ALEX HALEY

USCGC ALEX HALEY (WMEC 39)

SPECIFICATION FOR DOCKSIDE REPAIRS

JANUARY 2011

Developed By: CWO John Buckley

USCGC ALEX HALEY (WMEC-282) DOCKSIDE AVAILABILITY 2011

(Rev-0, 08 November 2010)

TABLE OF CONTENTS

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

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

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

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free 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 282-WMEC 100-3, Rev -, Shell Expansion Coast Guard Drawing 282-WMEC 101-1, Rev -, Fore End Framing Coast Guard Drawing 282-WMEC 103-1, Rev -, 1st & 2nd Platforms Coast Guard Drawing 282-WMEC 107-1, Rev -, Main Deck Coast Guard Drawing 282-WMEC 500-4, Rev -, Details of Reserve Feed Tanks & Feed & Drain Tank Coast Guard Drawing 282-WMEC 500-5, Rev -, Boiler Exhaust Uptake & Air Intake Arrangement Coast Guard Drawing 282-WMEC 500-8, Rev -, Ship's Steam & Boiler Feed Piping Arrangement Coast Guard Drawing 282-WMEC 545-14, Rev -, Diagram Ships Heating & Aux _Y Steam System Coast Guard Drawing 282-WMEC 845-3, Rev -, Booklet of General Plans

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual Coast Guard Technical Publication (TP) 4715, 0961-LP-035-4010 - Motor-Generator Power Supply Coast Guard Technical Publication (TP) 4803, 0951-LP-018-8010 - Auxiliary Boiler 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 3042 (SFLC Std Spec 3042), Jan 2009, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, And Installation Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), Jan 2009, Provide Temporary Services

OTHER REFERENCES

Contractors Environmental Guide, ISC Kodiak Complex (Copy to submitted to the Contractor by the KO upon contract award?)

General Specifications for Overhaul of Surface Ships (GSO) Naval Sea Systems Command (NAVSEA) 0951-LP-018-8010, Auxiliary Boiler Cyclotherm Nc-2500 - CGC ALEX HALEY Naval Ship's Technical Manual (NSTM) Chapter 221, Dec 2000, Boilers Naval Ship's Technical Manual (NSTM) Chapter 635, Jul 1998, Thermal, Fire and Acoustic Insulation The Society for Protective Coatings SSPC-SP 1, 11/1/2004; Solvent Cleaning The Society for Protective Coatings SSPC-SP 3, 11/1/2004; Power Tool Cleaning

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

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

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

***Government-furnished property, which is to be supplied by either the vessel or the C4IT ServiceCenter

Consolidated List of Critical Inspection Items The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000_STD, paragraph 3.2.6.5 (Inspection report particulars)):

Work Item Title

Principal Characteristics

PC_282_WMEC_0909

282' WMEC (39 CGC ALEX HALEY)

PHYSICAL CHARACTERISTICS

HULL CHARACTERISTICS

MACHINERY CHARACTERISTICS

TANK CAPACITIES

00000_0310_FLT

REC_0000_FLT_ Commercial Project @ ISC Kodiak, Alaska (1209) 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

Contractors Environmental Guide, ISC Kodiak Complex (Copy to submitted to the Contractor by the KO upon contract award?)

3. REQUIREMENTS

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

NOTE

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

3.2 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000.

3.2.1 The Contractor shall provide all fire watch personnel and equipment.

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 comply with the detailed instructions of the Contractors Environmental Guide, ISC Kodiak Complex. Submit the required Hazard Communications (HAZCOM) Plan to the COTR at the Arrival Conference.

3.5 Asbestos: The Contractor shall assume all removal work involves asbestos. Prior to commencing work, the Contractor shall obtain all required samples to determine the levels of asbestos present (if any) and the personnel protection required. Copies of the sample results shall be provided to the COTR prior to commencing work. In no case, will any asbestos be cut or otherwise treated without compliance with the Coast Guard Asbestos Exposure Control Manual (COMDTINST M6260.16). In addition to COMDTINST M6260.16, any asbestos abatement operations must comply with all federal, state and local laws and regulations including 40 CFR 61.150 and 29 CFR 1915.1001; National Emission Standards for Asbestos. Provide all notices to the EPA as required by 40 CFR 61.145 and other applicable state and local agencies prior to commencing asbestos removal work. Whenever this contract provides more than one standard for asbestos abatement, the Contractor must comply with the most restrictive law or regulation. Note that COMDTINST M6260.21 requires full compliance with OSHA Standards in 29 CFR 1910.1200. The Contractor shall provide forty-eight hours written notice to the Contracting Officer before commencing any asbestos work. Should there be any question as to the existence of asbestos in any material which may be disturbed, the Contractor is responsible for conducting hazard evaluations pursuant to OSHA requirements. The Contractor shall provide a CFR to the COTR with a description, location, and analysis results for all materials samples taken during personnel hazard evaluations before work commences in the affected area

4. NOTES

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

4.2 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 0000 to be completed and submitted during preservation of “critical-coated surfaces”, are provided at the end of this document.

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

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: _________

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)

| DP - Surface |

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

QA-3 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG)

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

(mils)

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: _________

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): ____________

(microsiemens/cm)

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

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

*BASE METAL READING (BMR)

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

Location (Frame Reference): ___________________

Overall Avg. DFT

ADJUSTMENTS

Avg.

Overall Avg. DFT

ADJUSTMENTS

Avg.

Overall Avg. DFT

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: _________

51700_JAH_0607_282

WORK ITEM 1: BOILER ANNUAL INSPECTION

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to conduct the initial annual inspection on the auxiliary boilers.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 282-WMEC 845-3, Rev -, Booklet of General Plans

COAST GUARD PUBLICATIONS

None.

OTHER REFERENCES

Naval Sea Systems Command (NAVSEA) 0951-LP-018-8010, Auxiliary Boiler Cyclotherm Nc-2500 - CGC ALEX HALEY Naval Ship's Technical Manual (NSTM) Chapter 221, Dec 2000, Boilers

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph(s): Not Applicable.

3.1.2 Technical Representative. The Contractor shall provide the services of qualified Tech Rep, who is familiar with the boilers, to accomplish the following tasks – on site:

· Conduct boiler internal inspections as described in paragraph 3.8.

· Conduct testing and adjustment of boiler automatic controls as described in paragraph 3.20.

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

3.2 Intent

3.2.1 The cutter is to be equipped with two (2) new Cyclotherm Model MC-2500 fire tube type auxiliary boilers. The intent of this item is to conduct the initial annual inspections on each of the boilers. The boilers are manufactured by Cylcotherm, Model NC-2500s.

3.3 General Guidance

3.3.1 Where valves are removed, install blank flanges with gaskets over the pipe openings, securing with at least four bolts, 90 degrees apart for valves with flanged connections. The blank flanges shall be at least 1/4" thick. For valves without flanged connections, install cap to pipe openings. Temporarily disconnect any remote operators and piping attached or connected to affected valves.

3.3.2 Hydrostatic Testing - Where required by later portions of this specification item, valve hydrostatic testing will be performed as described below.

3.3.2.1 Hydrostatic tests of the valve body/shell will be conducted with the valve in the open position to 150% of system operating pressure (but not less than 50 psig, otherwise see Table 505-11-1 of NSTM Chapter 505 for applicable pressures) for 3 minutes. Allowable leakage - none.

3.3.2.2 Hydrostatic tests for seat tightness will be conducted with the valve in the closed position (in the direction tending to open valve) with opposite side open for inspection. Test shall continue for three minutes, if there is no evidence of leakage or, in the event of visible leakage, until accurate determination of leakage can be made. Seat tightness test pressure shall be the normal operating pressure but not less than 50 psig, otherwise see Table 505-11-1 of NSTM Chapter 505 for applicable pressures. Maximum allowable leakage rate for metal to metal seated valve: 10 cubic centimeters (CC) per hour, per inch of nominal pipe size.

3.3.2.3 Valves which have been overhauled and which fail to pass the hydrostatic and tightness test leakage/tightness criteria shall be overhauled, again and tested at the Contractor's expense. Valves which fail the second test may be the subject of a contract change. Renewal valves which fail to pass the hydrostatic and tightness test leakage/tightness criteria shall be renewed with new valves and tested at the Contractor's expense.

3.4 Work Restrictions

3.4.1 No restrictions exist for auxiliary boiler work. Auxiliary boilers are not utilized while inport, as the Cutter utilizes electric heating and shore steam for galley services as backup for steam

3.5 Preparation For Boiler Inspection

3.5.1 Drain the boiler. Dispose of the boiler water in accordance with all related local, state, and federal regulations. It is anticipated that approximately 250 gallons of treated water will be drained from each boiler.

3.5.2 Disassemble the boiler to allow complete access to the boiler firesides and water sides. This will require removing the front and rear covers, the burner assembly, and any other appurtenances that interfere with these removals.

3.5.3 Wash the waterside interior of the boiler with clean, fresh water. Collect the wash water and properly dispose of it in accordance with all federal, state, and local regulations.

3.5.4 Remove lagging pads on the boiler nozzles, surface and bottom blow connections, boiler safety valve connections, and other off-stickers to allow for inspection. Reinstall the lagging pads after completion of inspections.

3.6 Boiler Fireside Cleaning

3.6.1.1 Not Applicable.

3.7 Burner Head Inspection

3.7.1 Not Applicable.

3.8 Boiler Inspection

3.8.1 Provide the service of a commercial boiler inspector certified by the National Board of Boiler and Pressure Vessels to perform a through inspection of each boiler, both internally and externally. Verify that the boilers are fit for service.

3.8.2 UT and PT Readings on Boiler Mounts

3.8.2.1 Not applicable.

3.9 Boiler Manual Valve Renewal

3.9.1 Not Applicable.

3.10 Feed System And Fuel Oil System Valve Renewal

3.10.1 Not Applicable.

3.11 Test Boiler Safety Valves

Each boiler is equipped with one (1) safety valve. The safety valves are manufactured by Kunkle Valve Co., size 1/2" x H x 2 1/2". The valves are cast steel and are set at 150 psig.

3.11.1 Disconnect and remove the steam safety valve from each boiler.

3.11.2 Bench Test Safety Valve

3.11.2.1 In the presence of Coast Guard Inspector, shop test and set the valve to the correct lifting pressure as specified in the referenced drawing. Using saturated steam as a test medium, simulate system temperature and pressure, and bring the test pressure to 10 psi below the relief or safety valve operating pressure. Slowly raise the test pressure to the set relief or safety pressure setting, and record the pressure where the valve provides relief or the safety valve lifts. Additional information about relief valve testing can be found in paragraph 505-9.18 of NSTM Chapter 505.

Note: During testing and relief valve setting, do not allow the test pressure to exceed the safety valve set point by more than 10 psi for longer than a few seconds.

3.11.2.2 Reset and retest the valve if the valve does not function properly. If Safety or Relief valves are found to require additional repairs or renewal, submit a CFR.

3.11.2.3 Provide the Coast Guard Inspector with Condition Found Report documenting the test pressure and relief pressure (lifting pressure) for the valve. Affix a metal tag (brass plate), using lock wire, to the valve showing the following information:

· Ship name and hull number.

· Valve number or identification.

· Valve lifting pressure.

· Valve operating pressure.

· Date valve tested and set.

· Name and location of repair facility (Contractor).

3.11.3 Reinstall the overhauled safety valve in its correct location aboard the ship along with any removed piping or interferences in the presence of the Coast Guard Inspector. Renew gaskets and seals in kind. Use new flange bolting to reinstall the relief valve.

3.11.3.1 Adjust the remote operating gear and demonstrate that it operates smoothly to the Coast Guard Inspector.

3.11.4 Verifying Safety Valve Set Point

Note: Perform this work after completion of other valve work involved in this specification item.

3.11.4.1 Remove lock wires and tags, slowly open isolation valves, and inspect the relief valve for leaks with the affected system at normal operating pressure and temperature. No leakage is allowed. Correct any deficiencies found and retest.

3.11.4.2 Test operate the relief valve by raising steam system pressure to verify that the relief valve operates properly. The Contractor is responsible for correcting any leaks discovered in the disturbed working areas. Pop test the boiler safety valves after the valves have been reinstalled on the boiler. Ensure that the valves lift at the proper set-point.

3.11.8 Submit a Condition Found Report.

3.12 Water Level Gage Glass

3.12.1 Not applicable.

3.13 Water Level Probe

3.13.1 Not applicable.

3.14 Calibration Of Pressure Gages

3.14.1 Remove the following pressure gages from each boiler. Transport the pressure gages to the shop. Calibrate each pressure gage. Affix a sticker to the inside of the face plate of each pressure gage showing the date the pressure gage was calibrated. Return the pressure gages to the ship and reinstall them in their original locations. A total of eight (8) pressure gages, four per boiler is involved. The pressure gages are listed below:

· Steam Pressure Gage

· Fuel Oil Supply Pressure Gage

· Feed Pressure Gage

· Fuel Oil Return Pressure Gage

3.15 Boiler Feed Pump And Motor

3.15.1 Not applicable.

3.16 Boiler Fuel Pump

3.16.1 Not applicable.

3.17 Acceptance Testing Criterea

3.17.1 Hydrostatic testing of the boilers will be conducted as described in NSTM Chapter 221. Lagging on the boiler casing will not be removed beyond what is directed by the specification item unless additionally directed by the boiler inspector. Any additional lagging removal will be subject of a contract modification.

3.17.1.1 Conduct hydrostatic testing as described in the boiler renewal item.

3.18 Hydrostatic Testing At 150% Of Design Pressure

3.18.1 Not applicable.

3.19 Boiler Reassembly

3.19.1 Flush the boilers with distilled/demineralized water.

3.19.2 Reassemble the boilers. Reinstall all components using new gaskets.

3.20 Final Hydrostatic Acceptance Testing

3.20.1 Boiler 100% Tightness Test

3.20.1.1 Fill each boiler with distilled/demineralized water.

3.20.1.2 Conduct a final hydrostatic test on each boiler at design operating pressure. Ensure that there are no leaks and that all gaskets are holding tight.

3.20.2 Inspect Automatic Control System

3.20.2.1 Provide a service technician to service, inspect, and adjust the boiler automatic control system on each boiler.

3.20.2.2 Vacuum clean the boiler control cabinet.

3.20.2.3 Adjust each of the automatic controls.

3.20.2.4 Demonstrate to the boiler inspector and to the COTR that each of the automatic controls functions properly.

3.20.2.5 For bidding purposes, assume that 2 days will be required to adjust and service the automatic controls on each boiler, for a total of 4 days service time.

3.20.3 Operational Test – Verify proper operation of the components or systems affected by this work. During this testing, run the equipment through its full range of capabilities in all configurations and operating modes.

3.20.3.1 Ship's force will operate each boiler for a minimum of 4 hours. Demonstrate the proper operation of equipment during that period.

3.21 Lagging Repairs

3.21.1 Restore lagging around the boiler mounts where it was removed. Pop rivet aluminum covers to the existing lagging aluminum cover to protect the new lagging.

3.22 Restoration

3.22.1 Prepare and paint all new and disturbed surfaces.

3.22.2 Restore all affected systems.

4. NOTES

This section is not applicable to this work item.

Snn-nnn_51700_JAH_0810_282_nnn

WORK ITEM 2: BOILER RENEWAL

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to remove the existing boilers and install new GFM boilers in the cutter.

1.2 Government-furnished property.

($/UNIT)

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 282-WMEC 101-1, Rev -, Fore End Framing Coast Guard Drawing 282-WMEC 100-3, Rev -, Shell Expansion Coast Guard Drawing 282-WMEC 103-1, Rev -, 1st & 2nd Platforms Coast Guard Drawing 282-WMEC 107-1, Rev -, Main Deck Coast Guard Drawing 282-WMEC 500-4, Rev -, Details of Reserve Feed Tanks & Feed & Drain Tank Coast Guard Drawing 282-WMEC 500-5, Rev -, Boiler Exhaust Uptake & Air Intake Arrangement Coast Guard Drawing 282-WMEC 500-8, Rev -, Ship's Steam & Boiler Feed Piping Arrangement Coast Guard Drawing 282-WMEC 545-14, Rev -, Diagram Ships Heating & Aux _Y Steam System Coast Guard Drawing 282-WMEC 845-3, Rev -, Booklet of General Plans

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Coast Guard Technical Publication (TP) 4715, 0961-LP-035-4010 - Motor-Generator Power Supply Coast Guard Technical Publication (TP) 4803, 0951-LP-018-8010 - Auxiliary Boiler 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 3042 (SFLC Std Spec 3042), Jan 2009, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, And Installation

OTHER REFERENCES

The Society for Protective Coatings SSPC-SP 1, 11/1/2004; Solvent Cleaning The Society for Protective Coatings SSPC-SP 3, 11/1/2004; Power Tool Cleaning General Specifications for Overhaul of Surface Ships (GSO) Naval Ship's Technical Manual (NSTM) Chapter 635, Jul 1998, Thermal, Fire and Acoustic Insulation

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. None.

3.1.2 Technical Representative. The Contractor shall provide the services of qualified Tech Rep, who is familiar with the boilers, to accomplish the following tasks – on site:

· Conduct boiler internal inspections.

· Conduct testing and adjustment of boiler automatic controls.

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

3.1.3 Protective measures.

3.1.3.1 The contractor will take all special protective measures required, including tarping and masking to ensure that paint chips and grit are not discharged into the water.

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.

· No. 1 and 2 Ship’s Service Air Compressors

· Boiler Exhaust Piping

· Bulkhead/Overhead Lagging

· Steam piping and lagging in the auxiliary machinery room upper level

· Wireway in Aux Machinery Room Upper Level

· AFFF piping in Aux Machinery Room Upper Level

· Ventilation ducting.

CAUTION!

Steam piping aboard the vessel is lagged with asbestos. All steam lagging removals must be dealt with as containing asbestos unless verified otherwise. Follow all federal regulations for dealing with removal of asbestos containing substances.

3.2 General Information and Preparation

The Coast Guard has determined that due to deterioration the boiler shells on both boilers require renewal. Due to the age of the boilers, the Coast Guard has determined to renew the entire boiler assembly rather than just the boiler shells.

The contractor may consult the drawings referenced above for location of each boiler. Information contained in CG Dwg 282 WMEC 845-3 is not accurate with regard to location of equipments. The motor generator sets have been relocated and ship’s service air compressors have been installed in this location.

Due to challenging weather conditions experienced in Kokiak harbor during winter months, the Coast Guard will not breast out the vessel and will tie up port side to the pier. There will not be sufficient access to allow the contractor to cut an access in the hull to install the new boilers. The contractor will be required to access the auxiliary machinery room from above by cutting access in the 01 Level, through the deck of the aft mess decks and through the deck of the auxiliary machinery room upper level.

It is anticipated that the contractor will remove the old boilers and install the new boilers by cutting an access in the deck above the boilers, cutting an access into the aft mess decks, cutting an access in the overhead of the mess decks to the weather forward of the cutter boat. These access cuts would require the contractor to temporarily remove one ship’s service air compressor, mess deck tables, misc. ventilation piping and three sections of steam piping in the auxiliary machinery room upper level.

CAUTION!

Steam piping aboard the vessel is lagged with asbestos. All steam lagging removals must be dealt with as containing asbestos unless verified otherwise. Follow all federal regulations for dealing with removal of asbestos containing substances.

3.2.1 Each boiler assembly has a dry weight of 6735 lbs. Verify with the Coast Guard that the Coast Guard pier can handle the weight of a crane with sufficient capacity to lift the boiler onto the cutter.

3.3 Hotwork – Conduct all hotwork in accordance with SFLC Std Spec 0740. All welds shall be continuous, 100% efficient welds. See AWS 3.5 for general guidance on hull welding.

3.4 Receipt of GFM and Inspection

The Coast Guard shall provide the contractor the new boiler assemblies listed as GFM in sufficient time to allow the contractor to inspect the boiler assemblies to ensure that they are received undamaged from shipment. The new boilers will be delivered to the Coast Guard’s Kodiak facility within five (5) days of the start of the contract. The contractor will open up packing cases to allow visual inspection of the boiler assemblies.

3.4.1 Open the packing casing on each boiler assembly and verify that there has been no significant damage to the boilers during shipment. Submit a condition found report documenting the condition of each boiler assembly.

3.4.2 As a part of the installation inspection of the new boilers, each boiler assembly will be disassembled and inspected as required to ensure proper operation. Boiler shells will be hydrostatically tested to verify that no tubes were damaged or loosened during shipment. The contractor may choose to disassemble the new boilers prior to installation on the vessel and reassemble the boilers after installation. Do not duplicate charges for disassembly and reassembly of the boilers.

3.5 Access Cuts

The contractor will be required to access the auxiliary machinery room from above by cutting access in the 01 Level, through the deck of the aft mess decks and through the deck of the auxiliary machinery room upper level. A total of three access cuts will be required.

3.5.1 Submit a copy of the proposed access route to the Coast Guard Inspector for review. Allow the Coast Guard Inspector 48 hours to review the proposed access route.

3.5.1.1 The contractor may use information provided in CG Dwg 282 WMEC 845-3, CG Dwg 282 WMEC 100-3, CG Dwg 282 WMEC 101-1, CG Dwg 282 WMEC 103-1, CG Dwg 282 WMEC 107-1 and in CG Tech Pub 4803 to assist in determining access routes.

3.5.2 Remove lagging and insulation around boundaries of proposed access cuts at least 12 inches away from affected areas.

3.5.3 In the presence of the Coast Guard Inspector, visually inspect the proposed access routes for the new boilers. Chalk mark all proposed accesses to be cut. Submit a condition found report showing the proposed accesses.

3.5.3.1 Where possible, cut all edges along existing seams. Corners shall intersect plating seams at 90 degree angles. Corners that are not formed by designed plating seams shall have a minimum radius of, three inches, or one-eighth of the transverse dimension of the cut, whichever is greater.

3.5.4 Crop required access openings for removal of old boilers and installation of new boiler assemblies. Set the plating removed for the access cuts aside for later reinstallation.

3.5.5 Cover any access openings when not in use to avoid allowing weather into the cutter. Install guards around all openings when not in use.

3.5.6 After the old boilers have been removed and the new boilers have been installed in the vessel, return the access cuts and reinstall in their original locations.

3.5.6 Access Cut Inspections - Upon completion of reinstallation of the deck and hull accesses, conduct the following inspections:

3.5.6.1 In the presence of the Coast Guard Inspector, visually inspect and perform an ultrasonic or dye penetrant test on 100% all new welds in accordance with AWS D1.1. Test acceptance standards shall be in accordance with AWS D1.1. Repair all weld deficiencies and retest.

3.5.6.2 Upon completion of all welding, perform a liquid film bubble emission test on all water tight boundaries (hull plating welds) in accordance with the General Requirements.

3.5.7 Provide a CFR for all nondestructive test findings to the Coast Guard Inspector.

3.5.8 Preservation Repair on Access Cuts – Upon completion of successful nondestructive testing, prepare all new and disturbed areas in accordance with SSPC-SP 11. Feather the surrounding surfaces to obtain a 3-inch wide smoothly tapered boundary from the existing paint to the prepared surface.

3.5.8.1 Prior to applying any paint, remove all dust, grease, oil, or other contaminants from all prepared areas in accordance with applicable local, state, and federal laws and regulations.

3.5.8.2 The Coast Guard Inspector will verify all surface preparation.

3.5.8.3 Upon verification from the Coast Guard Inspector on all surface preparation, prime and coat all prepared surfaces to match existing adjacent surfaces in accordance with the applicable sections of COMDTINST M10360. For surfaces to be covered with insulation, apply primer coats only.

3.5.9 Install new insulation in place of the previously removed insulation in accordance with NSTM Chapter 635.

3.5.9.1 Coat newly installed insulation in accordance with COMDTINST M10360.3.

3.6 Steam Piping in Auxiliary Machinery Room Upper Level

3.6.1 Remove lagging on three (3) twenty foot long sections of steam piping in the auxiliary machinery room upper level. Lagging contains asbestos. Follow all federal regulations for dealing with removal of asbestos containing substances. Properly encapsulate insulation ends where lagging removal was not required. Steam piping is shown in CG Dwg 282 WMEC 500-8 and CG Dwg 282 WMEC 545-14.

3.6.2 Crop and remove three (3) sections of steam piping in the auxiliary machinery room upper level to allow installation of new boilers.

3.6.3 Provide and install new flange connections where steam line was removed to allow use of jumper lines to restore steam services while boilers are removed.

3.6.3 Provide and install flexible jumper lines between new steam flange connections. Restore steam services as quickly as possible to maintain steam service to vessel. Hydrostatic testing of flexible hose and new flange fitting will not be required. Operation test only is required. Use existing system steam and steam pressure. Verify no leakage. Test operate jumper connections to verify that they do not leak

3.6.4 Upon completion of new boiler installation, install new steam piping in way of the removed steam piping. New steam piping will be carbon steel piping or cu-ni tubing as shown in CG Dwg 282 WMEC 545-14 to match existing system.

3.6.4.1 Hydrostatically test new steam piping as described in CG Dwg 282 WMEC 545-14. Verify no leakage.

3.6.4.2 After completion of successful hydrostatic test, provide and install new insulation and lagging on new steam piping. New lagging to conform with guidance in NSTM Chapter 635. New insulation and lagging will not be asbestos. Color code new insulation to show that it does not contain asbestos.

3.7 No. 1 and No. 2 Air Compressor

The air compressors described in CG Tech Pub SWBS 3914_551.

3.7.1 In the presence of the Coast Guard Inspector, test operate the No. 1 and No. 2 ship’s service air compressors and verify that it is operating properly.

3.7.2 Electrically disconnect the No. 1 and No. 2 ship’s service air compressors in accordance with SFLC Std Spec 3042.

3.7.3 Take and record electrical megger readings on the No. 1 and No. 2 ship’s service air compressors. Submit a condition found report to the Coast Guard Inspector showing the megger readings.

3.7.4 Mechanically disconnect the No. 1 and No. 2 ship’s service air compressors from the foundation and set it aside to allow for installation of the new boilers.

3.7.5 Preservation. - After installation of the new boilers, power tool clean the foundations and areas under the No. 1 and No. 2 ship’s service air compressors to a tight paint film in accordance with SSPC SP-3. Feather the surrounding surfaces to obtain a 3-inch wide smoothly tapered boundary from the existing paint to the prepared surface. Solvent wipe the foundations and the area under the motor generator set in accordance with SSPC SP-1. Paint the prepared areas with two coats of epoxy paint to match the existing in accordance with COMDTINST M10360.3.

3.7.6 After completion of preservation, reinstall the No. 1 and No. 2 ship’s service air compressors. Electrically and mechanically reconnect the motor generator set in accordance with SFLC Std Spec 3042.

3.7.7 Take and record electrical megger readings on the No. 1 and No. 2 ship’s service air compressors. Submit a condition found report to the Coast Guard Inspector showing the megger readings. Verify that the motor generator set is ready for operation.

3.7.8 Demonstrate proper operation of the No. 1 and No. 2 ship’s service air compressors to the Coast Guard Inspector.

3.8 AFFF Piping

3.8.1 Crop and remove AFFF piping in way of new boiler installation.

NOTE: Ensure AFFF system is available for use upon removal of existing piping.

3.8.2 Provide and install new AFFF piping upon completion of boiler repairs.

3.9 Ventilation Ducting - Remove ventilation ducting in way of boiler renewal. Restore ventilation ducting upon completion of boiler repairs.

3.10 Boiler Disassembly, Removals And Installations

Information about the boilers and boiler assembly is contained in the enclosure at the end of this document.

3.10.1 Disassemble the existing boilers as required to allow removal of the existing boilers through the contractor’s access cuts. The Coast Guard believes that the contractor may wish to remove relief valves, burner/blower housings, sight glasses, control panels and miscellaneous piping from each boiler. The Coast Guard believes that the contractor may be required to disconnect the boiler shell from the skid assembly to remove the existing boilers.

3.10.2 Insulation and Lagging Blankets - Remove and store insulation and lagging blankets on boiler exhaust piping and steam, blow down, and feed piping in way of boiler removals. Reinstall insulation and lagging blankets upon completion of new boiler installation. Follow guidance in NSTM Chapter 635.

3.10.3 Boiler Exhaust Piping - Disconnect and remove boiler exhaust piping on both boilers which is an interference in way of removal of the boilers. Store the piping in a secure location which will not interfere with existing work. Upon completion of boiler work, reinstall the exhaust piping. Use new gaskets and fasteners at each connection location. Information on boiler exhaust systems is contained in CG Dwg 282 WMEC 500-5.

3.10.3.1 Each boiler exhaust pipe is equipped with a periscope assembly and stack temperature monitor. Disconnect and remove the periscope assembly and stack temperature gages on the boiler exhaust piping on each boiler. Store them in a protected location. Reinstall the periscope assemblies and stack temperature monitors after new boilers have been installed. Demonstrate to the Coast Guard Inspector that the periscopes and the stack temperature monitors work after reinstallation.

3.10.4 Steam Piping - Disconnect the steam discharge valve and miscellaneous steam piping on the discharge of each boiler which is an interference in way of removal of the boilers. Store the piping and steam discharge valves in a secure location which will not interfere with existing work. Upon completion of boiler work, reinstall the steam piping and steam discharge valve on each boiler. Use new gaskets and fasteners at each connection location. Information on boiler steam system is contained in CG Dwg 282 WMEC 500-8, and CG Dwg 282 545-14.

CAUTION!

Steam piping aboard the vessel is lagged with asbestos. All steam lagging removals must be dealt with as containing asbestos unless verified otherwise. Follow all federal regulations for dealing with removal of asbestos containing substances.

3.10.4.1 Remove all of the insulation and lagging on any steam piping which was removed.

3.10.4.2 Provide and install new insulation and lagging on the steam piping. New lagging to conform with guidance in NSTM Chapter 635. New insulation and lagging will not be asbestos. Color code the new insulation to show that it does not contain asbestos.

3.8.5 Feed Piping - Disconnect the feed supply valve and miscellaneous feed piping on the discharge of each boiler which is an interference in way of removal of the boilers. Store the piping and feed supply valves in a secure location which will not interfere with existing work. Upon completion of boiler work, reinstall the feed piping and feed supply valve on each boiler. Use new gaskets and fasteners at each connection location. Information on boiler feed system is contained in CG Dwg 282 WMEC 500-8, and CG Dwg 282 545-27.

3.8.6 Boiler Blow Down Piping - Disconnect the boiler blow down piping and blow down valves on each boiler. Store the piping and valves in a secure location which will not interfere with existing work. Upon completion of boiler work, reinstall the piping and blow down valves on each boiler. Use new gaskets and fasteners at each connection location. Information on boiler blow down system is contained in CG Dwg 282 WMEC 500-8, and CG Dwg 282 545-27.

3.8.7 Boiler Fuel Piping - Drain the fuel piping connections to each boiler. Catch any fuel drained from the piping. Disconnect the fuel piping on each boiler. Upon completion of boiler work, reinstall the fuel piping on each boiler. Use new gaskets and fasteners at each connection location.

3.8.8 Boiler Automatic Controls - Electrically disconnect the automatic control panel on each boiler. Follow guidance in SFLC Standard Spec 3042. Upon completion of new boiler installation, electrically connect the new controls package on each boiler. Follow guidance in SFLC Standard Spec 3042.

3.8.9 Ripout - Remove the existing No.1 and No. 2 boilers through determined route and access as described previously. Boiler weight: dry 6735 lbs, wet 8735 lbs.

3.8.10 Install temporary caps or other suitable plugs on open piping upon removal to protect the system from contamination if installation is not immediately done.

3.8.11 Remove any additional attachment pipes and gages, and all necessary equipment from the boiler. Use the old boiler as a template, remove to the dockside to verify the rout and access plan. The attachments include: piping connections, combustion controls, water level controls and alarms, feed connections, steam connections, exhaust gas connections, chemical sampling connections, blow down connections, burner assembly, blower assembly, gage glass assembly, and any other attachments to the main boiler shell.

3.8.12 Installation - Install the new No. 1 and No. 2 boilers in accordance with CG Tech Pub 4803.

3.8.12.1 The Contractor shall supply all material (except the Government-furnished material) to accomplish the replacement of the boiler.

3.8.12.2 The new boilers being supplied as GFM include new boiler safety valves, new boiler control packages, new burner/blower assemblies, and new sight glass assemblies.