DALLAS

USCGC DALLAS (WHEC 716)

SPECIFICATION FOR NR2 MDE DOCKSIDE REPAIRS

Developed By: LTJG Jennifer Rest

USCGC DALLAS (WHEC-378E) DOCKSIDE AVAILABILITY 2011

(Rev-1, 27 December 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

378-FRAM-W 264-2, Rev D; Diagram Lube Oil Transfer & Purifying 378-FRAM-W 264-3, Rev G; Lube Oil Transfer and Purifying Piping a & D Add the lube oil arrangement drawing, and the foundation drawings for the filters – which are one sheet of a many page foundation drawing.

Coast Guard Drawing 378-FRAM-E 111-3, Rev -, Shell Expansion Aft Coast Guard Drawing 378-FRAM-E 117-5, Rev -, Web Frs 213, 218, 1/4, etc Coast Guard Drawing 378-FRAM-E 117-6, Rev -, Web Frs 234, 241, 248, ½ Coast Guard Drawing 378-FRAM-E 117-8, Rev -, Midship Sections Coast Guard Drawing 378-FRAM-E 635-3, Rev -, Det of Insulation Coast Guard Drawing 378-FRAM-E 85-1, Rev -, Booklet of General Plans Coast Guard Drawing 378-FRAM-W 182-2, Rev -, Main Propulsion Fdns Plan & Elevations Coast Guard Drawing 378-FRAM-W 182-5, Rev -, Blts, Chcks Prpln Dsl, Gas Turb & Red Gr Arr & L/M Coast Guard Drawing 378-FRAM-W 259-12, Rev -, Main Propulsion Gas Turbine Exhaust Coast Guard Drawing 378-FRAM-W 259-14, Rev -, Mn Prpl Dsl Eng & Dsl Gen Exh & Blr Flue Dets Coast Guard Drawing 378-FRAM-W 259-16, Rev -, Port & Stbd Prpln Dsl Eng Air Intk & Blr Flue Coast Guard Drawing 378-FRAM-W 259-2, Rev -, Gas Turb Emerg Gen Exh Sys a&D Coast Guard Drawing 378-FRAM-W 259-4, Rev -, Mn Prpln Dsl Eng & Dsl Gen Exh & Blr Flue Arr Coast Guard Drawing 378-FRAM-W 262-2, Rev C, Diag LO Serv Sys Mn Prpln Eng, Dsl Gen & Red Gr Coast Guard Drawing 378-FRAM-W 262-4, Rev -, LO Serv Pip Prpln Dsl Eng, Dsl Gen & Red Gear a&D Coast Guard Drawing 378-FRAM-W 801-1, 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 Commandant Instruction (COMDTINST) M10360.3, Jun 2006, Coatings and Colors Manual Coast Guard Technical Publication (TP) 3254A, Manufacturer's Instruction Book, SWBS Group(s) 233 Coast Guard Technical Publication (TP) 3254B, Manufacturer's Instruction Book, SWBS Group(s) 233 Coast Guard Technical Publication (TP) 3254B, Manufacturer's Instruction Book, SWBS Group(s) 233 Coast Guard Technical Publication (TP) 3257, Manufacturers Instruction Book, SWBS Group(s) 241-242 Coast Guard Technical Publication (TP) 3256B, Manufacturer's Instruction Book, SWBS Group(s) 241 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0000, Jan 2009, General Requirements 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

American Welding Society (AWS) D1.1, 2008, Structural Welding Code - Steel American Welding Society (AWS) D3.5, 1993, Guide for Steel Hull Welding 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-STD-2035, May 1995, Nondestructive Testing Acceptance Criteria Naval Sea Systems Command (NAVSEA) T9074-AS-GIB-010/271, Apr 1997, Requirements for Nondestructive Testing Methods Naval Ship's Technical Manual (NSTM) Chapter 233, Oct 2005, Diesel Engines Naval Ship's Technical Manual (NSTM) Chapter 254, May 2006, Condensers, Heat Exchangers and Air Ejectors Naval Ship's Technical Manual (NSTM) Chapter 635, Jul 1998, Thermal, Fire and Acoustic Insulation S9233-DM-HBK-010-002 Flush LSD-41/49 Class Fairbanks Morse 38ND 8-1/8 Diesel Generator Engine Lubricating Oil System and Engine The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 3), 2004, Power Tool Cleaning 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.

($/UNIT)

6 ea.

1 ea.

*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

PC_378E_WHEC_716_1109

Principal Characteristics

378E WHEC (DALLAS)

PHYSICAL CHARACTERISTICS

HULL CHARACTERISTICS

Material

MACHINERY CHARACTERISTICS

One 500KW-AC Type, 450V, 60 Hz, 3 Phase, Solar Model 101506-2001 gas turbine driven emergency service generator

Two 25 KVA (PF = 0.8), 120V, 400 Hz, 3 Phase Electronic Specialty motor generators

Two 10 KVA (PF = 0.8), 120V, 400 Hz, 3 Phase Electronic Specialty motor generators

TANK CAPACITIES

00000_0310_FLT

REC_0000_FLT_ Commercial Project @ CG Facility (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

Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation

3. REQUIREMENTS

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

NOTE

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

3.2 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.

· 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.

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: _________

86350_LNM_1009_FLT

WORK ITEM 1: Temporary services, provide

1. SCOPE

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

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

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

OTHER REFERENCES

None.

3. REQUIREMENTS

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

TABLE I - SERVICE SELECTION

-Contractor shall provide crane services for ship’s force Monday thru Friday, 0800-1600, to be arranged the week before by the cutter.

Y/N

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

TABLE 2 - HARZADOUS WASTE DISPOSAL

(lbs) Empty Containers (previously housed hazardous materials)

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

4. NOTES

This section is not applicable to this work item.

Snn-nnn_23300_JAH_1010_378E_716

WORK ITEM 2: No. 2 Main Diesel Engine Block Renewal

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to remove the port main diesel engine block and to install a new engine block.

1.2 Government-furnished property.

($/UNIT)

6 ea.

*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 Service Center.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 378-FRAM-E 85-1, Rev -, Booklet of General Plans Coast Guard Drawing 378-FRAM-E 111-3, Rev -, Shell Expansion Aft Coast Guard Drawing 378-FRAM-E 117-5, Rev -, Web Frs 213, 218, 1/4, etc Coast Guard Drawing 378-FRAM-E 117-6, Rev -, Web Frs 234, 241, 248, ½ Coast Guard Drawing 378-FRAM-E 117-8, Rev -, Midship Sections Coast Guard Drawing 378-FRAM-E 635-3, Rev -, Det of Insulation Coast Guard Drawing 378-FRAM-W 182-2, Rev -, Main Propulsion Fdns Plan & Elevations Coast Guard Drawing 378-FRAM-W 182-5, Rev -, Blts, Chcks Prpln Dsl, Gas Turb & Red Gr Arr & L/M Coast Guard Drawing 378-FRAM-W 259-2, Rev -, Gas Turb Emerg Gen Exh Sys a&D Coast Guard Drawing 378-FRAM-W 259-4, Rev -, Mn Prpln Dsl Eng & Dsl Gen Exh & Blr Flue Arr Coast Guard Drawing 378-FRAM-W 259-12, Rev -, Main Propulsion Gas Turbine Exhaust Coast Guard Drawing 378-FRAM-W 259-14, Rev -, Mn Prpl Dsl Eng & Dsl Gen Exh & Blr Flue Dets Coast Guard Drawing 378-FRAM-W 259-16, Rev -, Port & Stbd Prpln Dsl Eng Air Intk & Blr Flue

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), 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 Coast Guard Technical Publication (TP) 3254A, Manufacturer's Instruction Book, SWBS Group(s) 233 Coast Guard Technical Publication (TP) 3254B, Manufacturer's Instruction Book, SWBS Group(s) 233 Coast Guard Technical Publication (TP) 3256B, Manufacturer's Instruction Book, SWBS Group(s) 241

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 American Welding Society (AWS) D1.1, 2008, Structural Welding Code - Steel American Welding Society (AWS) D3.5, 1993, Guide for Steel Hull Welding Naval Ship's Technical Manual (NSTM) Chapter 635, Jul 1998, Thermal, Fire and Acoustic Insulation Naval Sea Systems Command (NAVSEA) T9074-AS-GIB-010/271, Apr 1997, Requirements for Nondestructive Testing Methods MIL-STD-2035, May 1995, Nondestructive Testing Acceptance Criteria

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. None.

3.1.2 Tech Reps.

3.1.2.1 The Contractor shall provide the services of qualified Tech Rep, who is familiar with the alignment of major equipment to accomplish the following tasks – on site and if the resources are already available:

· Provide technical guidance in alignment of the new engine foundation to the reduction gear.

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

3.1.2.3 The Coast Guard will provide the services of a qualified Fairbanks-Morse Tech Rep to oversee engine work performed by the contractor and by Coast Guard personnel.

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 contamination does not enter the engine block or reduction gears.

3.1.4 Interferences.

3.1.4.1 Interferences are described in the following paragraphs. Handle all interferences in accordance with SFLC Standard Specification 0000.

3.2 Background Data and Work Requirements

The cutter has suffered major damage to the No. 2 Main Diesel Engine (MDE) block. It has been determined by the Coast Guard to be more cost effective to renew the entire engine block than to attempt to repair the existing engine block in place. The contractor will be required to receive the new engine block, cut an access hole and remove the old engine block from the vessel, repair the existing foundations, install and align the new engine block, chock fast the new engine block to the foundation, and repair the access hole.

The cutter will be positioned port side to the pier and will be held off the pier by a barge, provided by the contractor, to allow the contractor sufficient room to work. The contractor must provide crane services of a crane able to reach over the barge to install the new engine block.

The contractor will crop an access hole in the hull, rig the old engine block out and rig a new GFM engine block into place. After rigging in the new engine block, the contractor will mount the new engine block to the existing foundation, then align the engine to the reduction gear and install new chockfast. The contractor will be required to weld up and machine all of the existing foundation bolt holes and drill and ream new mounting holes. Use of overhead padeyes will be required.

The access cut must be made a minimum of 4 ft. above the existing water line.

The Coast Guard believes that the contractor may benefit from installing a trolley system in the engine room to assist in removal of the engine block. This is a contractor decision and is not required. See the photograph attached to the end of this specification.

Ship’s Force will drain the jacket water, and raw water from the engine. Ship’s Force will completely disassemble the engine to the bare block prior to block removal except to require contractor assist for removal of the lower crankshaft, upper crankshaft and oil pan and transporting the crankshafts off the vessel.

Ship’s Force has already removed the Diesel Engine Quill shaft from the reduction gear to allow for laser alignment of the diesel engine to the reduction gear. The contractor will also be responsible for removing interferences in way of lifting the engine, lifting the block, removing the old engine block from the vessel, rigging the new block onto the vessel and aligning the engine to the reduction gear.

Final Alignment of the engine to the reduction gear will take place only after ship’s force has completed reassembly of the engine.

Several FRAM WEST drawings are used in the specification item because FRAM EAST drawings are not available or not applicable for the work being performed.

3.3 Availability Location And Duration

3.3.1 The work in this specification item will be performed at the Coast Guard cutter’s assigned pier at the Federal Law Enforcement Training Center, North Charleston, South Carolina. The contractor is responsible for all security and logistics requirements normally associated with working at this location.

3.3.2 The performance period will be as specified in the contract. Because maintaining the performance schedule will require joint cooperation between ship’s force and the contractor, performance delays by either party may delay overall contract completion. Any delays in the contract caused by ship’s force resulting in contract extension will not automatically be grounds for compensation to the contractor. To receive compensation for a contract extension, the contractor must demonstrate that the extension required the performance of additional work above and beyond what is already required under the specification or resulted in additional mobilization cost (i.e. additional days on the job site, or additional trips required). Inconvenience caused to the contractor that does not result in the performance of work not otherwise required will not be considered justification for payment.

NOTE:

The above paragraph should not be construed to limit the government’s ability to collect financial recompense from the contractor, in accordance with applicable laws, for delays in contract completion caused by untimely performance of contracted work, poor work quality, or any other delay caused by the contractor.

3.3.3 The contractor’s work in this specification item will be broken up into various sections to allow ship’s force to perform engine disassembly, inspections, and reassembly. The contractor can anticipate that his work will be broken up in the following manner:

a. Locate and crop an access cut in the engine room port side shell to allow removal of the No. 2 Main Engine Block.

b. Rig and remove interferences in Engine room and along the port shell to allow removal of the port main engine block. Install and test padeyes in the overhead to allow lifting and removing of the engine block. Lifting points and padeye testing are specified in section 3.8.

c. Lift the No. 2 Main Diesel Engine. Rig the engine block out of the engine room and off the vessel. The contractor will also be required to rig the engine upper and lower cranks out the engine room to the shop for inspection and certification.

d. Weld up old mounting holes in the engine foundation.

e. Provide and install the new GFM engine block in the engine room. Support the block to allow installation of the lower crankshaft.

f. Break to allow ship’s force to make engine repairs and allow certification of the upper and lower crankshafts.

g. Restore Lower Crankshaft oil pan, lower the new engine block and return upper crankshaft to the vessel.

h. Break to allow ship’s force to reassemble engine. The Coast Guard supplied Technical Representative will be required to oversee Ship’s Force engine disassembly, repair, and reassembly.

i. Realign main engine. Drill new mounting holes for engine foundations. Ream and install eight (8) new fitted bolts on engine foundation. Provide and install all new foundation bolts. Conduct alignment checks only after reassembly of engine components on the engine.

j. Reassemble interferences.

k. Clean up contractor waste in engine room.

3.4 Engine Room Cleaning

3.4.1 Clean the engine room and engine room bilges around the affected Diesel Engine and Reduction Gear in way of all hot work required by the work in this specification item. Remove all oil, grease and flammables from the hot work areas. Ventilate the designated areas to obtain gas free certification.

3.4.2 Gas free and certify the designated compartments/tanks in accordance with the General Requirements. The designated compartments/tanks must be certified as “Safe for Personnel – Safe for Hotwork” for the duration of work performed on this item.

3.4.3 Gas Free Certificates indicating the current status of each compartment/tank shall be posted on the Quarterdeck and at each open access to the compartments/tanks. Provide one copy to the Coast Guard Inspector.

3.4.4 Conduct all welding in accordance with SFLC Standard Spec 0740.

3.5 Access Cut

The contractor will be required to remove the engine block through an access cut in the port side engine room bulkhead. The access cut must be a minimum of 4 ft. above the water line of the vessel.

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 378 FRAM E 85-1, CG Dwg 378 FRAM E 111-3, CG Dwg 378 FRAM E 117-5, CG Dwg 378 FRAM E 117-6, and CG Dwg 378 FRAM E 117-8 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 engine block. 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 opening for removal of the old engine block and installation of new engine block. Set the plating removed for the access cut 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 engine block has been removed and the new engine block has been installed in the vessel, return the access cuts and reinstall in their original locations. Follow guidance in SFLC Standard Spec 0740 and AWS D3.5.

3.5.7 Access Cut Inspections - Upon completion of reinstallation of the access, conduct the following inspections:

3.5.7.1 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.

3.5.7.2 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.

3.5.8 Provide a written report of all nondestructive test findings to the Coast Guard Inspector.

3.5.9 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.

3.5.9.1 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.

3.5.9.2 The Coast Guard Inspector will verify all surface preparation.

3.5.9.3 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.

3.5.10 Install new insulation in place of the previously removed insulation in accordance with CG Dwg 378 FRAM E 635-3 and NSTM Chapter 635.

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

3.6 Interferences

3.6.1 The Contractor shall remove, modify, or protect all interferences to the work. All interferences that are removed shall be tagged to facilitate proper reinstallation. Ensure that all removed equipment is kept in a clean, dry, protected location. Obtain verification from the Coast Guard Inspector for the protective measures taken for equipment not removed. Any interference removed or protected during the course of this work shall be reinstalled and returned to its original condition in accordance with the General Requirements. All items, except structural members, shall be tested jointly by the Contractor and CG Inspector before removal and after reinstallation In the presence of the Coast Guard Inspector, inspect and test all equipment and systems that will be disturbed during the performance of this work to document their original condition. Submit a Condition Found Report for all such equipment and systems noting any existing (pre-work) discrepancies in their operation.

3.6.2 Specific Interferences to Be Removed

The interferences listed below are most of the major interferences that must be removed by the contractor. The list is not intended to be totally inclusive and the contractor is responsible as noted in the paragraph above to remove any additional interferences in way of the work being performed.

3.6.2.1 Miscellaneous Deck Plates and Framing

3.6.2.1.1 Disconnect and remove deck plating and framing located on the deck above the No. 2 Main Diesel Engine. The deck plating framing is bolted in place above the engine. Match mark all pieces to aid in reassembly and transport the pieces to a locations off the cutter.

3.6.2.1.2 After completion of engine block realignment, reinstall the deck plating and framing in its original locations.

3.6.2.2 Exhaust Piping Located in the Overhead Above the No. 2 Main Diesel Engine

3.6.2.2.1 Disconnect and remove NR2 engine and NR2 boiler exhaust piping located above the engine. Reinstall the exhaust ducting using new gaskets and fasteners upon completion of work.

3.6.2.3 No. 2 Main Diesel Engine Upper and Lower Crankshafts

3.6.2.3.1 Crankshafts will be addressed separately in this specification item.

3.6.2.4 Main Diesel Engine Quill Shaft Rotating Equipment Guard, and Coupling Guard

3.6.2.4.1 Ship’s force has already remove the rotating equipment guards. Rig the guards off the cutter to a safe storage locations.

3.6.2.4.2 After completion of engine block realignment and engine repairs, return the engine guards to the lower level of the engine room of the cutter and reinstall the guards.

3.6.2.5 Main Gas Turbine Exhaust Ducting

The Coast Guard believes it will be required to crop and remove a section of the exhaust piping in the port main gas turbine exhaust in order to remove the No. 2 MDE engine block and to install the new block.

3.6.2.5.1 Remove the inspection port cover on the side of the turbine exhaust ducting. Enter the ducting and cover the turbine exhaust discharge to prevent contamination from entering the port main gas turbine. After the covering is in place, inspect the covering in the presence of the Coast Guard Inspector and verify that there will be no entry of contamination into the main gas turbine.

3.6.2.5.2 Disconnect and remove exhaust lagging blankets around the port Main Gas Turbine exhaust. Store the exhaust blankets for later reinstallation.

3.6.2.5.3 Using CG Dwg 378 FRAM W 259-2 for guidance, determine the location to make cuts to allow removal of the main gas turbine exhaust. Mark the location of the proposed cuts.

3.6.2.5.4 Crop the port main gas turbine exhaust at the determined locations. Remove the sections of exhaust pipe from the vessel to allow removal of the old engine block and installation of the new engine block.

3.6.2.5.5 After installation of the new engine block, return the removed section of exhaust piping back into the vessel and reinstall in its original location.

NOTE:

Turbine exhaust piping is CORTEN material. Ensure that the contractor uses proper welding and heat treating procedures to weld this material without causing cracking.

3.6.2.5.6 Conduct magnetic particle or dye penetrant inspections on 100% of new welds and verify that there is no cracking of the material.

3.6.2.6 After completion of engine work and after the turbine exhaust ducting has been restored, remove the covering. Conduct a final inspection of the interior of the main gas turbine exhaust in the presence of the Coast Guard inspector. Reinstall the inspection port cover on the turbine exhaust.

3.6.2.7 After completion of engine work, reinstall the previously removed lagging blankets. Verify final installation with the Coast Guard Inspector.

3.7 Lifting Points

Lifting points or padeyes will be needed to lift the engine block and to maneuver the old engine block out of the vessel and maneuver the new engine block into the vessel.

3.7.1 The contractor shall install and test new lifting points and padeyes prior to lifting and removing the engine block. The quantity and the size of the lifting points or padeyes that are needed beyond those existing shall be based on information gathered during a shipcheck of the Cutter and shall be furnished by the contractor with his bid.

3.7.1.1 Calculate the engine block weight, including the lower crankshaft and lower crankcase compartment (oil pan).

3.7.1.2 Demonstrate to the Coast Guard Inspector and the Technical Representative that there are sufficient padeyes for lifting the engine block as described above.

3.7.1.3 Padeyes shall be sized in accordance with the diameter of the stock directly above the hole or eye of the padeye.

3.7.1.4 Testing: All padeyes installed by the Contractor shall be tested with the test force applied in the same direction as the working load is normally applied as verified by the Coast Guard Inspector.

3.7.1.5 The following proof loads will be used in testing all padeyes installed by the contractor.

3.7.1.6 A dynamometer shall be installed in the test lead immediately adjacent to the padeye to record the actual test load being applied. Provide a copy of the dynamometer calibration certificate to the Coast Guard Inspector.

3.7.1.7 The test proof loads listed in Table 1 are static loads. Dynamic loading will not be used in this test procedure.

3.7.1.8 Conduct dye penetrant weld inspection on all new welds. Dye penetrant weld inspections shall be in accordance with NAVSEA T9074-AS-GIB-010/271. Test acceptance standards shall be in accordance with MIL-STD-2035. Repair all weld deficiencies and retest until correct.

3.7.1.9 After inspection and testing, prime and paint all new padeyes with one coat of epoxy paint. Repair any disturbed insulation and touch up paint in accordance with COMDTINST M10360.3 to match surrounding area. Affix a label plate, inscribed with the test load and date tested adjacent to each padeye. All padeyes installed by the contractor shall remain in place at the end of the contract unless removal is required to facilitate reinstallation of equipment.

3.8 Technical Representative

3.8.1 The government is providing the services of a Fairbanks-Morse Technical Representative to oversee Coast Guard repair work on the Main Diesel Engine.

3.8.2 The contractor will be required to provide technical representatives to oversee alignment of the engine, if resources are already available to the contractor. Otherwise, the Coast Guard will provide services for engine alignment oversight.

3.9 General Information Concerning Main Engine Mounting And Alignment

3.9.1 The engine is held in place using chock fast and fitted bolts as described in CG Dwg 378 FRAM W 182-2 and CG Dwg 378 FRAM W 182-5.

3.9.2 Ship’s force will dismantle the engine as far as practical prior to the contractor’s arrival.

3.10 Main Engine Repairs

CAUTION!

Take extreme precautions during the work listed below to ensure that no contaminants are allowed to enter the reduction gear housing .

3.10.1 Perform the following work using information from the Main Diesel Engine technical manual.

3.10.1.1 Disconnect the supply and exhaust ducting from the two (2) engine turbochargers. Cover all openings to ensure that no contamination enters the engine through the supply and exhaust ducts.

3.10.2 Support any reduction gear quill shaft disassembly.

3.10.3 Using laser or optical alignment equipment measure and record the initial alignment of the reduction gear to the main engine. Take alignment readings in the presence of the Reduction Gear Technical Representative and the Coast Guard Inspector. Provide a CFR to the Coast Guard Inspector.

NOTE:

Engine alignment is to be checked between the hours of 2400 and 0600 to ensure that the foundations have not been affected by temperature gradients caused by uneven heating of the cutter from the sun .

3.10.4 Measure and record the distance between the aft end of the foundation of the diesel engine and the forward end of the foundation of the reduction gear to ensure that the engine is relocated correctly in the fore and aft direction.

CAUTION!

Correct distance of the engine block forward of the reduction gear will be critical in ensuring that the oil passage in the diesel pinion quill shaft properly centers in the oil groove for the quill shaft bearing. Pay particular care to this distance.

3.10.5 After initial alignment readings, install gasketed covers on openings to the reduction gears to ensure no contamination enters the reduction gears.

3.11 Main Engine Block Removal

Perform the following work:

3.11.1 Disconnect remaining lube oil, water, and air piping from the diesel engine.

3.11.2 Install the engine block lifting tools.

3.11.3 Remove the engine foundation mounting bolts.

3.11.3.1 Clean and dye penetrant test each bolt. Look for any evidence of cracking.

3.11.4 Rig the engine and…