IDA LEWIS SPECIFICATION.pdf

USCGC IDA LEWIS (WLM 551)

175 FOOT COASTAL BUOY TENDER

SPECIFICATION FOR DOCKSIDE REPAIRS

Developed By: Allison H Sullivan

(Rev-0, 20 January 2012)

USCGC IDA LEWIS (WLM-175) DOCKSIDE AVAILABILITY 2012

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ....................................................................................................................................... iii Consolidated List of References ................................................................................................................ iv Consolidated List of Government-furnished Property ............................................................................. viii

Consolidated List of Critical Inspection Items .......................................................................................... xi Principal Characteristics ........................................................................................................................... xii General Requirements WORK ITEM 1: SW Heat Exchangers, Clean, Inspect and Hydro WORK ITEM 2: Main Diesel Engine (MDE) Exhaust Stack Uptakes, Clean

WORK ITEM 3: Ship Service Diesel Generator (SSDG) Exhaust Piping, Commercial Clean WORK ITEM 4: Pad Eyes, Inspect and Test

WORK ITEM 5: Hydraulic Chain Stoppers, Overhaul WORK ITEM 6: Crossdeck Winches, Overhaul WORK ITEM 7: Mechanical Chain Stoppers, Overhaul WORK ITEM 8: Single Point Davit, Level 2 Inspect and Repair

WORK ITEM 9: Grey Water Holding Tanks, Clean and Inspect WORK ITEM 10: Sewage Vacuum Collection Tank, Clean and Inspect WORK ITEM 11: Sewage Piping, Clean and Flush

WORK ITEM 12: Decks – Exterior (Buoy), Preserve WORK ITEM 13: Hydraulic Power Unit Isolation Valves, Install

WORK ITEM 14: Buoy Chain (In-Haul) Winch, Modify WORK ITEM 15: Tanks (Ballast), Preserve “ Partial ” WORK ITEM 16: Towing Bitts, Chocks, and Fairleads; Inspect and Test

WORK ITEM 17: Mechanical Chain Stoppers, Relocate

WORK ITEM 18: Deck Covering (Electrical Matting), Renew WORK ITEM 19: Bridge Window Gaskets, Renew WORK ITEM 20: Buoy Chain Ports, Renew

WORK ITEM 21: Buoy Crane, Inspect and Repair WORK ITEM 22: Hydraulic Cargo Hatch, Inspect and Preserve

WORK ITEM 23: Hand Rails and Stanchions, Renew WORK ITEM 24: Hydraulic Power Unit Coupling Maintenance WORK ITEM 25: Hydraulic Inhaul Winch, Overhaul WORK ITEM 26: Cleaning Gear Locker Service Sink, Renew

WORK ITEM 27: Air Handler Unit Filter, Fabricate WORK ITEM 28: Oil Containment Coamings, Repair WORK ITEM 29: Sewage Tank, Clean, Inspect and Preserve

WORK ITEM 30: Small Boat Fueling Fill Station Piping, Repair WORK ITEM 31: Miscellaneous Tank Vent Piping Assembly, Renew WORK ITEM 32: UT Inspection, Deck Plating WORK ITEM 33: Ventilation Systems, Overhaul

WORK ITEM 34: Warping Capstan (Aft), Level 2 Inspect and Repair iii (Rev-0)

Revisions Record

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

DATE REV# WORK

ITEM#

CHANGES MADE

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

iv (Rev-0)

Consolidated List of References

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

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

Appleton Marine Drawing Q426218, Appleton Marine Motor Assembly Block Manifold Assembly

Coast Guard Drawing 175-WLM 201-001, Rev C, Machinery Spaces Arrangment

Coast Guard Drawing 175-WLM 256-001, Rev H, Seawater Cooling System Diagram

Coast Guard Drawing 175-WLM 256-003, Rev D, Seawater Cooling System FR 61 Forward

Coast Guard Drawing 175-WLM 256-004, Rev J, Seawater Cooling System Arrangements and Details

Coast Guard Drawing 175-WLM 256-005, Rev -, Z-Drive Lube Oil Heat Exchanger Tube Bundle, Replacement and Piping Mods

Coast Guard Drawing 175-WLM 256-012, Rev A, Auxiliary Seawater System Piping Mods

Coast Guard Drawing 175-WLM 259-001, Rev A, Combustion Exhaust Diagram

Coast Guard Drawing 175-WLM 259-005, Rev C, Combustion Exhaust A&D, Hull Block 970

Coast Guard Drawing 175-WLM 437-001, Rev E, Tank Level Indicator System Block Diagram

Coast Guard Drawing 175-WLM 505-001, Rev C, General Requirements for Piping Systems

Coast Guard Drawing 175-WLM 506-001, Rev G, Overflows, Air Escapes & Sounding Tubes Diagram

Coast Guard Drawing 175-WLM 506-005, Rev E, Vents and Sounding Tubes A & D, Frames 42-61, Hull

Block 930

Coast Guard Drawing 175-WLM 506-007, Rev D, Vents & Sounding Tubes Main Deck & Above A & D, Hull 551

Coast Guard Drawing 175-WLM 506-008, Rev C, Oil Containment Coamings

Coast Guard Drawing 175-WLM 508-001, Rev B, Piping & Machinery Insulation Coast Guard Drawing 175-WLM 512-001, Rev E, HVAC Diagram

Coast Guard Drawing 175-WLM 512-008, Rev C, HVAC A &D, Frame 61-42, Hull Block 930 http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace v (Rev-0)

Coast Guard Drawing 175-WLM 512-011, Rev E, HVAC A & D, FR 70-50, Main Deck & Above, Hull

Block 960

Coast Guard Drawing 175-WLM 512-013, Rev B, HVAC Std Details & General Instructions Coast Guard Drawing 175-WLM 528-001, Rev E, Plumbing & Interior Deck Drains Diagram

Coast Guard Drawing 175-WLM 528-006, Rev G, Plumbing & Deck Drains A & D, Hull Blocks 910, 930

Coast Guard Drawing 175-WLM 528-008, Rev E, Plumbing & Deck Drains A & D, Hull Block 970

Coast Guard Drawing 175-WLM 533-001, Rev G, Potable Water System Diagram

Coast Guard Drawing 175-WLM 533-005, Rev D, Potable Water System A & D, Hull Block 970 Coast Guard Drawing 175-WLM 541-001, Rev H, Fuel Oil System Diagram

Coast Guard Drawing 175-WLM 541-005, Rev F, Fuel Oil Transfer System A/D Hull Block 940,970

Coast Guard Drawing 175-WLM 549-001, Rev E, Onboard Lubrication Requirements.

Coast Guard Drawing 175-WLM 556-007, Rev A, Isolation Valves for Deck Machinery Hydraulic Power

Unit

Coast Guard Drawing 175-WLM 556-008, Rev-, Deck Machinery Hydraulic Power Unit Piping Mods.

Coast Guard Drawing 175-WLM 573-001, Rev M, Buoy Deck Arrangement

Coast Guard Drawing 175-WLM 573-008, Rev -, ATON Tie Downs

Coast Guard Drawing 175-WLM 573-050, Rev A, Hydraulic Piping Installation for Chain Stopper

Coast Guard Drawing 175-WLM 573-051, Rev B, Chain Stopper Structural Modifications for Hydraulic

Roller Assembly

Coast Guard Drawing 175-WLM 582-001, Rev D, Mooring and Towing, A & D

Coast Guard Drawing 175-WLM 593-001, Rev G, Sewage & Waste Water System Diagram

Coast Guard Drawing 175-WLM 593-009, Rev E, Independent Tanks, Sewage Holding Tank

Coast Guard Drawing 175-WLM 601-001, Rev N, General Arrangement and Inboard and Outboard Profiles

Coast Guard Drawing 175-WLM 601-002, Rev E, Booklet of General Plans (IDA LEWIS)

Coast Guard Drawing 175-WLM 602-003, Rev C, Operating Instructions & Label Plates

Coast Guard Drawing 175-WLM 612-001, Rev G, Lifeline, Rails & Stanchions

Coast Guard Drawing 175-WLM 625-001, Rev K , Windows and Portlights

Coast Guard Drawing 175-WLM 631-001, Rev D, Painting Schedule, Hull 551

Coast Guard Drawing 175-WLM 633-001, Rev D, Cathodic Protection

Coast Guard Drawing 175-WLM 635-001, Rev F, Hull Thermal & Acoustic Insulation Schedule

Coast Guard Drawing 175-WLM 644-001, Rev G, Sanitary Facilities & Laundry Space A & D Coast Guard Drawing 175-WLM 801-015, Rev C, Scantlings, Decks & Platforms

Coast Guard Drawing 175-WLM 920-001, Rev K, Hull Block 920 Panels

Coast Guard Drawing FL 2605-013, Rev C, Buoy Chain Model CW1: Pins

Coast Guard Drawing FL 2605-029, Rev H, Chain Stopper System – Hydraulic Roller Assembly

Coast Guard Drawing FL 2605-031, Rev D, Mechanical Chain Stopper, 1-7/8" Buoy Chain

Coast Guard Drawing FL 2605-034, Rev C, Mechanical Chain Stopper Repair Kit: 1-7/8", 1-5/8" & 1-1/4"

Coast Guard Drawing FL 2605-035, Rev-, Buoy Chain Winch Pedestal Bearing Modification

Coast Guard Drawing FL 2605-037, Rev A, Mechanical Chain Stopper Reinstallation

Coast Guard Drawing FL 7101-573, Rev L, Buoy Chain Winch Assy Model CW1

COAST GUARD PUBLICATIONS

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

Coast Guard Technical Publication (TP) 3498, 573-A, July 2009, Buoy Chain Winch

Coast Guard Technical Publication (TP) 3610, 167-A, Nov 2005, Power Operated Cargo Hatch, Coastal

Buoy Tender, Model No. D-WK-787

Coast Guard Technical Publication (TP) 3613, 245-A, Jan 1998, Z-Drive Model 1350-H

Coast Guard Technical Publication (TP) 3626, 516-A, Jan 2007, Heat Pumps and Air Handlers for 175’ Buoy

Tenders vi (Rev-0)

Coast Guard Technical Publication (TP) 3627, 556-A, Feb 2007, HPU Deck Machinery, Model 7D3-05575 Coast Guard Technical Publication (TP) 3630, 573-A, Oct 2011, Hydraulic Crane, Model SB230-42

Coast Guard Technical Publication (TP) 3631, 573-B, Mar 2007, Cross Deck Winch, Model BMD-463

Coast Guard Technical Publication (TP) 3631, 573-D (for WLM Hulls 551-553), Dec 1997, Chain Stopper

Coast Guard Technical Publication (TP) 3632, 582-A, Sep 1999, Aft Capstan, Model X-2316

Coast Guard Technical Publication (TP) 3632, 583-C, Jul 2011, Slewing Arm Davit Model D6000FCT

NAVSEA Drawing 804-5773931, Rev A, Acoustic & Thermal Insulation For Compartments Installation

Details

Surface Forces Logistics Center (SFLC) Naval Engineering Directive (NED) 5735-01, Inspection and Test

Procedure For Buoy Chain Winch Model CW-1 Onboard WLM 551-564 and WLB 201-215, May 2010

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

Requirements

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

Processes

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3020, Jan 2009, Overhaul AC

Electrical Motors

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 5000, Jan 2009, Auxilary Machine

Systems

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 5100, Jan 2009, Clean Shipboard

Ventilation Systems

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

Covering Systems

OTHER REFERENCES

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

American Society of Mechanical Engineers (ASME) B16.11, 2005, Forged Steel Fittings, Socket-Welding and Threaded

American Society of Mechanical Engineers (ASME) B16.22, 2005, Wrought Copper and Copper Alloy

Solder Joint Pressure Fittings American Society of Mechanical Engineers (ASME) B16.25, 2007, Buttwelding Ends

American Society of Mechanical Engineers (ASME) B16.5, 2003, Pipe Flanges & Flanged Fittings: Nps 1/2

Through Nps 24

American Society of Mechanical Engineers (ASME) B16.9, 2007, Factory-Made Wrought Buttwelding

Fittings

ASTM International (ASTM) A105, 2005, Standard Specification for Carbon Steel Forgings for Piping

Applications

ASTM International (ASTM) A106, 2008, Standard Specification for Seamless Carbon Steel Pipe for High-

Temperature Service

ASTM International (ASTM) A181, 2006, Standard Specification for Carbon Steel Forgings, For General-

Purpose Piping

ASTM International (ASTM) A234M, 2011, Standard Specification for Piping Fittings of Wrought Carbon

Steel and Alloy Steel for Moderate and High Temperature Service ASTM International (ASTM) B61-08, 2008, Standard Specification for Steam or Valve Bronze Castings

ASTM International (ASTM) B62, 2002, Standard Specification for Composition Bronze or Ounce Metal

Castings

ASTM International (ASTM) B75, 2005, Standard Specification for Seamless Copper Tube

ASTM International (ASTM) B466, 2007, Standard Specification for Seamless Copper-Nickel Pipe and Tube ASTM International (ASTM) D1330, 2004, Standard Specification for Rubber Sheet Gaskets vii (Rev-0)

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

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

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

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

Administration, Department Of Transportation

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

Commercial Item Description (CID) A-A-59588, Jul 2005, Rubber Silicone

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

Federal Specification (Fed Spec) QQ-N-281, Oct 1985, Nickel-Copper-Aluminum Alloy Bar, Rod, Plate, Sheet, Strip, Wire, Forgings, And Structural and Special Shaped Sections

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

MIL-A-46106, Jun 1992, Adhesive-Sealants, Silicone, Rtv, One-Component

MIL-F-1183, May 1987, Fittings, Pipe, Cast Bronze, Silver-Brazing, General Specifications for

MIL-T-24107, Oct 1987, Tube, Copper (Seamless) (Copper Alloy Numbers C10100, C10200, C10300, C10800, C12000, C12200, And C14200) MIL-PRF-1149, Jun 1998, Gasket Materials, Synthetic Rubber, 50 and 65 Durometer Hardness

MIL-PRF-16173, Sep 2006, Corrosion Prevention Compound, Solvent Cut-Back, Cold-Application

NAVSEA Drawing 804-5773931, Rev A, Acoustic & Thermal Insulation For Compartments Installation

Details

NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), May 1997, Requirements for

Fabrication, Welding, and Inspection of Submarine Structure

Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) C 6183, 2005, Cork and

Rubber Composition Sheet; For Aromatic Fuel and Oil Resistant Gaskets

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 3), 2004, Power Tool Cleaning

The Society for Protective Coatings (SSPC)/NACE-International (NACE) Joint Surface Preparation Standard

SSPC-SP 10/NACE No. 2, 2007, Near-White Blast Cleaning

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

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

Surfaces Prepared by Dry Abrasive Blast Cleaning viii (Rev-0)

Consolidated List of Government-furnished Property

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

WORK

ITEM

MTI ITEM

DESCRIPTION

NSN/PN QTY ESTIMATED

COST

($/UNIT)

1 N Gasket 5330-01-449-2451 1 22.53

1 N Gasket 5330-01-449-2479 1 18.66

1 N Gasket 5330-01-124-8979 2 11.89

1 N Gasket 5330-01-420-3726 2 11.02

5 N Overhaul Kit 2040-01-496-9418 2 1,409.15

6 N Directional

Control Valve

YMD-7884

4810-01-543-3252

4 2,500.00

6 N Counter-Balance

Valve

SUN CBEH-LJN T-2A 8 80.00

6 N Shuttle Valve SUN CSAD-XXN T-11A 8 20.00

6 N Flow Control

Valve

SUN NFDC-KAN T-5A 4 39.00

7, 17 N Chain Stopper

Overhaul Kit

2030-01-485-7215 2 467.07

7, 17 N Chain Stopper

Pin Repair Kit

2030-01-485-7209 2 630.23

8 N Swing Brake

Seal Kit

2030-01-351-2820 2 168.76

8 N Swing Brake

Disc & Bearing

Kit

2030-01-349-9486 2 937.70

8 Y **Winch

Assembly

2030-01-505-1581 1 21,990.00

8 N Accumulator, Hydraulic

2090-01-570-9809 1 4,169.21

13 N Check Valve, In-line

123A-6 PL4354 (CPV MFG, Inc/800-386-

8830)

3 400.00

14, 25 N Pillow Block

Housing

3130-01-504-4363

2 2,410.00 ix (Rev-0)

21 N Pedestal &

Turret Hex head

Cap Screw:

1.500 Dia-

6NCx6.0 LG

TP3630, Figure 7-1, Item 80 90 9,630.00

21 N Pedestal &

Turret Threaded

Stud: 1.500 Dia-

6NCx6.0 LG

TP3630, Figure 7-1, Item 81 3 2,640.00

21 N Pedestal &

Turret Hardened

Flat washer: 1.5

Dia

TP3630, Figure 7-1, Item 82 93 186.00

21 N Swivel Head

Bolts: ¾ -10NC

2-3/4” length

TP3630, Figure 7-1, Item 102 22 484.00

21 N Hand Pump YMD-0541 1 837.00

21 N Hydraulic

Control Valve

YMD-6861 2 5,217.00

21 N Hydraulic

Control Valve

YMD-6862 1 1,956.00

21 N Hydraulic

Control Valve

YMD-6859 1 9,222.00

21 N Needle Valve NFDC-KAN 3 197.00

21 N Holding Valve CBEA-LHN 6 205.00

21 N Shuttle Valve CSAD-XXN 6 123.00

25 N Grease seal

(for Para. 3.2.1, Task #5)

5330-01-462-5544 4 84.87

25 N Level wind pivot bushing

(for Para. 3.2, Task #6)

7101-573-1 PC-17 (Marinette Marine) 1 392.00

25 N Level wind thrust bearing

(for Para. 3.2.1, Task #6)

7101-573-1 PC-16 (Marinette Marine) 2 249.00

25 N Hand Pump

(for Para. 3.2.1, Task #7)

4320-01-015-9422

P-18 (Enerpac, LTD)

1 415.57

25 Y Level wind hydraulic cylinder

(for Para. 3.2.1, Task #8)

3040-01-441-3721 1 8,533.90

25 N 3:1 Pilot Ratio, CWEA-LHN (Sun Hydraulics Corp) 1 98.70 x (Rev-0)

Vented

Counterbalance

Valve Assembly

(For Para. 3.2.1, Task #18)

25 N Fully Adjustable

Needle Valve

(for Para. 3.2.1, Task #18)

NFDC-LAN (Sun Hydraulics Corp) 1 48.75

25 Y **Hydraulic

Motor

(for Para. 3.2.1, Task #22)

4320-01-445-2248 1 23,994.00

26 N ELKAY

Stainless Steel

Wall Mount

Service Sink

ESS2118C 1

500.00

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

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

***Government-furnished property, which is to be supplied by either the vessel or the C4IT ServiceCenter xi (Rev-0)

Consolidated List of Critical Inspection Items

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

3.2.6.5 (Inspection report particulars)):

Work

Item Title

Pad Eyes, Inspect and Test

Hydraulic Chain Stoppers, Overhaul

6 Crossdeck Winches, Overhaul

7 Mechanical Chain Stoppers, Overhaul

8 Single Point Davit, Level 2 Inspect and Repair

21 Buoy Crane, Inspect and Repair

22 Hydraulic Cargo Hatch, Inspect and Preserve

25 Hydraulic Inhaul Winch, Overhaul

34 Warping Capstan (Aft), Level 2 Inspect and Repair xii (Rev-0)

PC_175_WLM_310

Principal Characteristics

175' WLM BUOY TENDER

PHYSICAL CHARACTERISTICS

Length Overall 174' 8”

Length between Perpendiculars 155' 1”

Depth 14' 8”

Maximum Beam 36' 0”

Designed Draft 8' 0”

Mast Height (Above 8' Waterline) 58' 8”

Frame Spacing 20”

Full Load Displacement 906.42 long tons

Light Load Displacement 840 long tons

Minimum Op Condition Displ 870 long tons

MACHINERY CHARACTERISTICS

Main Propulsion

Two Caterpillar 3508 DITA V-8 diesel; 999 BHP ea @ 1500 RPM

Two Ulstein 360 degree steerable Z-Drives, 403

SRPM @ 1600 ERPM

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

Shaft Seal John Crane Type ND

Shaft Bearings Five pedestal mounted, Cooper split roller bearings

Number of Propellers 2

Number of Blades 4

Diameter 57.1”

Rudders None; Z-drive

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

285KW, 450V, 60 Hz, 1800 RPM

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

Hz, 1800 RPM

TANK CAPACITIES

Diesel Oil Capacity (100%) 16,385 gal

Fresh Water Capacity (100%) 7,339 gal

Lubricating Oil (100%) 86 gal xiii (Rev-0)

This page was left blank intentionally. Do not delete.

1 (Rev-0)

00000_PWB_0811_FLT

REC_0000_FLT_ Commercial Project @ CG Facility (0211)

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) M10360.3 (series), Jun 2006, Coatings and Colors

Manual

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

Requirements

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

Allied Processes

OTHER REFERENCES

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

Profile of Blast Cleaned Steel

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

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

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

Administration, Department Of Transportation

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

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

NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), May 1997, Requirements for

Fabrication, Welding, and Inspection of Submarine Structure

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

Surfaces Prepared by Dry Abrasive Blast Cleaning

3. REQUIREMENTS

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

2 (Rev-0)

NOTE

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

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

NOTE

NAVSEA approval is NOT required for welding procedures submitted but the procedures must be reviewed and shown to satisfy the requirements set forth in NAVSEA TP 1688, by a welding regulatory agency. The requirements for welding Weldox 900 shall be considered the same as those for welding HY-

3.3 HW disposal. The Contractor shall be responsible for all hazardous wastes generated by work under this contract. Label and package all hazardous 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.

3.3.1 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.

3.3.2 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.

3.3.3 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 in writing 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).

3.3.4 The Contractor shall be aware of the following:

3.3.4.1 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.

3.3.4.2 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 local and state regulations.

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

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

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

”critical-coated’ surface:

3 (Rev-0)

3.4.1 Coupon material and test set-up particulars.

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

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

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

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

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

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

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

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

Delivery rate and pressure settings.

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

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

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

The selected abrasive media type and size.

The nozzle size and type.

The delivery rate and pressure.

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

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

2 inches shall be recorded).

NOTES

1. A performance test of the abrasive blasting operations on a test coupon and measuring the resultant

4 (Rev-0) anchor profile prior to performing the abrasive blasting operation on the cutter is required. The test coupon will be used to evaluate the anchor profile produced by the equipment setup and selected abrasive media.

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

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

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

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

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

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

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

When Directed by the COTR.

CAUTION!

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

3.5 Interim changes to SFLC Std Spec 0000. The Contractor shall be aware of the following interim changes to the SFLC Std Spec 0000:

3.5.1 Contents of paragraph 3.3.2.1.1 (Water depth) have been revised to read as follows:

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

Ordinary low water mark on non-tidal rivers.

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

3.5.2 Paragraph 3.2.11.1 (Sanitary facilities for vessel-personnel – due to disruption of grey water system) has been revised as follows:

“3.2.11.1 Sanitary facilities for vessel-personnel – due to disruption of grey water and sewage systems.

When the shipboard grey water and sewage systems are disrupted due to repairs required by contract work, the Contractor shall provide vessel-personnel with a sanitary facility, within a five minute walking distance from the vessel, to include the amenities listed in Table II (Sanitary Facility

Amenities). Ensure the following:

Shower stalls are equipped with privacy screens.

5 (Rev-0)

Sinks are provided with fresh hot and cold water.

Electrical convenience GFI receptacles, in accordance with NFPA 70, National Electric Code (NEC), are located in vicinity of sinks.

Toilets have doors or privacy dividers.

Lockers are capable of being locked.”

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.

http://www.uscg.mil/directives/cim.asp

6 (Rev-0)

QA-1 – QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

Vessel Name Hull # Work Item # Work Item Title

Location of Work (incl. Frame #’s) Area (sqft)

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 mfgr.

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 mfgr.

CHECKPOINT 4 – PRE-SURFACE PREPARATION

Remove surface contaminants (soluble salts, loose rust, mud, and marine growth) with low pressure fresh water wash down

(maximum 5,000 psi). If oil and grease are present, perform solvent cleaning, as per SSPC SP-1.

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

CHECKPOINT 5 – SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

Threshold: 70 microsiemens/cm for non-submerged surfaces, 30 microsiemens/cm for submerged surfaces).

CHECKPOINT 6 – PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

Verify wet film thickness (WFT) at random, to prevent under or over application. Verify final DFT.

Brush out all runs, sags, drips, and puddles.

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

After primer coat (mist coat after inorganic zinc), brush-apply un-thinned coat of same primer paint over edges, weld seams, cut-outs, and areas of complex geometries @ 3-4 mils wet film thickness (WFT).

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

Verify wet film thickness at random, to prevent under or over application.

Brush out all runs, sags, drips, and puddles.

CHECKPOINT 9 – FINAL INSPECTION

Verify final system dry film thickness. Conduct 5 sets of 3 readings for each of the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area.

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

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

7 (Rev-0)

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/NACE Inspector Signature Cert. # Date / Time

8 (Rev-0)

QA-2 – QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

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

DATE &

TIME

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

LOCATION

(Frame &

Deck, relation to equipment, etc.)

TEMPERATURE % REL.

HUMID-

ITY DEW PT. SURFACE AMBIENT ΔT

| DP – Surface |

9 (Rev-0)

QA-3a – QUALITY ASSURANCE INSPECTION FORM

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

Location of Work (Frame References) Area (sqft)

SURFACE PREPARATION METHOD

PROFILE ACHIEVED (mils) Min Max Mean

SSPC-SP-10/NACE No. 2 SSPC-SP-12/NACE No. 5

SSPC-SP-3

SSPC-SP-11

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

Abrasive Manufacturer and Sieve Size: _________________________________

Place surface profile replica tapes in the spaces provided below, to serve as permanent QA record. Maintain a separate log for each 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

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

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

10 (Rev-0)

QA-3b – QUALITY ASSURANCE INSPECTION FORM

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

SURFACE PREPARATION METHOD

PROFILE ACHIEVED (mils) Min Max Mean

SSPC-SP-10/NACE No. 2 SSPC-SP-12/NACE No. 5

SSPC-SP-3

SSPC-SP-11

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

Abrasive Manufacturer and Sieve Size: _________________________________

Record measurements taken in the spaces provided below, to serve as permanent QA record. Maintain separate log for each location. When an area is divided into separate sections, maintain a separate log for each section.

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils Mean Mil Reading (IAW ASTM D4417-Method B) for above 10 readings (by column):

_____ mils _____ mils _____ mils _____ mils _____ mils

11 (Rev-0)

QA-4 – QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15

DATE TEST LOCATIONS CONDUCTIVITY

(microsiemens/cm)

12 (Rev-0)

QA-5 – QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

Coating Mfg Product Name Batch # Induction

Time Coating System Sequence

(Primer/Touchup/3 rd Coat, etc.)

DRY FILM THICKNESS (DFT) MEASUREMENTS IAW SSPC-PA 2

SPOT 1 2 3 4 5 AVERAGE

VALUE

*BASE METAL

READING (BMR)

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

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation 3 Before

Adjustments After Adjustments

Avg.

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation 3 Before

Adjustments After Adjustments

Avg.

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation 3 Before

Adjustments After Adjustments

Avg.

Application Method (Airless, Conventional Spray, Rolled) Average DFT

13 (Rev-0)

25610_MWC_0811_FLT

REC_25610_FLT_175 WLM (ALL) (1011)

WORK ITEM 1: SW Heat Exchangers, Clean, Inspect and Hydro

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to clean and inspect the following heat exchanger(s):

DESCRIPTION LOCATION QTY

Z-Drive Hyd. Fluid Cooler Prop. Thrust Room, 3-88-0-E 2 Z-Drive Lube Oil Cooler * Prop. Thrust Room, 3-88-0-E 1**

* Gasket part numbers 5330-01-449-2451 and 5330-01-449-2479, 2 each. All other coolers, see Coast Guard drawings for gasket requirements.

** Z-Drive L/O Cooler will be designated by CG Inspector

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

N Gasket 5330-01-449-2451 1 $22.53 N Gasket 5330-01-449-2479 1 $18.66 N Gasket 5330-01-124-8979 2 $11.89 N Gasket 5330-01-420-3726 2 $11.02

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 175-WLM 201-001, Rev C, Machinery Spaces Arrangment

Coast Guard Drawing 175-WLM 256-001, Rev H, Seawater Cooling System Diagram

Coast Guard Drawing 175-WLM 256-003, Rev D, Seawater Cooling System FR 61 Forward

Coast Guard Drawing 175-WLM 256-004, Rev J, Seawater Cooling System Arrangements and Details

Coast Guard Drawing 175-WLM 256-005, Rev -, Z-Drive Lube Oil Heat Exchanger Tube Bundle, Replacement and Piping Mods

Coast Guard Drawing 175-WLM 256-012, Rev A, Auxiliary Seawater System Piping Mods

COAST GUARD PUBLICATIONS

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

Coast Guard Technical Publication (TP) 3613, 245-A, Jan 1998, Z-Drive Model 1350-H

14 (Rev-0)

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

Requirements

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 5000, Jan 2009, Auxiliary

Machine Systems

Commercial Item Description (CID) A-A-59588, Jul 2005, Rubber Silicone

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.

3.1.3.1 Install blanks on the open ends of piping to prevent any contamination or foreign debris from entering the affected systems. Ensure that all cleaning equipment or media used in the cleaning process do not cause any damage to cooler components.

3.1.3.2 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):

Piping and hoses.

Filters.

Deck plating and associated framing.

Electrical cables.

Thermal insulation.

3.2 Environmental compliance. The Contractor shall dispose of all waste fluids in accordance with all Federal, state and local regulations. Document a complete chain of custody record of the removed tank contents and

15 (Rev-0) generated wastes, from the vessel to the point of final destination or delivery. Submit document to the COTR upon completion of work.

3.3 Disassembly. The Contractor shall drain and disassemble the designated heat exchangers (see paragraph 1.1

(Intent)), as specified by the CG Inspector to the extent necessary to perform all work specified herein. Refer to

Coast Guard Drawings 175-WLM 201-001, 175-WLM 256-001, 175-WLM 256-003, 175-WLM 256-004, 175-

WLM 256-005, and 175-WLM 256-012, and CG Tech Pub 3613 for guidance.

NOTE

The Contractor shall perform all disassembly and reassembly in accordance with manufacturer-recommended procedures using manufacturer-recommended tooling to ensure parts are reinstalled in proper sequence and configuration.

3.4 Inspection. Before cleaning is begun, the Contractor shall visually inspect all heat exchanger surfaces for excessive deterioration and any other defects. Submit a CFR.

3.5 Cleaning requirements. The Contractor shall clean all interior and exterior heat transfer surfaces to a state free of all debris, scale and surface contaminants in accordance with the heat exchanger manufacturer’s recommendations, and in compliance with all Federal, state, and local environmental regulations.

NOTE

The Contractor shall be aware that historically chemical cleaning has been necessary to thoroughly clean most heat exchanger tubes. The Contractor shall ensure that chemical cleaners do not damage the environment, heat exchanger or the vessel.

3.6 Reassembly. After authorized repairs, if any, the Contractor shall reassemble each heat exchanger. Renew all software (seals, gaskets, O-rings). Renew isolation fittings/mounts and fasteners if disturbed. Renew all hoses, thermostats and anodes as applicable. Apply silicone rubber sealant conforming to CID A-A-59588 around all fasteners, nozzles or gaskets that penetrate the hull. Refill all heat exchanger fluid levels in accordance with manufacturer and vessel specifications.

3.7 Reinstallation. After completion of testing and all authorized repairs, if any, the Contractor shall reinstall each cooler (if previously removed). Where applicable, renew all zinc electrode plates, gaskets, and recessed hex-head bolts in accordance with the manufacturer's specifications. Apply a copper-based anti-seize compound on all bolts, and torque in accordance with manufacturer’s specifications.

3.8 Touch-up preservation. The Contractor shall prepare and touch-up coat all disturbed surfaces of the heat exchangers, to match existing adjacent surfaces in accordance with COMDTINST M10360.3, Appendix B

(Cutters and Boats Interior Painting Systems). Abide by all touch-up requirements outlined in paragraph 3.11.9

(Touch-ups and minor coating repairs)) of SFLC Std Spec 0000, Appendix A (Requirements for Preservation of

Ship Structures).

3.9 Cleanliness requirement. The Contractor shall ensure that all cleaned surfaces are one hundred percent free of debris and surface contaminants.

3.10 Pressure test. After all authorized work is complete and prior to reconnecting the heat exchanger(s), the

Contractor shall pressure test each heat exchanger in the presence of the COTR, in accordance with paragraph

C2.7 (Heat exchangers and fluid coolers) of SFLC Std Spec 5000. Be aware that no leakage or permanent deformation of pressure-containing parts is permissible. Repair all leaks and discrepancies found. Submit a CFR.

3.11 Label plates. The Contractor shall attach an anodized aluminum test data plate to each heat exchanger using

16 (Rev-0) epoxy resin cement. Ensure that each plate is engraved with ¼-inch high letters, stating the following:

Test pressure.

Test date.

Testing facility.

NOTE and CAUTION!

1. If the heat exchanger design makes mounting a test data plate impractical, the Government reserves the right to request written documentation of the above-listed testing data in lieu of a test data plate, at no additional cost to the Government.

2. Extreme precaution must be taken to not exceed manufacturer’s recommended test pressure during hydrostatic testing!

3.12 Leak test. After reconnecting the heat exchanger(s) on the vessel (and post undocking, if applicable), the

Contractor shall perform an operational test of the heat exchanger and associated system piping for one hour using the system fluid at normal operating pressure. Be aware that no visible leakage or deformation is acceptable.

Repair all leaks and discrepancies found. Submit a CFR.

4. NOTES

This section is not applicable to this work item.

17 (Rev-0)

25901_0611_FLT

REC_25901_FLT_175 WLM (ALL) (0411)

WORK ITEM 2: Main Diesel Engine (MDE) Exhaust Stack Uptakes, Clean

1.1 Intent. This work item describes the requirements for the Contractor to clean the Main Diesel Engine (MDE) exhaust stacks.

1.2 Government-furnished equipment.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 175-WLM 259-001, Rev A, Combustion Exhaust Diagram

Coast Guard Drawing 175-WLM 259-005, Rev C, Combustion Exhaust A&D, Hull Block 970

COAST GUARD PUBLICATIONS

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

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

Requirements

OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not applicable.

18 (Rev-0)

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):

Access covers.

Exhaust stack.

MDE.

Piping.

Pipe insulation.

Vent ducting.

Wiring.

Exhaust pipe expansion joints.

Exhaust insulation blankets.

Engine Room Ventilation Motor

3.1.5 Scaffolding. The Contractor shall, in accordance with 29 CFR 1915, Subpart E, erect suitable staging or scaffolding, as required, to facilitate performance of work.

3.1.6 Safety precaution. The Contractor shall rig suitable safety netting, to protect workers during possible falls, and to protect the Engine Room and machinery from falling tools.

3.2 Work plan. The Contractor shall develop and submit, to the COTR, a plan for collecting and disposing of waste extracted during cleaning process. Ensure that the proposed plan shall detail how and where exhaust piping will be disconnected, how entire length of exhaust piping will be divided/sectioned for cleaning, and precautions to protect the MDE. The Contractor shall perform this work upon receiving Coast Guard approval of the plan.

3.3 Operational test – initial. Prior to commencement of work, the Contractor shall remove flange shielding and witness an operational pre-test (by Coast Guard personnel) of the exhaust stack system, to demonstrate existing operational condition. Submit a CFR.

3.4 Cleaning. The Contractor shall clean the interior surfaces of the exhaust piping to the MDE, shown on Coast

Guard Drawings 175-WLM 259-001 and 175-WLM 259-005, to a condition free from soot, tar, and any other foreign matter as follows:

19 (Rev-0)

3.4.1 Disconnect the exhaust piping as necessary to facilitate cleaning.

3.4.2 Thoroughly sweep, mechanically clean, and vacuum the interior of each exhaust pipe system, including the mufflers, from the exhaust outlet to the topmost location outside the vessel.