.3 System draining.

3.3.1 Before inspecting and changing out seals, the Contractor shall drain the lubrication, steering, and seal oils from both the Z-drive propulsion units in accordance with TP- 3613 and Coast Guard Drawing 175 WLM 245-

001. Dispose all drain fluids in accordance with applicable Federal, state, and local environmental regulations.

3.3.2 Once the systems have been drained, open all system tanks and clean to dry bare metal removing all condensation residue using new low-lint cleaning cloths conforming to CID A-A-59323, Type II.

3.3 Z-drive initial inspection. The Contractor shall clean the external portion of the Z-drive propulsion units to remove any marine growth, dirt grease and surface contaminants. Visually inspect the propeller and external portion of the Z-drive propulsion units for any damage, cracks, and other defects. Remove inspection covers located on the upper gearbox, steering housing and lower gear case (see Drawing #B8106242 of TP-3613 for location of inspection covers and drain plugs). Thoroughly inspect cases, gears, and bearings. Submit a CIR.

3.5 Z-drive removals. The Contractor shall remove the existing port and starboard Z-drive “Legs” (the lower units), as designated by the Tech Rep. Weld-install suitable pad eyes on the hull, in locations designated by the Tech Rep, to facilitate lowering of the Z-drives.

3.6 Propeller removal and inspection. The Contractor shall accomplish the following tasks;

3.6.1 Remove the propellers from their shaft in accordance with all referenced Coast Guard drawings and Coast Guard TP-3613, Tab 245A “Propeller Removal Procedure” (page 80).

3.6.2 Once each propeller has successfully been broken free, is adequately restrained, and hydraulic hose removed, the propeller nut may be fully removed, cleaned, and inspected. The exposed threads on shaft’s end shall be protected from damage by use of suitable tape or wrap.

3.6.3 Carefully handle and protect the removed propellers from damage until it is re-installed.

11 (Rev-1)

3.6.4 Thoroughly clean the removed propellers free of all marine growth and fouling. Remove marine growth and fouling of the propellers. After cleaning, polish the propeller hub and blade to a 63 micron RMS finish, ensuring as little material as possible is removed.

3.6.5 Perform NDI of the propellers, in accordance with SFLC Std Spec 0740. Record the results of the test, noting the size and location of any defects found, the surface condition of the blades, any evidence of corrosion or cavitation. Submit a CFR.

3.7 Propeller shaft seal renewal. Contractor shall procure and furnish the proper Z-drive seal set (PN ULM- A135OH-USCG). With the propellers removed and the systems drained the Contractor shall renew the propeller shaft seals in the presence of the Tech Rep, in accordance with Coast Guard TP-3613, Tab 245A “Propeller Shaft Seals Change-out Procedure” (page 51). Slide out the chromium propeller shaft (outer) seal sleeve and inspect.

Resurface the seal sleeve if required in accordance with cited procedure and per the Tech Rep guidance. Remove and inspect the companion seal ring (4803). Unbolt and remove the seal set (4026). Inspect the inner seal sleeve (4080) for scoring in accordance with referenced procedure and submit CFR. Reassemble propeller shaft seal components renewing the inner lip seals (4028), the gasket (4029), and the propeller shaft seal set (4026). Utilize new Contractor-Furnished Capscrews (4034) to fasten the sealbox to lower unit.

NOTE

All piece number identifications of above paragraph refer to Drawing D8107068 “Lower Unit Assembly” and/or Drawing D8107069 “Prop & Nozzle Assembly.”

3.8 Steering tube seal renewals. The Contractor shall renew the steering tube seals (3008) in the intermediate section assembly in accordance with TP-3613, Tab 245A “Steering Tube Seal Change Out Procedure” (page 51).

Be aware that this will require (per cited procedure) lowering and then removing the lower unit assembly, lifting then lowering out of the way the torque tube assembly (3018).

3.8.1 Remove the seal ring (3006) and inspect the stainless steel liner the seals run against for damage or scoring.

Visually inspect the remaining components of the intermediate section assembly in the presence of the technical representative and submit a CFR with findings.

3.8.2 Renew any disturbed seals and/or gaskets including but not limited to the gasket (3021).

NOTES

1. All piece number identifications of above paragraph refer to D8107050 “Intermediate Section Assembly.”

2. The propeller shaft seal and steering tube seal renewals are not specified in mandatory sequence; the Contractor shall consult with the Tech Rep in determining proper and logical sequencing.

3.9 Contractor Furnished Parts. For all disturbed seals, and/or gaskets, and capscrews the Contractor shall obtain and provide renewal parts, including but not limited to the parts in the following Table (table does not repeat renewal parts called out elsewhere in specification):

12 (Rev-1)

Rolls Royce Drawing; P/N Part Number Description Quantify for a Single Z-Drive

Lower Unit Assembly

DWG D8202104; P/N 68 325 O-RING 1 (each)

DWG D8202104; P/N 71 456 O-RING 1 (each)

DWG D8202104; P/N 78 SCS1-1/8NCX4 SOCKET

CAPSCREW

14 (each)

DWG D8202104; P/N 79 SCS1-1/4NCX4 SOCKET

CAPSCREW

4 (each)

DWG D8202104; P/N 93 214 O-RING 1 (each)

DWG D8202104; P/N 95 3-932 O-RING 1 (each)

Intermediate Assembly

DWG B8202064; P/N 21 B8104941 GASKET 1 (each)

DWG B8202064; P/N 17 SCS3/8NCX1-1/4SS SOCKET

CAPSCREW

16 (each)

Inspection Access Cover Gaskets (found on upper and steering sections)

B7807058 GASKET 2(each)

3.10 Propeller reinstallation. The Contractor shall reinstall the propellers in accordance with Coast Guard TP- 3613, Tab 245A “Propeller Installation Procedure” (page 81). Use new o-ring (4807) on propeller nut (4806).

Install new Contractor-furnished gasket (4802) between propeller and seal ring (4803).

3.10.1 Inspect all disturbed and/or removed bolts, studs and nuts for damage and suitability for re-use. Coat the threads with anti-seize compound.

3.10.2 Be aware that the Government reserves the right to furnish propellers, new seal sleeves (4080) and seal rings (4803), for installation in-place of the parts removed.

3.10.3 Upon completion of propeller installation of each unit, perform final visual inspection of the propeller assembly and submit a CFR.

3.11 System fluids replenishment. The Contractor shall furnish new replacement oils conforming to the manufacturer's recommendations to the seal oil tank, the Z-drive units and to the steering hydraulic systems.

Follow the procedures for renewing the Contractor-furnished oils and filters in accordance with TP-3613. The replacement oil shall be filtered through a non-bypass type filter with a 10-micron filter element conforming to MIL-F-24402 during refilling.

3.11.1 Ensure that the tanks shall be inspected and verified by the Coast Guard Inspector prior to closing.

13 (Rev-1)

3.11.2 Renew all tank cover gasket materials.

3.12 Calibration. The Contractor in conjunction with Coast Guard Inspector, shall calibrate the actual versus the indicated azimuth position mechanical indicators throughout the entire azimuth range in accordance with TP- 3613. Coordinate with the Coast Guard Inspector during calibration to allow for the electronic indicators in the MPCMS and MSCC systems to be also verified true and accurate.

NOTE

Only Coast Guard Inspector shall operate shipboard equipment.

3.13 Pad eye removal. The Contractor shall remove and dispose of all previously- installed pad eyes, upon completion of Z-drive restoration work.

3.13.1 Grind all remaining weldments flush with the hull.

3.13.3 Prepare and coat all new and disturbed exterior and interior surfaces to match existing adjacent surfaces, in accordance with COMDTINST M10360.3, Appendix A (Cutter and Boat Exterior Painting Systems) and Appendix B (Cutter and Boat Interior Painting Systems), respectively, and as applicable. Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

3.14 Operational test – post repairs. After completion of all work, the Contractor shall witness an operational test (by Coast Guard personnel) of all items or shipboard devices that have been disturbed, used, repaired, altered, or installed, to prove that they are in satisfactory operating condition. Submit a CFR.

3.14.1 The systems shall be inspected for oil leaks prior to undocking and while Z-drive propulsion units are operationally tested.

3.14.2 Operational testing shall be performed under the supervision of the Tech Rep.

This section is not applicable to this work item.

14 (Rev-1)

86340_KAM_0310_FLT

REC_86340_FLT_175 WLM (ALL) (0310)

WORK ITEM 2: Drydocking

1.1 Intent. This work item describes the requirements for the Contractor to drydock and undock the cutter and perform various drydocking-related tasks.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y *Transducer Cover Plate N/A 3 ea. 50.00

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 175 WLM 801-006, Rev H, Docking Drawing

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 8634 (SFLC Std Spec 8634), Jan 2009, Drydocking

OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative.

Not applicable.

15 (Rev-1)

3.1.3 Protective measures.

Not applicable.

3.1.4 Interferences.

None.

3.2 General. The Contractor shall drydock and undock the cutter, in accordance with SFLC Std Spec 8634, using Coast Guard Drawing 175 WLM 801-006 for guidance.

3.2.1 Cutter Conditions. The Contractor shall use the Full Load Condition, listed below for purposes of performing Pre-Award calculations as described in Appendix A (Requirements for Calculations) of SFLC Std Spec 8634.

• Displacement (LT): 906.4

• VCG (FT ABL): 13.73

• LCG (FT aft amidships): 10.09

• Length Overall (FT): 174.85

• Length Between Perpendiculars (FT): 155

• Length of supported keel (FT):135.

3.2.2 Blocking position. The Contractor shall arrange keel and side blocks, as shown on the vessel's docking plan, to facilitate docking of the vessel in blocking position No. 1. Ensure that the minimum keel block height is 48 inches above the docking facility deck.

3.3 Immediate work and routine Inspections The Contractor shall perform designated routine drydocking work, in accordance with SFLC Std Spec 8634, paragraph 3.4.4 (Within twenty four hours after docking).

NOTES

1. This vessel has a Z-drive propulsion system .

2. When setting keel blocks particular attention should be paid to ensure clearance around the sonars at Frames 21-22 and Frames 51-52.

3. Fuel offloading is not mandatory to drydock the vessel.

4. NOTES

4.1 Arrival conditions. The COTR will advise the Contractor of the actual tank and draft readings when the vessel arrives, and will discuss with the Contractor any liquid loading changes necessary.

16 (Rev-1)

86350_LNM_1009_FLT

WORK ITEM 3: Temporary Services, Provide

1.1 Intent. This work item describes the requirements for the Contractor to provide temporary logistics.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), Jan 2009, Provide

Temporary Services

OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General. The Contractor shall provide the below listed temporary logistics, in accordance with SFLC Std Spec 8635.

TABLE I - SERVICE SELECTION

*SUB-

PARAGRAPH TITLE Y/N

3.3.1 Office space N

3.3.2 Telephone (to include long distance line(s). Y

3.3.3 Parking N

3.3.4 Duty section berthing: __ male, __ female. Duty section berthing shall be provided for {Note: Choose one and delete the rest: (1) The entire duration of the availability, (2) during disruption of berthing areas or (3) ______ days}

N

3.3.5 Electrical power (including all requirements in associated sub-paragraphs). Cutter will bring isolation transformer.

Y

3.3.6 Compressed air (including all requirements in associated sub-paragraphs) N

17 (Rev-1)

3.3.7 Hazardous material/hazardous waste disposal (see Table 2 below) N

3.3.8 Heavy lift equipment: {__day(s)/or _5_ hour(s)}. Crane service for food supplies and sea chest valve removal and installation (Ships project).

Y

3.3.9 Water supply Y

3.3.9.1 Potable water: {_400__ gallons per day, at _50-60 _ psig.}{ or _____ gallons, bulk}

3.3.9.2 Hot-circulating water

N

3.3.9.3 Cooling water ( ASW 40-50 PSI with 2 pots for discharge).

Y

3.3.9.4 Firemain system (including all requirements in associated sub-paragraphs)

3.3.10 Steam (including all requirements in associated sub-paragraphs) N

3.3.11 Refuse disposal N

3.3.12 Sewage and grey water disposal (including all requirements in associated sub-paragraphs)

3.3.13 Storage – General (including all requirements in associated sub-paragraphs):

Dry stores. N

Paint and flammable stores.

N

Refrigerated stores.

N

3.3.14 Small boat storage (including all requirements in associated sub-paragraphs)

*Each sub-paragraph number relates directly to the identical sub-paragraph number in SFLC Std Spec 8635.

TABLE 2 - HARZADOUS WASTE DISPOSAL

LIQUIDS (GALLONS) SOLIDS

Paint Thinners

Engine Coolant

Bilge Water Oily Filters

Oily Rags (lbs)

Empty Containers (previously housed hazardous materials) 1-gal 5-gal 55-gal

00 00 00 00 00 00 00 00

3.2 Extended temporary services. If the performance period of the contract is extended by the KO, the contractor shall continue to provide all temporary services as specified herein for the extension period.

18 (Rev-1)

ECxxx_24506_Z-DrvTank_0310_175

WORK ITEM 4: Z-Drive Propulsion Unit Seal oil Tank , Relocate

1.1 Intent. This work item describes the requirements for the Contractor to relocate both Z-drive’s seal Oil Head Tanks.

1.2 Government-furnished property.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 175 WLM 245-1, Rev A, Propeller Coast Guard Drawing 175 WLM 561-1, Rev J, Z-Drive Hydraulic System Diagram Coast Guard Drawing 175 WLM 635-1, Rev F, Hull Thermal & Acoustic Insulation Schedule

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0000, Jan 2009; General

Requirements Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 085, Jan 2009, General

Requirements for Drawing Preparation Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes

OTHER REFERENCES

Coast Guard Technical Publication (TP) 3613, Jan 1997, Manufacturers Instruction Book-SWBS

Group(s) 242-262 Commercial Item Description (CID) A-A-59323, Rev A, Cloths, Cleaning, Low-Lint DOD-STD-1399 Section 301A, Jul 1986, Ship Motion and Attitude MIL-F-1183, Rev J; Fittings, Pipe Cast Bronze Silver-Brazing MIL-T-24107, Oct 1987, Tube, Copper (Seamless) (Copper Alloy Numbers C10100, C10200, C10300, C10800, C12000, C12200, and C14200) Manufacturers Standardization Society of the Valve and Fittings Industry (MSS), SP-69, 2003, Pipe

Hangers and Supports - Selection and Application Manufacturers Standardization Society of the Valve and Fittings Industry (MSS), SP-89, 2003, Pipe

Hangers and Supports – Fabrication and Installation Practices

19 (Rev-1)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures. The Contractor shall take the following protective measures, to prevent contamination of the Z-drive, during the performance of the work specified herein:

• 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.

• Furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

• Process any new oil added to the Z-drive propulsion units or hydraulic system through a non-bypass filter assembly prior to its introduction into the hydraulic system. Filter assembly shall utilize new clean disposable filter elements with a minimum Beta 10 = 75 ratio rating. Do not exceed filter assembly and/or element flow ratings or pressure ratings (both maximum collapse as well as delta across) during filling.

3.1.4 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):

• Bulkhead Insulation (to facilitate new tank foundation’s welding and potential other hotwork)

3.2 General description. The Contractor shall be aware of the following:

• The Z-drives are located at FR 93, Port and Starboard symmetrically about the centerline, at the 8’-0” grating level. The drives are housed with a 95” by 1114” square frame module that is flange connected to the ship structure. The propeller protrudes about 6 feet below the stern.

• The referenced Coast Guard Drawings 175 WLM 245-1 and 175 WLM 561-1 describe the z-drive’s layout and hydraulic piping system.

3.3 Removal of existing seal oil tank and piping.

20 (Rev-1)

3.3.1 In conjunction with other Z-drive work, ensure the head tank has been fully drained. Dispose in accordance with applicable Federal, state, and local environmental regulations.

3.3.2 Disconnect and remove the head tanks from their current locations. Clean and inspect the tank internals in preparation for its relocation. Use low lint rags, conforming to CID A-A-59323.

3.3.3 Once clean and inspected keep tank openings sealed from contamination.

3.4 Removal of old seal tank piping.

3.4.1 Drain and collect all oil from piping (from old head tank location to the z-drive connection) and disconnect piping from z-drive. Once piping is disconnected provide a temporary plug for opening, to ensure no contamination enters the z-drive prior to new piping being installed. Dispose of collected oil in accordance with applicable Federal, state, and local environmental regulations.

3.4.2 Ripout, scrap, and remove from Cutter all existing seal oil piping from old head tank location to the z-drive connection.

3.5.3 Remove all existing piping supports. For welded on pipe supports, grind flush all welds.

3.5 Removal of existing seal oil tank support.

3.5.1 Crop the existing Seal Oil Tank Support foundation.

3.5.2 Retain foundation to template mounting hole locations and possibly for reinstallation.

3.5.3 Grind all welds down smooth with adjacent surfaces.

3.6 installation of new seal oil tank support.

3.6.1 Relocate the foundation to the location specified in Figure, “NEW Arrangement Diagrammatic” in accordance with SFLC Std Spec 0740 and DOD-STD-1399. Depending on the configuration of the base structure in the relocated position, mounting the removed foundation may not be suitable to resist ship’s motion. Therefore the Contractor may select either one of the following options:

3.6.1.1 Install the removed foundation in accordance with in accordance with SFLC Std Spec 0740 and DOD- STD-1399. Fabricate and install additional support if required, e.g. add additional angle/flat bar stiffeners.

3.6.1.2 Fabricate and install a new Seal Oil Tank Support foundation in accordance with SFLC Std Spec 0740 and DOD-STD-1399, using the photos below as guidance.

3.6.2 Drill holes in the new/relocated foundation to mount the Seal Oil Tank. Quantity and holes size shall be templated from the removed foundation or the tank itself.

3.7 Installation of existing seal oil tank in new location.

3.7.1 Ensure the new support has been properly preserved and insulation restored prior to mounting tank to its new location.

3.7.2 Bolt the seal oil tank to its new foundation using new fasteners of similar size, material, and grade as those used previously.

21 (Rev-1)

3.8 Installation of new seal oil tank piping.

3.8.1 The Contractor shall be aware that the attached figure, “Plumbing Diagram Seal Oil” depicts the affected piping and provides details of the new piping arrangement. No additional detailed drawings have been develop, thus far. In addition to the Figure, “Plumbing Diagram Seal Oil” numerous photographs have been taken to document the prototype installation on the first two Cutters of this class (CGC ABBIE BURGESS and CGC WILLIAM TATE). These photographs have been arranged into figures, “Photographs of Existing Arrangement”, “Photographs of New Arrangement Port Z-drive”, and “Photographs of New Arrangement Starboard Z-drive”.

NOTE

To facilitate the installation, additional photographs and/or installation details may be available upon Contractor’s request. Request shall be as specific as possible and be made to the Coast Guard Inspector.

Request would ultimately be relayed for assistance to CGC Abbie Burgess or CGC William Tate who have previously completed the work.

3.8.2 The Contractor shall, using the supplied photographs of prototype installation, layout (chalk) the proposed piping runs for Coast Guard’s concurrence. Once proposed pipe routing has been concurred to, Contractor shall template and install piping to suit shipboard conditions.

3.8.4 Specific details on the fittings and connections at the two ends, the z-drive end and head tank end are supplied in Figures “Plumbing Diagram Seal Oil” and “Photographs of New Arrangement Port Z-drive”, and “Photographs of New Arrangement Starboard Z-drive”.

3.8.5 Interconnecting piping shall be 1” IPS Copper seamless tubing, MIL-T-24107, 0.065” wall thickness.

Fittings shall be silver-brazed bronze per MIL-F-1183.

3.8.6 The new Z-drive piping shall have a take-down joint (union) in its layout/design that will allow the piping to be removed during future z-drive renewals when the Z-drive is lifted out of the well and off the Cutter.

3.10 Cleaning and flushing of new piping.

3.10.1 Clean and flush all new and disturbed piping systems with clean fresh water for five minutes or until systems are thoroughly cleaned and reasonably free of contamination, and any remaining residue on the surface does not interfere with system operations or damaged system components. Ensure that flushing fluid is directed to move scale and foreign debris away from installed machinery to prevent possible damage upon operational testing. Blow dry all flushed piping with dry low-pressure compressed air. Ensure that all water has been completely removed to prevent contamination of Z-drive system oil. All open ends shall remained capped or plugged (until final connections) to prevent subsequent contamination.

3.10.1 Dispose of flushing fluid in accordance with all applicable Federal, state, and local regulations.

WARNING!

Do not drain ANY fluids (including fresh water) into any space, bilge, or exterior location.

3.10.2 It is preferred that piping assemblies be prefabricated, cleaned, and flushed to the maximum extent possible in the shop prior to final assembly shipboard. Upon satisfactory cleaning and flushing of the pipe assemblies, cleanliness must be preserved by the immediate sealing of the open ends until ultimate assembly shipboard.

3.12 Pipe hangers.

22 (Rev-1)

3.12.1 The Contractor shall, using the supplied photographs of prototype installation, layout (chalk) the proposed hangar locations (4 per side, 8 total) for Coast Guard’s concurrence.

3.12.2 Once proposed hangar location has been concurred to, Contractor shall fabricate and install pipe hangers in accordance with MSS SP-69 and MSS SP-89.

3.13 Leak test. After all authorized repairs of mechanical (i.e. threaded, bolted, etc.) joints, the Contractor shall perform an operational test of the Z-drive piping system using the system fluid at normal operating pressure. Be aware that no visible leakage or deformation is acceptable. Repair all leaks and discrepancies found. Submit a

CFR.

3.14 System fluids replenishment. In conjunction with other Z-drive work refill the seal oil tank with new replacement oils conforming to the manufacturer's recommendation (page 60 of CG TP-3613). The replacement oil shall be filtered through a non-bypass type filter with a 10-micron filter element.

NOTE

For purpose of bid, assume the oil will be supplied and paid for in other related Z-Drive work items. Do not include that cost in the bid of this item.

3.15 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed exterior and interior surfaces to match existing adjacent surfaces, in accordance with COMDTINST M10360.3, Appendix A (Cutter and Boat Exterior Painting Systems) and Appendix B (Cutter and Boat Interior Painting Systems), respectively, and as applicable. Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

3.16 New drawing deliverables. The Contractor shall, in accordance SFLC Std Spec 085, produce a new drawing depicting…