CGC SPAR SPECIFICATION R0.pdf

USCGC SPAR (WLB 206)

225 FOOT "B CLASS" SEAGOING BUOY TENDER

SPECIFICATION FOR DOCKSIDE REPAIRS

Developed By: CWO Ken Miller

(Rev-0, 19 May 2011)

USCGC SPAR (WLB-225B) DOCKSIDE AVAILABILITY 2011

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ....................................................................................................................................... iii Consolidated List of References ................................................................................................................ iv Consolidated List of Government-furnished Property .............................................................................. vii Consolidated List of Critical Inspection Items ........................................................................................ viii Principal Characteristics ............................................................................................................................ ix

General Requirements WORK ITEM 1: Ship Service Diesel Generator, Engine Top End Overhaul WORK ITEM 2: Circuit Breakers (60 Hz), Inspect and Test

WORK ITEM 3: Potable Water Pneumatic Tanks, Clean and Inspect WORK ITEM 4: Potable Water System Relief Valve, Renew WORK ITEM 5: Compressed Air Receivers, Clean, Inspect, and Test

WORK ITEM 6: Compressed Air System Valves, Inspect and Test WORK ITEM 7: Grey Water Holding Tanks, Clean and Inspect WORK ITEM 8: Sewage Holding Tanks, Clean and Inspect

WORK ITEM 9: Sewage Piping, Clean and Flush

WORK ITEM 10: Tanks ( Grey Water Holding ), Preserve “ Partial ” WORK ITEM 11: Tanks ( Sewage Holding ), Preserve “ Partial ” WORK ITEM 12: Temporary Services, Provide

WORK ITEM 13: Shower Deck Drain, Modification WORK ITEM 14: Deck Covering (Interior Wet/Dry) , Renew

WORK ITEM 15: Fuel Transfer Pumps, Align WORK ITEM 16: Tanks (Potable Water), Clean WORK ITEM 17: Tanks (Potable Water), Inspect

WORK ITEM 18: Tanks ( Grey Water Holding ) , Preserve “ 100% ” WORK ITEM 19: Tanks (Potable Water), Preserve “ 100% ”

WORK ITEM 20: Tanks ( Potable Water ), Preserve “ Partial ”

WORK ITEM 21: Tanks ( Sewage Holding ) , Preserve “ 100% ” WORK ITEM 22: Deck Covering (Wet/Dry), Seal iii (Rev-0)

Revisions Record

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

iv (Rev-0)

Consolidated List of References

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

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free 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

Coast Guard Drawing 225 WLB 528-001, Rev H, Plumbing and Interior Deck Drains

Coast Guard Drawing 225B WLB 167-1, Rev H, Structural Closures

Coast Guard Drawing 225B WLB 635-1, Rev B, Hull Thermal & Acoustic Insulation

Coast Guard Drawing 225B WLB 180-005, Rev G, Foundations Hull Block 940

Coast Guard Drawing 225B WLB 201-001, Rev C, Machinery Spaces Arrangement

Coast Guard Drawing 225B WLB 320-1, Rev L, Electrical One - Line Diagram

Coast Guard Drawing 225B WLB 532-002, Rev D, Potable Water Sys Dia

Coast Guard Drawing 225B WLB 541-004, Rev C, Fuel Oil Transfer System A/D Fr 66 Aft Block 940, 950

Coast Guard Drawing 225B WLB 551-001, Rev D, Compressed Air System Diagram

Coast Guard Drawing 225B WLB 593-001, Rev D, Sewage and Waste Water System Diagram

Coast Guard Drawing 225B WLB 593-001, Rev G, Sewage and Waste Water System

Coast Guard Drawing 225B WLB 593-009, Rev B, Sewage Holding Tank

Coast Guard Drawing 225B WLB 601-001, Rev F, General Arrangement Inboard & Outboard Profiles

Coast Guard Drawing 225B WLB 601-1, Rev G, General Arrangements Inboard and Outboard Profiles

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (Series), Coatings and Colors Manual

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

Manual

Coast Guard Technical Publication (TP) 3534A, 07-JAN-97, Switchboards, Ship Service and Emergency

Diesel Generator - Model D2

Coast Guard Technical Publication (TP) 3534B, 07-JAN-97, Switchboards, Ship Service and Emergency http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace v (Rev-0)

Diesel Generator - Model D2

Coast Guard Technical Publication (TP) 3537A, 07-MAY-01, Ship's Service Diesel Generator Set (SSDG) -

Model 3508

Coast Guard Technical Publication (TP) 3537B, 07-MAY-01, Ship's Service Diesel Generator Set (SSDG) -

Model 3508

Coast Guard Technical Publication (TP) 3551, SWBS 541, Section B, Feb 2000, Pump, Fuel Oil Transfer

Model-GPXL3A-HRA E-4669

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

Processes

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3042, Jan 2009, Shipboard Electrical

Cable Removal, Relocation, Splice, Repair and Installation

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

Requirements

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

Allied Processes

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

Temporary Services

Surface Forces Logistics Center Standard Specification 8636 (SFLC Std Spec 8636), Jan 2009, Temporary

Hull Accesses

OTHER REFERENCES

American National Standards Institute/American Water Works Association (ANSI/AWWA) C652, 2002, Disinfection of Water-Storage Facilities

American National Standards Institute/NSF International (ANSI/NSF) 61, 2008, Drinking Water System

Components - Health Effects

American Society for Testing and Materials (ASTM), F1508, 1 May 2004, Standard Specification for Angle

Style, Pressure Relief Valves for Steam, Gas, and Liquid Services

American Society of Mechanical Engineers (ASME), PTC 25, 2001, Pressure Relief Devices

ASTM International (ASTM) D1330, 2004, Standard Specification for Rubber Sheet Gaskets

ASTM International (ASTM) D4417, 2003, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel

Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters

Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency

Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety

Administration, Department Of Transportation

Commercial Item Description (CID) A-A-59316, Nov 2003, Abrasive Materials for Blasting

DOD-STD-2187, Aug 1987, Chemical Cleaning of Salt Water Piping Systems

MIL-A-22262, Mar 1996, Abrasive Blasting Media Ship Hull Blast Cleaning

MIL-D-16791, Jan 1993, Detergents, General Purpose (Liquid, Nonionic)

MIL-D-3134, Sep 1989, Deck Covering Materials

MIL-PRF-24613, Dec 1990, Deck Covering Materials, Interior, Cosmetic Polymeric

National Electrical Manufacturers Association (NEMA) Stds, Pub. No. AB4, 2003, Guidelines for Inspection and Preventive Maintenance of Molded Case Circuit Breakers Used in Commercial and Industrial Applications

Surface Forces Logistics Center Standard Specification 6341 (SFLC Std Spec 6341), Jan 2009, Install New

Deck Covering Systems

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

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

The Society for Protective Coatings (SSPC) VIS 1, 2004, Guide and Reference Photographs for Steel Surfaces vi (Rev-0)

Prepared by Dry Abrasive Blast Cleaning

The Society for Protective Coatings (SSPC)/NACE International (NACE) 2004, Joint Surface Preparation

Standard SSPC-SP 10/NACE No.2, Near-White Blast Cleaning

Underwriters Laboratories Inc. (UL) 489, May 2002, Molded Case Circuit Breaker vii (Rev-0)

Consolidated List of Government-furnished Property

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

WORK

ITEM

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

1 Y Unit Injector 10R-1284 16 ea. $750.00

1 Y Cylinder Head 10R-7765 16 ea. $750.00 *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 viii (Rev-0)

Consolidated List of Critical Inspection Items

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000_STD, paragraph

3.2.6.5 (Inspection report particulars)):

Work

Item Title

This section is not applicable to this package.

ix (Rev-0)

PC_225B_WLB_1109

Principal Characteristics

225' WLB (B-CLASS)

PHYSICAL CHARACTERISTICS

Length Overall 225' 0" Length between Perpendiculars 206' 0" Maximum Beam 46' Designed Draft 13' 0" Full Load Displacement 2000 long tons Light Ship Displacement 1523 long tons Minimum Operating Displacement 1800 long tons Mast Height (Above 12' Waterline) 67' 5"

Anchor

Two 4000 lb standard Navy stockless anchors, 8 shots each, port and starboard, 1-3/8 die lock chain

HULL CHARACTERISTICS

Bilge Keels (Port & Starboard) Frames 42-79 Frame Spacing

FR 0 to 12 21" FR 12 to 30 22"

FR 30 to 102 24"

MACHINERY CHARACTERISTICS

Main Propulsion Diesel Reduction

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

Number of Propellers 1 Number of Blades 4 Diameter 10' Pitch Controllable

RPM 254

Ship's Service Diesel Generators Two Caterpillar 3508 TA, 450 kW

Emergency Diesel Generator One Caterpillar 3406 DITA, 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

TANK CAPACITIES

Diesel Oil 76,498 gal Fresh Water Capacity 8056 gal Hydraulic Oil Capacity 2785 gal x (Rev-0)

Lube Oil Storage 764 gal Grey Water Tank 2700 gal Sewage Holding Tank 1700 gal xi (Rev-0)

1 (Rev-0)

00000_PWB_0111_FLT

REC_0000_FLT_ Commercial Project @ CG 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

ASTM International (ASTM) D4417, 2003, Standard Test Methods for Field Measurement of Surface

Profile of Blast Cleaned Steel

Commercial Item Description (CID) A-A-59316, Nov 2003, Abrasive Materials for Blasting

Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters

Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency

Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety

Administration, Department Of Transportation

MIL-A-22262, Mar 1996, Abrasive Blasting Media Ship Hull Blast Cleaning

The Society for Protective Coatings (SSPC) VIS 1, 2004, Guide and Reference Photographs for Steel

Surfaces Prepared by Dry Abrasive Blast Cleaning

3. REQUIREMENTS

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

2 (Rev-0)

NOTE

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

3.2 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec

0000, in accomplishing the following task:

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

Coast Guard fire watch personnel.

Provide fire watch personnel and fire extinguishers for the duration of the availability period, during and beyond noted Coast Guard fire watch support.

3.3 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740.

3.4 HW disposal. The Contractor shall be responsible for all hazardous wastes generated by work under this contract. Label and package all hazard wastes in 49 CFR-approved containers, and in accordance with all other applicable Federal, state, and local laws and regulations. In addition, comply with applicable parts of 40 CFR

262, applicable to handling of hazardous wastes.

3.4.1 Along with the Government, the Contractor shall be contractually considered the co-generator of all hazardous wastes; be aware that the Government will make available its facility’s EPA Generator Identification

(ID) Number for manifesting of hazardous wastes.

3.4.2 The Contractor shall identify, arrange, and be responsible for the turnover of all hazardous wastes, within the confines of the Coast Guard shore facility, to the facility’s HM/HW Coordinator. Notify the ship’s HW

Coordinator prior to any transfers of HW from ship to shore.

3.4.3 The Contractor shall prepare a manifest of hazardous waste to be reviewed and signed by the HM/HW

Coordinator. Contact the HM/HW Coordinator for turnover of any hazardous waste; in addition, notify the

COTR 24 hours prior to any waste removals, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.4.4 The Contractor shall be aware of the following:

3.4.4.1 No Contractor or Subcontractor shall have the authority to sign a Hazardous Waste Manifest using the

Coast Guard facility’s EPA Generator ID Number or remove contract generated hazardous waste from the Coast

Guard facility without COTR or KO-approval.

3.4.4.3 Local environmental regulations at the Government facilities may be more stringent than in many jurisdictions. As with all environmental regulations, it is the Contractor's responsibility to research, prepare for, and comply with, the local and state regulations.

3.4.4.4 Coast Guard facilities do not have Facilities Response Plans (see 33 CFR 154 Subpart F). It is the

Contractor’s responsibility to furnish the Facility Response Plan (FRP) when required for over-the-water liquids transfers to and from vessels. This requirement is applicable to transfers to/from vessels with an oil/fuel capacity of 250 barrels or more.

3 (Rev-0)

3.5 Pre-surface preparation test coupon. In order to ensure production of required surface profile, the Contractor shall accomplish the following, tasks, whenever abrasive-blasting is required in a work item that is deemed a

”critical-coated’ surfaces:

3.5.1 Coupon material and test set-up particulars.

3.5.1.1 Conduct a performance test on all abrasive blasting operations on a Contractor- provided test coupon, prior to starting abrasive blasting operations on the vessel. Ensure the following:

The coupon shall be a new metal plate, of the same metal type and material properties as the vessel area to be blasted - steel or aluminum plate, as applicable, and shall have no existing anchor profile - other than the surface irregularities from the manufacturing process.

The test coupon shall be flat, with nothing welded to the side used for the anchor profile test, no thinner than a 1/8-inch plate and measuring no smaller than 1-foot by 1-foot.

For steel substrates, the coupon shall have the mill scale intact, and be in a Rust Grade "A" condition, in accordance with SSPC-VIS 1.

The test coupon shall be affixed so as to not permit excessive movement during the performance test, but shall not be affixed to the vessel.

3.5.1.2 Ensure that the abrasive-blasting operation for the test coupon is conducted with the identical setup and parameters that will be used blasting the designated vessel surfaces – including, but not limited to:

The abrasive media type and media size selected to achieve the anchor profile range, as specified in the applicable work items.

Nozzle size and type (straight bore, high velocity nozzle, angle nozzle...).

Delivery rate and pressure settings.

3.5.1.3 Blast a one-square foot area on one side of the test coupon to the abrasive surface preparation standard specified in the work item, and perform an anchor profile test of the blasted surface in accordance with ASTM

D4417, Method B or C. Notify the COTR in advance of the abrasive blasting operation test, to permit the witnessing of the test by the COTR. Submit a CFR documenting the results of the abrasive blasting operation test. The CFR shall include at a minimum, the following:

Area of the vessel for which the verified setup will be used to abrasive blast.

The selected abrasive media type and size.

The nozzle size and type.

The delivery rate and pressure.

The test coupon starting properties (material type and surface conditions).

4 (Rev-0)

The resultant anchor profile readings from the test (a minimum of 3 locations, separated by a minimum of

2 inches shall be recorded).

NOTES

1. A performance test of the abrasive blasting operations on a test coupon and measuring the resultant anchor profile prior to performing the abrasive blasting operation on the cutter is required. The test coupon will be used to evaluate the anchor profile produced by the equipment setup and selected abrasive media.

2. The reverse side of the test coupon may be used for the subsequent test, provided that the conditions in paragraph 3.5.1 (Coupon material and test set-up particulars) are met.

3. Ultra high pressure water jetting does not create an anchor profile and is exempt from the anchor profile test coupon check.

3.5.1.4 Repeat the abrasive blasting operation test in the following instances:

The equipment setup, that was evaluated during the test coupon abrasive blasting performance test in paragraph 3.5.1 (Coupon material and test set-up particulars), has changed.

The resultant anchor profile readings observed on the vessel are outside the specified anchor profile range.

Media is changed from MIL-A-22262 to CID A-A-59316 or vice versa.

The supplier of the abrasive blasting media changes, regardless if the new source for the media has the same specifications.

When Directed by the COTR.

CAUTION!

Ensure that blast media from the performance test does not strike the vessel during the test.

3.6 Interim changes to SFLC Std Spec 0000. The Contractor shall be aware of the fact that the requirements of paragraph 3.3.2.1.1 (Water depth) have been revised to read as follows:

“3.3.2.1.1 Water depth. Ensure that water depth is sufficient at the pier to allow the vessel's lowest underwater appendage to clear the bottom by at least two feet at:

Ordinary low water mark on non-tidal rivers.

At all tide conditions predicted during the availability for tidal rivers and other navigable waterways (Bay, Lake, etc.).”

4. NOTES

4.1 Access to COMDTINST M10360.3. The COMDTINST M10360.3 may be accessed at the following URL address: http://www.uscg.mil/directives/cim.asp http://www.uscg.mil/directives/cim.asp

5 (Rev-0)

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.

6 (Rev-0)

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

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

Verify equipment setup, blast media, and surface preparation methods match designated test coupon.

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

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

Verify surface anchor profile using ASTM D4417-Methods B or C against COMDTINST M10360.3. Conduct profile readings at a minimum of 5 locations for the first 1000-sqft area, and 2 locations for each succeeding 1000-sqft area.

Measure soluble salt conductivity in accordance with SSPC-Guide 15. Conduct 5 measurements per each 1000 sqft area

(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. Conduct 5 sets of 3 readings for each of the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area.

Ensure that system cure is in accordance with manufacturer's recommendation for intended service.

Ensure potable water tank exhaust ventilation is maintained continuously from and during coating application through final system cure, to exhaust all solvent to the atmosphere and to prevent solvent entrapment.

For immersion coatings (including tank U/W body), record date and time of the following events:

Final coat application:_________/_________; Return to service or removal from environment controls: _______/_______

CHECKPOINT 10 – RECORD KEEPING

Complete, sign, and submit all provided QA Inspection Forms.

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

7 (Rev-0)

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

ΔT

| DP - Surface

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

8 (Rev-0)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

Vessel Name: _______________________ Hull Number: ______________

CLIN No.: _____________ Work Item Title: ________________________________________________

Location of Surface Profile Measurements: __________________________________________________________________

SURFACE PREPARATION METHOD

PROFILE ACHIEVED (mils)

Min Max Mean SSPC-SP-10/NACE No. 2 SSPC-SP-12/NACE No. 5

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area) Brush-blasting (non-metallic substrate)

Abrasive Manufacturer and Sieve Size: _________________________________

Place Surface Profile Replica Tapes In The Spaces Provided Below, To Serve As Permanent QA record. Maintain 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

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Mean 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: _________

9 (Rev-0)

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

Vessel Name: _______________________ Hull Number: ______________

CLIN No.: _____________ Work Item Title: ________________________________________________

Location of Surface Profile Measurements: __________________________________________________________________

SURFACE PREPARATION METHOD

PROFILE ACHIEVED (mils)

Min Max Mean SSPC-SP-10/NACE No. 2 SSPC-SP-12/NACE No. 5

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area) Brush-blasting (non-metallic substrate)

Abrasive Manufacturer and Sieve Size: _________________________________

Place Surface Profile Replica Tapes In The Spaces Provided Below, To Serve As Permanent QA record. Maintain 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

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Replica Tape Here

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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: _________

10 (Rev-0)

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): ____________

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15

DATE TEST LOCATIONS CONDUCTIVITY

(microsiemens/cm)

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

11 (Rev-0)

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: _________

12 (Rev-0)

31100_0910_225B_SSDG Top End Overhaul

WORK ITEM 1: Ship Service Diesel Generator, Engine Top End Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform Top End Overhauls on both

SSDG’s Caterpillar 3508B Diesel prime movers.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y Unit Injector 10R-1284 16 ea. $750.00

Y Cylinder Head 10R-7765 16 ea. $750.00

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 225B WLB 601-1, Rev G, General Arrangements Inboard and Outboard Profiles

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3537A, 07-MAY-01, Ship's Service Diesel Generator Set

(SSDG) - Model 3508

Coast Guard Technical Publication (TP) 3537B, 07-MAY-01, Ship's Service Diesel Generator Set

(SSDG) - Model 3508

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3042, Jan 2009, Shipboard

Electrical Cable Removal, Relocation, Splice, Repair and Installation

OTHER REFERENCES

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

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

13 (Rev-0)

3.1.2 Technical Representative. The Contractor shall provide the services of qualified Tech Rep, who is familiar with - the Caterpillar Diesel Engine 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.

Technical Representative shall be present for all disassembly, inspection, and reassembly of the Diesel

Engine.

3.1.3.1 The Contractor shall ensure that the Tech Rep is a certified representative of Caterpillar.

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

3.1.3.3 The Contractor shall be required to have this Technical Representative present (mandatory), on site, while the following engine work is being performed:

a. Disassembly

b. Inspection and qualification of parts

c. Re-assembly of engine

d. Engine Final Preparation For Testing

e. Engine Cleaning

f. Engine Testing

NOTE

The Caterpillar Technical Representative may be present at other times in addition to the mandatory times listed above. The above represents the minimum required Technical Representative usage.

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

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):

Catwalks will require removing handrails and placing adequate supports/shoring under, if they are intended to be used to hold heavy engine parts.

3.2 Both Ship Service Diesel Generator Engine Overhaul General Guidance

14 (Rev-0)

3.2.1 Upon completion of this item both Ship Service Diesel Generators (SSDGs) engines shall be restored to a condition defined by the OEM as “0 hours since last top end overhaul” for all components discussed herein.

3.2.2 Overhaul of the engine requires the use of special tools. The technical manual describes the tools needed.

The contractor or the technical representative being supplied by the contractor is responsible for supplying all of the special tools and any other tools needed to overhaul the engine. The ship does not have any of the special tools required for overhaul of the engine.

3.2.3 The Contractor shall perform the following work within the first three weeks of the availability:

a. Disassemble the engine.

b. Determine which, if any, parts require replacement. These parts are those beyond those already called out in this specification (paragraph 3.4 and its sub-paragraphs) for mandatory renewal.

c. Provide this information to the CG Inspector, via a CFR, making special note of any parts that require renewal considered to be long lead time (greater than 30 calendar days).

3.2.4 When reassembling the engine, components will be torqued to values given in the technical manual. If no value is given in the technical manual, rely in directions from the Caterpillar Technical Representative.

3.2.5 Any replacement parts used on the engine shall be certified Caterpillar parts.

3.2.6 The serial numbers for the engines are:

SSDG 1: BAG00002

SSDG 2: BAG00003

3.3 Overhead Wipe Down

3.3.1 Prior to commencing work, protect the open sections of the engine with a drop cloth to prevent contamination of the engine.

3.3.2 Wipe down the overheads above both Ship’s Service Diesel Generator, including all framework, stiffeners, piping, exhaust piping and other items in the overhead to remove dirt and dust which could fall into the engine during work.

3.4 Lifting Points

NOTE

Lifting points or padeyes are available in the overhead to assist with lifting engine components.

3.4.1 There are four (4) padeyes in the overhead above the SSDG. Visually inspect the padeyes prior to use.

Determine that there is no evidence of deterioration or deformation before using padeyes to lift engine components.

3.5 Both Ship Service Diesel Generator Engine Overhaul Preparations

15 (Rev-0)

3.5.1 In the presence of the CG Inspector, drain and disconnect the SSDG engine assembly fluid systems including, but not limited to, fuel oil supply and return, jacket water, sea water, and lube oil systems

(approximately 200-gallons jacket water, 150-gallons lube oil, and 5-gallons fuel oil, per engine assembly).

Remove the fluid systems from the Cutter and dispose of in accordance with all applicable federal, state, and local laws and regulations. Clean the sump, inspect, and submit a CFR. Obtain verification from the CG Inspector on the cleanliness of the sump prior to the installation of the sump screens.

3.5.1.1 Seal each end of each fuel line, lube oil line, water line, and starting air line. For each connection, immediately upon disconnection, seal with clean plastic caps, plugs, or flanges with gaskets to prevent contamination. Rags and wooden plugs shall not be used. Obtain verification from the CG Inspector for protective measures.

3.5.2 Disconnect, as required, to repair the engine (repairs further delineated by the full content of this specification), all associated service systems including, but not limited to, exhaust, ventilation, fuel, sea water, and lube oil.

3.5.3 Determine a suitable means of dismantling the engine top end and rigging components without causing any damage to equipment or ship structure.

3.5.3.1 Engine components, which require removal for performance of this work item, shall be labeled, and stored in a protected location for reuse. If necessary, cables attached to such items may also be disconnected and pulled back per SFLC Std Spec 3042.

3.5.3.2 The Contractor shall take precautions to ensure protection of piping and electrical systems adjacent to hot work operations, as applicable.

3.6 Both Ship Service Diesel Generator Engine Top End Overhaul And Reassembly (11,000 HRS)

3.6.1 Overhaul the engine components in accordance with the applicable procedures of the referenced CG Tech

Pubs and the instructions of the following paragraphs. Use new gaskets and seals when reassembling all equipment.

3.7 Air Starting Motor/Electric Starting Motor (CG TP 3537A, Disassembly and Reassembly Tab, pp 5-19)

3.7.1.1 Disconnect the air start motor assembly.

3.7.1.2 Disassemble the air start motor and clean and inspect all parts.

3.7.1.3 Reassemble the air start motor. Renew all bearings and seals. Renew the rotor vanes.

3.7.1.4 Reinstall and reconnect the air motor upon completion of other work.

3.7.2 Air Cleaner Housing (CG TP 3537A, Disassembly and Reassembly Tab, pp 34-35)

3.7.2.1 Remove each of the air cleaner housings. Remove the filter assemblies from the air cleaner housings.

3.7.2.2 Clean the interior of each of the filter housings. Install a new filter assembly in each air filter housing.

3.7.2.3 Upon completion of other engine work, reinstall the air filter housings.

3.7.3 Pressure and Temperature Gauges and RPM Indicators on Local Control Panel

16 (Rev-0)

The pressure and temperature monitoring on this engine is electronic.

3.7.3.1 Disconnect and remove the gauge panel and the contactor group to allow access to the engine for overhaul. Mark all connections to ensure correct reassembly upon completion of other engine work.

3.7.3.1.1 Calibrate the following pressure and temperature gages and RPM indicators on the local operating stations for the engine. Put a calibration sticker on the inside face plate of the gauge showing the last calibration date, facility performing the work, and next calibration due date.

Local Control Panel

Engine Coolant Temperature

Engine Oil Pressure

Engine Oil Temperature

3.7.3.2 After completion of other engine work, reassemble and reconnect the gauge panel and contactor group.

3.7.3.3 Demonstrate the proper operation of each of the indicators listed above during engine testing which will be required later in this specification item. Verify proper operation in the presence of the technical Representative and the Coast Guard Inspector.

3.7.4 Crankcase Breather (CG TP 3537A, Disassembly and Reassembly Tab, pp 129-130)

3.7.4.1 Disassemble and clean each of the two (2) crankcase breather assemblies. Clean the wire screen assembly in each breather assembly.

3.7.4.2 Reassemble each of breather assemblies upon completion of other engine work. Use new o-ring seals.

3.7.5 Water Temperature Regulators (CG TP 3537A, Disassembly and Reassembly Tab, pp 58-59)

NOTE

Removal of the water temperature regulator housing requires prior removal of the fuel filter housing. The fuel filter housing is removed later in this specification item.

3.7.5.1 Disconnect and remove the water temperature regulator housing.

NOTE

The regulator housing can be installed backwards and cause overheating of the engine. Mark and identify the correct orientation for installation purposes prior to removal of the housing.

3.7.5.2 Disassemble the water temperature regulator housing and clean all mating surfaces. Renew the water temperature regulators and lip seals in the regulator housing. There are four (4) water temperature regulators and seals in the water regulator housing.

3.7.5.3 Reassemble the water temperature regulator housing using new gaskets.

17 (Rev-0)

3.7.5.4 Reinstall the water regulator housing using new gaskets upon completion of other engine work.

3.7.6 Auxiliary Water Pump (Aftercooler) (CG TP 3537A, Disassembly and Reassembley Tab, pp 66-71)

3.7.6.1 Disconnect the after cooler pump from the engine.

3.7.6.2 Provide and install a rebuilt after cooler pump. Use new gaskets and seals when installing the pump.

3.7.6.3 Clean the used after cooler pump and pack it in the crate which contained the rebuilt pump for return to the manufacturer.

3.7.6.4 Return the after cooler pump to the manufacturer for core value.

3.7.7 Fresh Water Pump (CG TP 3537A, Disassembly and Reassembly Tab, pp 60-66)

3.7.7.1 Disconnect the fresh water pump from the engine.

3.7.7.2 Provide and install a rebuilt fresh water pump. Use new gaskets and seals when installing the pump.

3.7.7.3 Clean the used fresh water pump and pack it in the crate which contained the rebuilt pump for return to the manufacturer.

3.7.7.4 Return the fresh water pump to the manufacturer for core value.

3.7.8 Auxiliary Water Pump (Sea Water) (CG TP 3537A, Specification Tab, pp 71-91)

3.7.8.1 Disconnect the raw water pump from the engine.

3.7.8.2 Provide and install a rebuilt raw water pump. Use new gaskets and seals when installing the pump.

3.7.8.3 Clean the used raw water pump and pack it in the crate which contained the rebuilt pump for return to the manufacturer.

3.7.8.4 Return the raw water pump to the manufacturer for core value.

3.7.9 Fuel Filter Elements and Filter Housing (CG TP 3537A, Disassembly and Reassembly Tab, pp 24-28)

3.7.9.1 Disconnect and remove the fuel filter housing.

3.7.9.2 Remove the covers from the fuel filter housing. Remove the old fuel filter element. Wipe out the fuel filter housings. Provide and install new fuel filter elements. Close up the fuel filter housing. Dispose of the old fuel filter elements. Dispose of the old fuel filter elements in accordance with all federal, state, and local regulations. Provide and install new o-ring seals when closing up the fuel filter element housings.

3.7.9.3 Reinstall the fuel filter housing upon completion of other engine work.

3.7.10 Engine Oil Filter Elements (CG TP 3537A, Disassembly and Reassembly Tab, pp 115-116)

3.7.10.1 Drain the lube oil from the oil filter housings.

3.7.10.2 Open the filter housings and remove the old lube oil filter elements.

18 (Rev-0)

3.7.10.3 Wipe out the lube oil filter housings.

3.7.10.4 Provide and install new lube oil filter elements.

3.7.10.5 Close up the lube oil filter housings using new o-rings.

3.7.11 Engine Oil Filter Housing (CG TP 3537A, Disassembly and Reassembly Tab, pp 109-116)

NOTE

To remove the oil filter housing it is first necessary to remove the fuel filter housing. The fuel transfer pump is removed in a separate section of this specification item.

3.7.11.1 While the lube oil filters are removed, disassemble the oil filter housing. Clean all parts.

3.7.11.2 Reassemble the oil filter housing on the engine. Use new o-rings.

3.7.11.3 Inspect the operation of the oil change valve.

3.7.12 Fuel Transfer Pump.

3.7.12.1 Remove the fuel transfer from the oil pump. Clean and inspect.

3.7.12.2 When sequenced with other work, re-install the fuel transfer pump. Ensure the new O-ring seal, is installed on fuel transfer pump. Make sure that the drive coupling is correctly engaged with the shaft of the engine oil pump.

3.7.13 Oil Pump.

3.7.13.1 Remove the oil pump from engine. Clean and inspect.

3.7.13.2 When sequenced with other work, re-install the oil pump. Ensure the new O-ring seal, is installed on the oil pump.

3.7.14 Engine Oil Cooler (CG TP 3537A, Disassembly and Reassembly Tab, pp 98-102)

NOTE

The lube oil will have already been drained from the engine.

3.7.14.1 Drain any residual oil from the cooler assembly.

3.7.14.2 Disconnect and remove the engine oil coolers assembly and transport it to the shop.

3.7.14.3 Disassemble the oil cooler. Remove the cooler core.

3.7.14.4 Soak the core in a cleaning solution bath (Caterpillar Hydrosolv 4165 or Hydrosolv 100). After soaking, clean the core.

3.7.14.5 Hydrostatically test the core as directed by the technical representative to ensure that it does not leak.

3.7.14.6 Reassemble the oil cooler using new gaskets and seals.

19 (Rev-0)

3.7.14.7 Reinstall the cooler assembly on the engine. Use new gaskets and O-rings.

3.7.15 Turbochargers (CG TP 3537A, Disassembly and Reassembly Tab, pp 37-41)

3.7.15.1 No work shall be accomplish on the turbochargers since they were just replaced.

3.7.16 Exhaust Manifolds (CG TP 3537A, Disassembly and Reassembly Tab, pp 53-54)

NOTE

To remove the exhaust manifolds from the engine, it is necessary to remove the turbochargers and the air intake shutoff. The turbochargers and the air intake shutoff were removed previously in this specification item.

3.7.16.1 Remove the exhaust elbows and the exhaust manifolds.

3.7.16.2 Clean the exhaust manifold and visually inspect for indication of cracks or leaks. Store the exhaust manifolds in a location where they will not be damaged.

3.7.16.3 Upon completion of other engine work, reinstall the exhaust manifolds and exhaust elbows in place.

Use new seals and gaskets when reinstalling the exhaust manifolds. Coat the threads of all bolts with 5P-3931 anti-seize compound when reassembling the exhaust manifolds.

3.7.16.4 After completion of engine testing, which will be conducted later in this specification, re-tighten and re-torque all of the exhaust system bolts.

3.7.17 Aftercooler (CG TP 3537A, Disassembly and Reassembly Tab, pp 48-49)

3.7.17.1 Disconnect the aftercooler and transport it to the shop.

3.7.17.2 Disassemble the aftercooler. Remove the aftercooler core.

3.7.17.3 Soak the aftercooler core in a cleaning solution bath (Caterpillar Hydrosolv 4165 or Hydrosolv 100).

After soaking, clean the aftercooler core.

3.7.17.4 Hydrostatically test the core as directed by the technical representative to ensure that it does not leak.

3.7.17.5 Reassemble the aftercooler using new gaskets and seals.

3.7.17.6 After completion of other engine work, transport the aftercooler back to the ship and reinstall the aftercooler on the engine using new gaskets and seals. Install the aftercooler core upon completion of other engine work.

3.7.18 Vibration Damper (CG TP 3537A, Disassembly and Reassembly Tab, pp 154)

3.7.18.1 Remove the damper guard from the engine.

3.7.18.2 Remove the vibration damper from the engine.

3.7.18.3 Wipe off and inspect the vibration damper. Inspect the viscous type damper for signs of leakage or a dented (damaged) housing.

20 (Rev-0)

Inspect the damper for signs of damage and for indications of unexplained damage in the gear train as described on page 48 of the operation and maintenance manual.