ALEX HALEY

USCGC ALEX HALEY (WMEC-282) DOCKSIDE AVAILABILITY 2011

USCGC ALEX HALEY (WMEC 39)

SPECIFICATION FOR DOCKSIDE REPAIRS

Developed By: AUT (Rev-0, 10 January 2011)

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 302-2, Rev -, Power Wiring Deck Plan Coast Guard Drawing 282-WMEC 520-3, Rev -, Windlass Section Arrangement & Bk Operating Coast Guard Drawing 282-WMEC 520-32, Rev -, Arrangement of Anchor Windlass Room Coast Guard Drawing 282-WMEC 520-5, Rev -, Windlass Wiring Diagram Coast Guard Drawing 282-WMEC 520-51, Rev -, General Arrangement Windlass Coast Guard Drawing 282-WMEC 520-52, Rev -, Windlass Brake Box Assembly Coast Guard Drawing 282-WMEC 520-54, Rev -, Windlass Capstan Assembly Coast Guard Drawing 282-WMEC 520-55, Rev -, Windlass Below Deck Assy.

Coast Guard Drawing 282-WMEC 520-56, Rev -, Windlass Bolting Plan Coast Guard Drawing 282-WMEC 845-3, Rev -, Booklet of General Plans Coast Guard Drawing 905 WMEC 635-001, Rev L, Insulation

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual Coast Guard Technical Publication (TP) 4828, 0926-LP-020-3010 - Windlass, Forward (Volume 1) Coast Guard Technical Publication (TP) 4829, 0926-LP-020-3020 - Windlass, Forward (Volume 2) Coast Guard Technical Publication (TP) 4830, 0926-LP-020-3030 - Windlass, Forward (Volume 3) 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 3041 (SFLC Std Spec 3041), Jan 2009, Shipboard Electrical Cable Test Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), Jan 2009, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, And Installation

OTHER REFERENCES

ASTM International (ASTM) F1836M, Reapproved 2007, Standard Specification for Stuffing Tubes, Nylon and Packing Assemblies (Metric) 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 DOD-STD-2003-1, Dec 1990, Not 1, Electric Plant Installation, Standard Methods for Surface Ships & Submarines (Cable), Section 1 MIL-DTL-24643, Aug 2007, Cables and Cords, Electric, Low Smoke, For Shipboard Use, General Specification for MIL-STD-1310, Jun 1996, Shipboard Bonding, Grounding, And Other Techniques for Electromagnetic Compatibility and Safety

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.

This section is not applicable to this package.

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

Work Item Title

This section is not applicable to this package.

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

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

3.4 HW disposal. The Contractor shall be responsible for all hazardous wastes generated by work under this contract. Label and package all hazard wastes in 49 CFR-approved containers, and in accordance with all other applicable Federal, state, and local laws and regulations. In addition, comply with applicable parts of 40 CFR 262, applicable to handling of hazardous wastes.

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

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

3.4.3 The Contractor shall prepare a manifest of hazardous waste to be reviewed and signed by the HM/HW Coordinator. Contact the HM/HW Coordinator for turnover of any hazardous waste; in addition, notify the COTR 24 hours prior to any waste removals, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.4.4 The Contractor shall be aware of the following:

3.4.4.1 No Contractor or Subcontractor shall have the authority to sign a Hazardous Waste Manifest using the Coast Guard facility’s EPA Generator ID Number or remove contract generated hazardous waste from the Coast Guard facility without COTR or KO-approval.

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

3.4.4.4 Coast Guard facilities do not have Facilities Response Plans (see 33 CFR 154 Subpart F). It is the Contractor’s responsibility to furnish the Facility Response Plan (FRP) when required for over-the-water liquids transfers to and from vessels. This requirement is applicable to transfers to/from vessels with an oil/fuel capacity of 250 barrels or more.

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: _________

S10_XXX_32100_JSP_0111_39

WORK ITEM 1: Renew Anchor Windlass Controls and Wiring

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew electrical controls and all associated wiring of Port and Starboard Anchor Windlass on the Cutter. The Contractor shall replace existing Hydraulic Power Panel and Hydraulic Pump Controls for Port & STBD Anchor Windlass.

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 Drawing 282-WMEC 302-2, Rev -, Power Wiring Deck Plan Coast Guard Drawing 282-WMEC 520-3, Rev -, Windlass Section Arrangement & Bk Operating Coast Guard Drawing 282-WMEC 520-32, Rev -, Arrangement of Anchor Windlass Room Coast Guard Drawing 282-WMEC 520-5, Rev -, Windlass Wiring Diagram Coast Guard Drawing 282-WMEC 520-51, Rev -, General Arrangement Windlass Coast Guard Drawing 282-WMEC 520-52, Rev -, Windlass Brake Box Assembly Coast Guard Drawing 282-WMEC 520-54, Rev -, Windlass Capstan Assembly Coast Guard Drawing 282-WMEC 520-55, Rev -, Windlass Below Deck Assy.

Coast Guard Drawing 282-WMEC 520-56, Rev -, Windlass Bolting Plan Coast Guard Drawing 905 WMEC 635-001, Rev L, Insulation Coast Guard Publications 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 3041 (SFLC Std Spec 3041), Jan 2009, Shipboard Electrical Cable Test Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), Jan 2009, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, And Installation Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Coast Guard Technical Publication (TP) 4828, 0926-LP-020-3010 - Windlass, Forward (Volume 1) Coast Guard Technical Publication (TP) 4829, 0926-LP-020-3020 - Windlass, Forward (Volume 2) Coast Guard Technical Publication (TP) 4830, 0926-LP-020-3030 - Windlass, Forward (Volume 3) Other References MIL-DTL-24643, Aug 2007, Cables and Cords, Electric, Low Smoke, For Shipboard Use, General Specification for MIL-STD-1310, Jun 1996, Shipboard Bonding, Grounding, And Other Techniques for Electromagnetic Compatibility and Safety ASTM International (ASTM) F1836M, Reapproved 2007, Standard Specification for Stuffing Tubes, Nylon and Packing Assemblies (Metric) DOD-STD-2003-1, Dec 1990, Not 1, Electric Plant Installation, Standard Methods for Surface Ships & Submarines (Cable), Section 1

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative.

Not applicable.

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

3.1.4 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences):

· Sheathing

· Bulkhead insulation

· Piping

3.1.5 The Coast Guard Drawings referenced in the Para 2 shows the existing installation of Anchor Windlass System on the Cutter. CG Dwg 282-WMEC-520-005& 282-WMEC-302-002 (Sheet 5) shows all electrical controls associated with Port & STBD Anchor Windlass.

3.1.6 Operational test - initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of Port &STBD Anchor Windlass, to demonstrate existing operational condition in accordance with CG Tech Pub 4828, 4829 & 4830. Submit a CFR

3.2 Electrical requirement.

3.2.1 All new cables shall be of unarmored construction with low smoke insulation conforming to MIL-DTL-24643. Each cable shall be continuous from terminal end to terminal end with no splicing permitted. Cables that penetrate watertight decks or bulkheads below the main deck shall be of watertight construction (e.g., LSTSGU, LSFSGU). The Contractor shall supply all cables required for complete installation.

3.2.2 Power cable wiring shall be color coded as follows (apply a 1 inch length of appropriately colored heat shrinkable tubing to each end of a conductor, as needed, to override an inapplicable insulation color):Power cable wiring shall be color coded as follows (apply a 1 inch length of appropriately colored heat shrinkable tubing to each end of a conductor, as needed, to override an inapplicable insulation color):

3.2.3 Disconnect, reroute, and/or remove cables in accordance with SFLC Std Specification 3042. Use existing wire ways whenever possible. The Contractor shall install new cables in similar layout as per removed cables.

3.2.4 Install cable tags on all new cables in accordance with SFLC Std Specification 3042. Tags shall be located at equipment cable entrances and on each side of a deck or bulkhead penetration.

3.2.5 Wiring installation methods and cable supports shall be in accordance with SFLC Std Specification Standard 3042 and DOD-STD-2003.

3.2.6 Terminate cable with ring type terminals. Spade type lugs shall not be used. No more than three wires shall terminate at any one stud or terminal.

3.2.7 Except when not practical because of component design (e.g., box lug terminals), wiring shall terminate in solderless compression type lugs and shall have ring terminals or a machined hole for connection to the terminal stud. Spade type lugs shall not be used. No more than three wires shall terminate at any one stud or terminal.

3.2.8 The Cable entrances to splash proof, spray tight and watertight enclosures shall be through plastic stuffing tubes in accordance with ASTM F 1836M.

3.2.9 Reuse existing stuffing tubes when practicable. Plug newly vacated stuffing tubes that will not be reused. Install new watertight deck or bulkhead penetrations, as necessary, in accordance with DOD-STD-2003-3. When an existing multi-cable transit block is disturbed to install new wiring, remove and discard the old semi-rigid insert material. Install new insert material to accommodate the remaining cables and any new wiring that is installed.

3.2.9.1 If existing stuffing tubes and deck penetration are not suitable for new cables, the contractor shall install new stuffing tubes and deck penetration for new cables in accordance with SFLC Std Specification 074 & SFLC Std Specification 3042.

3.2.10 Test all new and rerouted cables per SFLC Std Specification 3041 in the presence of the Coast Guard Inspector.

3.2.11 Wire Marking. New wires grouped in harnesses, or single wires more than 12 inches in length (unless they are unique in color or size and can be traced visually from one end to the other), shall be marked for identification. Marking may be accomplished by stamping the identification symbol on the wire insulation, by sliding a sleeve type wire marker over the wire insulation. Marking shall be applied in a permanent manner, resistant to water, heat, oil, and abrasion.

3.2.12 Labeling. All labeling and markings shall be consistent with Cutters existing procedure. Label and information plates shall be of laminated phenolic with inner and outer layers of contrasting colors to match similar existing markings. Outer layers shall normally be colored black, white, or gray. Inner layers (exposed through engraving) shall be a contrasting white or black. The Contractor shall install label plate on each new control panels & Junction Box. The Coast Guard Inspector will approve nomenclature of each label plate.

3.2.13 The Contractor shall supply all material required for complete installation of the new wiring. The contractor shall provide miscellaneous hardware required for electrical installation (i.e. Q Stuffing Tubes, Box Connectors, Lugs, Fasteners, Wire Nuts, Tape, Cable ties & Brackets) of new wiring.

3.3 Anchor Windlass Controls Renewal. The Contractor shall renew all existing controls of Port and Starboard of Anchor Windlass. New Controls shall be similar to existing controls or state of the art design with same function as the existing controls.

3.3.1 The Contractor shall conduct shipcheck validation of CG Dwg 282 WMEC 520-005 to verify existing wiring configuration of Anchor Windlass on the Cutter. All discrepancy shall be submitted in accordance with SFLC Std Spec 085.

3.3.1.1 Red-lined drawing deliverable(s). The Contractor shall “red-line” CG Dwg 282 WMEC-520-005 to clearly reflect the existing wiring information of Anchor Windlass on the Cutter.

3.3.1.2 Within 24 hours after completion of verification of existing wiring, the Contractor shall submit a draft copy of the marked-up CG Dwg 282 WMEC-520-005 to the COTR for review and approval.

3.3.1.3 The Contractor shall document all wiring information for Above Deck Hand Controller and submit CFR. (Note: Hand Held Controller wiring is NOT shown on CG Dwg 282-WMEC-520-005 and requires all wiring information for re-installation with new controls).

NOTE

CG Dwg 282 WMEC-520-005 may not be latest and may not provide complete existing wiring information of Anchor Windlass Controls. Existing wiring information of Anchor Windlass Controls will be re-used to terminate new cables with new controls. The Contractor shall precisely document existing wiring information before removal of controls and wiring.

3.4 Below Deck Control Pedestal and Changeover Switch (PORT & STBD). The Contractor shall disconnect following cables connected to Below Deck Controller and Changeover Switch Pedestals.

TABLE 1a - Below Deck Control PEDESTAL and ChangeOver Switch (port)

TABLE 1B - Below Deck control PEDESTAL and ChangeOver Switch (stbd)

3.4.1 The Contractor shall thoroughly clean, remove all corrosion, oil and re-paint Below Deck Control Pedestal and Changeover Switch (PORT & STBD). The Contractor shall re-paint Pedestals in accordance with COMFTIST M10360. . Install new gasket and seal on Pedestals to make it watertight. The Contractor shall renew all control circuits inside the Pedestals and neatly install new control circuits and secure all new components inside the Pedestals.

4.4.2 The Contractor shall renew following items mounted inside the Below Deck Control Pedestal and Changeover Switch (PORT & STBD).

TABLE 2 – parts IDENTIFICATION (PORT & STBD)

Door Mounted Selector Switch (11 Contacts)

Control Potentiometer

Center Detecting Switch

Reset Push Button (Two NO & Two NC Contact)

Off Position Interlock Switch

Terminal Block

3.4.2 The Contractor shall supply and install Parts Listed in Table 2 inside Below Deck Pedestal and Changeover Switch (PORT & STBD).

3.4.3 The Contractor shall supply and install new cables listed in the Table 1A & 1B in accordance with MIL-DTL-24643. The Contractor shall install nylon stuffing tubes in accordance ASTM F 1836 to install new cables to Below Deck Control Pedestal and Changeover Switch (PORT & STBD).

3.4.4 For internal wiring inside the Control Panel, the Contractor shall use 14 Gauge UL approved hook up wires.

3.4.5 The Contractor shall terminate new cable with previously recorded information to terminal block and selector switch inside the Below Deck Control Pedestal and Changeover Switch (PORT & STBD).

3.4.6 The Contractor shall install Name Tag on the cover “BELOW DECK CONTROL PEDESTAL & CHANGEOVER SWITCH”.

3.5 Above Deck Controller Panels (PORT & STBD). The Contractor shall disconnect following cables connected to Above Deck Controller Panels (PORT & STBD).

TABLE 3A – above Deck Control panel (PORT)

TABLE 3B – above Deck Control panel (stbd)

3.5.1 The Contractor shall renew Above Deck Control Panels (PORT & STBD). New enclosure shall be Stainless steel NEMA 4X with mounting panel and shall be same size as removed Panel. The Contractor shall renew following items mounted inside the Control Panel.

TABLE 4 – parts IDENTIFICATION (PORT & STBD)

Terminal Block

Cannon Connector Plug (Female)

3.5.2 The Contractor shall supply and install Parts Listed in Table 4 inside new Control Panel (PORT & STBD).

3.5.3 The Contractor shall supply and install new cables listed in the Table 3A & 3B in accordance with MIL-DTL-24643. The Contractor shall install nylon stuffing tubes in accordance ASTM F 1836 to install new cables to Control Panel.

3.5.4 For internal wiring inside the Control Panel, the Contractor shall use 14 Gauge UL approved hook up wires.

3.5.5 The Contractor shall terminate new cable with previously recorded information to terminal block and selector switch inside the Control Panel

3.5.6 The Contractor shall install Name Tag on the cover “ ABOVE DECK CONTROL PANEL”.

3.5.7 Above Deck Hand Held Controller (PORT & STBD). The Contractor shall supply and install Hand Held Controller similar to currently installed on the Cutter. The Contractor shall supply cable and MS connector (i.e. Cannon Plug & Socket) required for complete operation. The Hand Held Controller Parts are listed in the Table 5 below:

TABLE 5 – HAND HELD CONTROLLER (port & stBD)

Reset Push Button(1 NO & 1 NC Contact)

Start Push Button (1 NO & 1 NC Contact)

Stop Push Button (1 NO & 1 NC Contact)

Center Detecting Switch

Potentiometer Meter

Off Position Switch

Cannon Connector

3.6 Remote Master Switches Panel (PORT & STBD). The Contractor shall disconnect following cables connected to Remote Master Switches Panel. (Note: This Start/Stop & Emergency Run Pushbutton Station is mounted near AC Controller).

TABLE 6 – remote master Switches panelS (port & stbd)

3.6.1 The Contractor shall renew Remote Master Switches Panels (PORT & STBD). New enclosure shall be Stains steel NEMA 4X and shall be same size as removed Panel. The Contractor shall renew following items mounted inside the Control Panels.

TABLE 7 – parts IDENTIFICATION (PORT & STBD)

Emergency Run Push Button (1 NO & 1 NC Contact)

Start Push Button (1 NO & 1 NC Contact)

Stop Push Button (1 NO & 1 NC Contact)

3.6.2 The Contractor shall supply and install Parts Listed in Table 7 inside new Control Panels (PORT & STBD).

3.6.3 The Contractor shall supply and install new cables listed in the Table 6 in accordance with MIL-DTL-24643. The Contractor shall install nylon stuffing tubes in accordance ASTM F 1836 to install new cables to Control Panels (PORT & STBD).

3.6.4 For internal wiring inside the Control Panels, the Contractor shall use 14 Gauge UL approved hook up wires.

3.6.5 The Contractor shall terminate new cable with previously recorded information to Push Buttons.

3.6.6 The Contractor shall install Name Tag on the cover “Remote Master Switches Panel”.

3.7 Thermostat Renewal (PORT & STBD). The Contractor shall renew thermostats mounted on Power Rack Vickers Sperry-Rand. New thermostat shall have same specification as old thermostat. The Contractor shall remove cables (Port: ANW3, Type DSGA-3, STBD: ANW20, Type DSGA-3) and install new cable (LSDSGU-4) from thermostat to A. C .Controller.

3.8 Hydraulic Motor Power Wiring Renewal (PORT & STBD). The Contractor shall remove and replace following cable from A C Controller to 90 HP Hydraulic Motor. Install nylon stuffing tube and terminate new cables with previously recorded information. (Note: Existing AC Controller s will be re-used without any modification).

TABLE 8A–SWITCHBOARD POWER CABLE TO AC CONTROLLER (PORT & STB)

3.8.1 The Contractor shall remove and replace following cables from Ship Service Switchboard (1SA & 1SB ) to AC Controller (PORT & STBD).

TABLE 8B–SWITCHBOARD POWER CABLE TO AC CONTROLLER (PORT & STB)

3.8.2 The Contractor shall disconnect following cables connected to AC Controller (PORT & STBD).

TABLE 8c– aC controller (PORT)

TABLE 8c– aC controller (STBD)

3.8.3 The Contractor shall supply and install new cables listed in the Table 8B & 8C in accordance with MIL-DTL-24643. The Contractor shall install nylon stuffing tubes in accordance ASTM F 1836 to install new cables to AC Controller (PORT & STBD).

3.8.4 For internal wiring inside the Control Panels, the Contractor shall use 14 Gauge UL approved hook up wires.

3.8.5 The Contractor shall terminate new cable with previously recorded information to AC Controller (PORT & STBD).

3.9 Hydraulic Power Panel Replacement (PORT & STBD). The Contractor shall replace existing Hydraulic Power Panels with newer Control Panels with same “Form, Fit & Function” as existing controls. The existing controls is manufactured by Vickers Sperry Rand Ltd and identified by Dwg 840440 & 840450. The CG Tech Pub 4830 describes hydraulic controls and Vickers drawings (i.e. 839357, 840541,838361,840540 & 840440) are attached in the CG Tech Pub 4830. New controls shall be mounted in side NEMA 4X Stainless steel enclosure. Existing Hydraulic Power Panel which requires the replacement is shown in the Figure 8 at the end of this specification. The Contractor shall mount new Control Panels at same location as existing Panel location. The Contractor shall provide all mounting hardware to mount new Control Panels.

3.9.1 Hydraulic Power Panels (PORT & STBD). The Contractor shall disconnect and remove following cables connected Hydraulic Power Panels (PORT & STBD).

TABLE 9a – Hydraulic Power Panel (port)

TABLE 9B – Hydraulic Power Panel (stbd)

3.9.2 The Contractor shall supply and install new cables listed in the Table 9A & 9B in accordance with MIL-DTL-24643. The Contractor shall install nylon stuffing tubes in accordance ASTM F 1836 to install new cables to Hydraulic Power Panels (PORT & STBD).

3.9.3 For internal wiring inside the Control Panel, the Contractor shall use 14 Gauge UL approved hook up wires.3333

3.9.4 The Contractor shall terminate new cable with previously recorded information to Hydraulic Power Panels (PORT & STBD).

3.10 Hydraulic Pump Control (PORT & STBD). The Contractor shall replace Servo Valve, Feed Back Potentiometer, Brake & Bypass Solenoid, Centering Solenoid, Overpass Switch & Replenishing Pressure Switch mounted on the Hydraulic Pump Package (Note: These Controls are manufactured by Vickers Sperry Rand Ltd). The CG Tech Pub 4829 describes the controls of these components. The Contractor shall mount new controls in NEMA 4X Panel and mount the Panel on the Hydraulic Package. Figure 11 at the end of this specification shows the location on Hydraulic Package.

3.10.1 The Contractor shall disconnect and remove following cables connected Hydraulic Pump (PORT & STBD).

TABLE 10A – Hydraulic PUMP (port)

TABLE 10b – Hydraulic PUMP (STBD)

3.10.2 The Contractor shall supply and install new cables listed in the Table 10A & 10B in accordance with MIL-DTL-24643. The Contractor shall install nylon stuffing tubes in accordance ASTM F 1836 to install new cables to Hydraulic Pump (PORT & STBD).

3.10.3 For internal wiring inside the Control Panel, the Contractor shall use 14 Gauge UL approved hook up wires.

3.10.4 The Contractor shall terminate new cable with previously recorded information to Hydraulic Pump (PORT & STBD).

3.11 Junction Box (PORT & STBD). The Contractor shall remove existing 4 Inch X 4 Inch X 2 Inch Junction Box and installed new Junction Box. The Junction Box is located near 90 HP Hydraulic Motor.

3.11.1 The Contractor shall disconnect and following cables connected Junction Box (PORT & STBD).

TABLE 11a– JUNCTION BOX (port)

TABLE 11b– JUNCTION BOX (stbd)

3.11.2 The Contractor shall supply and install new cables listed in the Table 11A &11B in accordance with MIL-DTL-24643. The Contractor shall install nylon stuffing tubes in accordance ASTM F 1836 to install new cables to Junction Box (PORT & STBD).

3.11.3 For internal wiring inside the Control Panel, the Contractor shall use 14 Gauge UL approved hook up wires.

3.11.4 The Contractor shall terminate new cable with previously recorded information to Junction Box (PORT & STBD).

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

3.13 Continuity Checks and Megger Readings. The Contractor shall perform continuity checks of each reconnected and reinstalled new cables. Continuity checks shall be from distribution panel to each terminal end. The Contractor shall also take megger readings for each reconnected new cable between each phase and from each phase to ground to ensure proper cable reconnection and insulation.

3.14 Insulation resistance measurements. The Contractor shall measure and record insulation resistance measurements for all new cable installations in accordance SFLC Std Specification 3042.

3.15 New drawing deliverable(s). The Contractor shall produce a new drawing of Anchor Windlass System in accordance SFLC Std Spec 085. New drawings shall provide complete installation of all electrical wiring and controls of PORT & STBD Anchor Windlass. Drawings shall list all parts required for maintenance of Anchor Windlass.

3.15.1 Preliminary/draft submission. Within 50 percent completion of this work item, submit a draft copy of the drawings to the COTR for review and approval.

3.15.2 Final submission. Within 30 calendar days after receiving final Coast Guard comments on the draft submission and completion of this work item, whichever occurs first, accomplish the following:

· Incorporate all comments.

· Jointly sign the drawings with the Coast Guard Inspector.

· Deliver four bond paper copies and an electronic media/AutoCAD generated copy on CD-ROM to the KO.

3.16. Operational test – post repairs. After completion of work, the Contractor shall witness an operational test (by Coast Guard personnel) of Anchor Windlass System (PORT & STBD to prove that they are in satisfactory operating condition. Submit a CFR.

4. NOTES

This section is not applicable to this work item.

Figure 1: Below Deck Control Pedestal & Changeover Switch (PORT & STBD) Figure 2: Below Deck Control Pedestal & Changeover Switch-Showing Switch only

(THE CONTRACTOR SHALL REPLACE THIS SWITCH)

Figure 3: Below Deck Control Pedestal & Changeover Switch Wiring

(THE CONTRACTOR SHALL REPLACE CHANGEOVER SWITCH & WIRING)

Figure 4: Below Deck Control Pedestal & Changeover Switch Amplifier Data

(THE CONTRACTOR SHALL REPLACE CHANGEOVER SWITCH & WIRING)

Figure 5: Below Deck Control Pedestal & Changeover Switch showing Potentiometer

(THE CONTRACTOR SHALL REPLACE CONTROL POTENTIOMETER)

Figure 6: Above Hand Held Controller

(THE CONTRACTOR SHALL REPLACE THIS HAND HELD CONTROLLER & COMPONENTS)

Figure 7: Above Deck Control Panel

(THE CONTRACTOR SHALL REPLACE THIS PANEL, COMPONENTS & WIRING)

Figure 8: Hydraulic Power Panel (Below Deck)

(THE CONTRACTOR SHALL REPLACE THIS PANEL & CONTROLS FOR PORT & STBD)

Figure 9: Hydraulic Power Module

(THE CONTRACTOR SHALL REPLACE THIS PANEL & CONTROLS FOR PORT & STBD)

Figure 10: Diode Assembly

(THE CONTRACTOR SHALL REPLACE THIS COMPONENTS FOR PORT & STBD)

The Contractor shall replace this servo valve The Contractor shall replace all the internal components inside this Box.

Figure 11: Hydraulic Pump Accessories Figure 12: Hydraulic Pump Accessories (THE CONTRACTOR SHALL REPLACE HYDRAULIC PUMP ACCESSORIES FOR PORT & STBD ANCHOR WINDLASS)

Figure 13: Hydraulic Pump Controller

(THIS AC CONTROLLER WILL BE RE-USED WITH WIRING)

Figure 14: Hydraulic Pump Accessories (THE CONTRACTOR SHALL REPLACE HYDRAULIC PUMP ACCESSORIES FOR PORT & STBD ANCHOR WINDLASS)

Figure 15: Hydraulic Pump & Motor for Reference