BOUTWELL_(WHEC_378W)_DS_BJR_13R0.doc

USCGC BOUTWELL & USCGC MUNRO (WHEC-378W) DOCKSIDE AVAILABILITY 2013

USCGC BOUTWELL (WHEC 719)

USCGC MUNRO (WHEC 724)

378 FOOT W HIGH ENDURANCE CUTTER

SPECIFICATION FOR MAIN REDUCTION GEAR DOCKSIDE REPAIRS

Developed By: Jennifer L Rest (Rev-0, 29 June 2012)

TABLE OF CONTENTS

iiiRevisions Record ivConsolidated List of References viConsolidated List of Government-furnished Property viiiConsolidated List of Critical Inspection Items ixPrincipal Characteristics

1General Requirements

19BOUTWELL WORK ITEM 1: NO. 1 Main Reduction Gear Overhaul and Accessory Drive Renewal

40BOUTWELL WORK ITEM 2: No. 1 Main Reduction Gear Lube Oil Cooler Clean and Inspect for Debris

45BOUTWELL WORK ITEM 3: REDUCTION GEAR HOT OIL FLUSH

52BOUTWELL OPTIONAL WORK ITEM 4: MAIN ENGINE LIFTING AND REALIGNMENT FINAL

60BOUTWELL WORK ITEM 5: Sea Trial Performance, Provide Support

64MUNRO WORK ITEM 6: NO. 1 Main Reduction Gear Overhaul and Accessory Drive Renewal

84MUNRO WORK ITEM 7: No. 1 Main Reduction Gear Lube Oil Cooler Clean and Inspect for Debris

89MUNRO WORK ITEM 8: REDUCTION GEAR HOT OIL FLUSH

96MUNRO OPTIONAL WORK ITEM 9: MAIN ENGINE LIFTING AND REALIGNMENT FINAL

104MUNRO WORK ITEM 10: Sea Trial Performance, Provide Support

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 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 Coast Guard Drawing 378-FRAM-W 262-2, Rev C, Diag LO Serv Sys Mn Prpln Eng, Dsl Gen & Red Gr Coast Guard Drawing 378-FRAM-W 262-4, Rev -, LO Serv Pip Prpln Dsl Eng, Dsl Gen & Red Gear a&D

(1) Coast Guard Drawing 378-FRAM-W 182-2, Rev -, Main Propulsion Fdns Plan & Elevations

(2) Coast Guard Drawing 378-FRAM-W 182-5, Rev B, Blts, Chcks Prpln Dsl, Gas Turb & Red Gr Arr & L/M Coast Guard Publications Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Coast Guard Technical Publication (TP) 3255I, 11-MAY-00, Manufacturer's Instruction Book, SWBS Group(s) 234 Coast Guard Technical Publication (TP) 3256B, Manufacturer's Instruction Book, SWBS Group(s) 241 Coast Guard Technical Publication (TP) 3257, Manufacturer's Instruction Book, SWBS Group(s) 241-242 Coast Guard Technical Publication (TP) 3254A, Manufacturer's Instruction Book, SWBS Group(s) 233 Coast Guard Technical Publication (TP) 3254B, Manufacturer's Instruction Book, SWBS Group(s) 233Coast Guard Technical Publication (TP) 3257, Manufacturers Instruction Book, SWBS Group(s) 241-242 Coast Guard Technical Publication (TP) 3257, Manufacturers Instruction Book, SWBS Group(s) 241-242 Other References The Society for Protective Coatings SSPC-SP 1, 11/1/2004; Solvent Cleaning The Society for Protective Coatings SSPC-SP 3, 11/1/2004; Power Tool Cleaning Naval Ship's Technical Manual (NSTM) Chapter 241, Mar 2004, Propulsion Reduction Gears, Couplings, Clutches, And Associated Components Naval Ship's Technical Manual (NSTM) Chapter 254, May 2006, Condensers, Heat Exchangers and Air Ejectors Naval Sea Systems Command (NAVSEA) T9074-AS-GIB-010/271, Apr 1997, Requirements for Nondestructive Testing Methods Naval Ship's Technical Manual (NSTM) Chapter 241, Mar 2004, Propulsion Reduction Gears, Couplings, Clutches, And Associated Components Naval Ship's Technical Manual (NSTM) Chapter 262, Dec 2001, Lubricating Oils, Grease, Specialty Lubricants, And Lubrication Systems Consolidated List of Government-furnished Property

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

($/Unit)

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

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

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

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

Work Item Title

BOUTWELL NO. 1 Main Reduction Gear Overhaul and Accessory Drive Renewal

MUNRO NO. 1 MAIN REDUCTION GEAR OVERHAUL AND ACCESSORY DRIVE RENEWAL

PC_378W_WHEC_719_1109

378W WHEC (BOUTWELL)

Physical Characteristics

Hull Characteristics

Material

Machinery Characteristics

engines; 235 RPM max on Gas turbines

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

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

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

Tank Capacities

Principal Characteristics

378W WHEC (MUNRO)

Physical Characteristics

Hull Characteristics

Material

Machinery Characteristics

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

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

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

Tank Capacities

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00000_PWB_0312_FLT

REC_0000_FLT_ Commercial Project @ CG Facility (0212) General Requirements

1. SCOPE

1.1 Intent. This item describes the general requirements to be followed by the Contractor while conducting this availability.

2. REFERENCES

Coast Guard Drawings None.

Coast Guard Publications Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Other References ASTM International (ASTM) D4417, 2003, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel Commercial Item Description (CID) A-A-59316, Nov 2003, Abrasive Materials for Blasting Federal Standard (FED-STD) 595, 2008, Colors Used In Government Procurement 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 Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation

3. REQUIREMENTS

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

NOTE

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

3.2 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

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

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

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-130

3.4 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.

3.4.1 The Contractor shall dispose of all waste IAW all local applicable Navy Regulations. The Coast Guard is not responsible for the handling of any waste generated by the contractor.

3.4.2 The Coast Guard will NOT provide or assist the contractor in attaining an EPA facility ID, it is the contractors responsibility to manage that.

3.4.3 Deleted paragraph.

3.4.4 The Contractor shall be aware of the following:

3.4.4.1 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.

3.4.4.2 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.

3.5 Interim changes and additions to SFLC Std Spec 0000. The Contractor shall be aware of the following interim changes and additions to the 2009 Edition of SFLC Std Spec 0000:

3.5.1 Acronyms and term definitions – paragraph 1.3 (Acronym and term definitions).

3.5.1.1 The term “COR” has been replaced with “COR”, which is defined as follows:

“COR”: Contracting Officer’s Representative – the person delegated by the KO as the on-scene representative for matters concerning performance of work; this includes correctness, timeliness, and quality of the Contractor’s work. Normally, the CO/OINC is designated the COR.”

3.5.1.2 Definition addition for the term “Ungrounded, as follows:

· “Ungrounded”: A power system where all of the current-carrying conductors and windings (including any neutral connection) are insulated from ground. In contrast, a generator or transformer in which at least one conductor or point (usually the midpoint or corner of a delta winding or the common center of a wye winding) is intentionally grounded, either solidly or through an impedance, is considered grounded. Note that the distinction concerns only current-carrying conductors; for both ungrounded and grounded power systems, non-current carrying metal parts and equipment grounding conductors are always bonded to earth ground for personnel safety. At non-Governmental facilities, dockside wye connected transformer secondary windings are almost always grounded and are generally not suitable for connection to a Coast Guard cutter without a separate Contractor furnished isolation transformer.”

3.5.2 Changes to paragraph 3.2.4 2.3 (QP-1 Inspector or Tech Rep duties).

“3.2.4.2.3 QP 1 Inspector or Tech Rep duties.

3.2.4.2.3.1 The Coating Inspector for the “QP 1-certified” Contractor or the Contractor-provided NACE-certified Tech Rep shall remain on site, to perform the following duties, as applicable, for each work item that involves preservation of “critical-coated surfaces”:

· Verify inspection instrument calibration.

· Verify and approve the suitability of ambient conditions before surface preparation is begun, and before each coat of paint is applied.

· Verify all aspects of surface preparation – including, but not limited to:

· Cleanliness of compressed air.

· Adequacy of solvent cleaning.

· Proper handling of blast media.

· Actual surface preparation procedure.

· Inspect and approve final surface preparation, before application of primer coat.

· Supervise and approve coating system preparation and application procedures, including but not limited to: mixing and thinning, stripe coating application, spray techniques, and film thickness measurements and recordings.

· Determine when applied coats have sufficiently cured for overcoating, or for system service resumption (see paragraph A2.1.18 (Critical drying time requirements)).

· Complete and sign the quality assurance (QA) inspection forms (see QA-1 thru QA-5), provided in Appendix A (Requirements for Preservation of Ship Structures) of this document.

· Submit all completed QA inspection forms to the COR (through the Contractor), upon completion of work.

3.2.4.2.3.2 The Contractor shall ensure the NACE Inspector is formally informed - via suitable subcontract documentation- and is willing and able to perform of all duties listed above. Submit documentation of this contract and assumption of duties to the KO at the Arrival Conference.”

3.5.3 Changes to contents of paragraph 3.2.5 (Planning document).

“3.2.5 Planning document. The Contractor shall generate a legible Planning Document (PD) with the following characteristics:

· Graphical in format (see Fig. 1 (Sample Planning Document Submittal)).

· Shows overall period of performance for each CLIN, with start and stop dates of major sub-tasks.

· Contains due dates for Critical Inspection Reports (CIR) and any events requiring Coast Guard Inspector presence.

· Identifies all work item time periods that require OEM Tech Rep assistance.

· Identifies the “critical paths” for the project.

· Shows calculations for the “float” along the critical paths and labels the critical paths with the number of delay days the critical paths can absorb without affecting the final delivery date.

NOTE

Float is the number of days that the critical paths can be delayed without affecting the final delivery date.

3.2.5.1 Ensure that the PD also includes the names, contact information, and written commitment from all Tech Reps required by the Contract - indicating they are available for work during the proposed time period.

3.2.5.2 Submit a preliminary electronic copy of the PD to the COR - for Government review - no later than one week after contract award.

3.2.5.3 Submit 3 copies of the PD to the COR, 15 days prior to the start of the performance period, and at all weekly Progress Meetings.

NOTE

A separate document, specifically prepared for the Government is not desired or required. A copy or summary of the Contractor’s internal scheduling document is preferred.

FIG. 1 - SAMPLE PLANNING DOCUMENT SUBMITTAL

3.2.5.4 When the critical path extends beyond or encroaches upon the final delivery date, provide a resource constraint and scheduling evaluation of the critical path before any request for extension will be entertained. Submit the resource constraint and scheduling evaluation via a CFR.

NOTE

The intent of the resource constraint and scheduling evaluation is to identify the resources necessary to ‘crash’ the critical path or make adjustments to the production schedule to meet the delivery date in lieu of a project extension.”

3.5.4 Additional sub-paragraphs to paragraph to 3.2.6.5 (Inspection report particulars).

“3.2.6.5.3 CFR tracking system. The Contractor shall create and maintain a CFR tracking system for the project. At a minimum, ensure that the CFR tracking system shall list all required reports, broken down by the following:

· Work item and paragraph number.

· Due dates.

· Submission dates.

· CFR/CIR submission number.

3.2.6.5.3.1 Be aware that the COR will respond via the CFR reply as to whether the CIR/CFR ‘fully’ or ‘partially’ satisfied the inspection and reporting requirements in the associated work item.

3.2.6.5.3.2 When submitting a CFR, ensure that the applicable work item and paragraph number for which the inspection report is being submitted is included on the CFR.

3.2.6.5.3.3 Submit a copy of the CFR tracking sheet to the COR at the arrival conference.

3.2.6.5.3.4 At a minimum the Contractor shall update and submit a copy of the CFR tracking sheet to the COR the day before each weekly progress meeting. At the required CFR due date, submit the CFR tracking sheet to the COR via a CFR for review and formal archiving with the project records.”

3.5.5 Changes to contents of paragraph 3.2.11.1 (Sanitary facilities for vessel-personnel due to disruption of grey water and sewage systems).

“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.

· 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.”

3.5.6 Changes to contents of paragraph 3.3.2.1.1 (Water depth).

“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.).”

3.5.7 Electrical compliance planning.

“3.3.14 Electrical compliance planning. For cutter availabilities, the Contractor shall submit to the KO the following electrical compliance planning documentation during the pre-award phase of the contract.

3.3.14 1 Shore power. When ungrounded shore power is to be provided per SFLC Std Spec 8635, provide a one line electrical diagram showing how such power will be supplied, including the winding and grounding configuration and rating of any generator or isolation transformer. For drydock availabilities, separate diagrams should be submitted for waterborne and non-waterborne periods.

3.3.14.2 Arc welding. When electric arc welding is to be performed per SFLC Std Spec 0740 while the vessel is waterborne, provide a diagram showing the general proposed location of each welding machine, the grounding configuration of each machine, and the return current conductor size and length. For drydock availabilities, separate diagrams may be necessary for waterborne and non-waterborne periods.

3.3.14.3 Hull bonding and lightning protection. For work periods while the vessel is not waterborne, provide a diagram showing how the hull grounding straps required by SFLC Std Spec 8635 will be sized (length and gauge) and connected.

3.3.14.4 Tool and equipment power. Provide a diagram showing how Contractor tool and equipment power will be supplied and distributed for dockside and shipboard use in accordance with SFLC Std Spec 0450. For drydock availabilities, separate diagrams should be submitted for waterborne and non-waterborne periods.”

3.5.8 Changes to paragraph to A2.1.1.3 (Document submission).

“A2.1.1.3 Document submission.

A2.1.1.3.1 For all work involving preservation of “critical-coated surfaces”, ensure the following is submitted to the COR at the Arrival Conference, for each coating system intended to be applied:

· Coating system manufacturer’s name.

· Product data sheets.

· MSDS.

· COC.

A2.1.1.3.2 Documentation shall be broken out by work item, to also include the following information:

· Brand name.

· Color.

· Intended mil thickness.

· Time between coats.

· Intended final cure time prior to immersion or full duty rating, as applicable.

A2.1.1.3.3 For work involving preservation of surfaces not designated as “critical-coated surfaces”, submit all product data sheets, MSDS, and COC to the COR, prior to commencement of work.”

3.5.9 Requirements changes to paragraphs A2.1.5 (Tenting) and A2.1.6 (Ambient condition control).

“A2.1.5 Tenting and ambient condition control – “for critical-coated surfaces”.

A2.1.5.1 When the ambient condition parameters necessary for full paint cure or to meet environmental conditions, as required in paragraph A.2.1.4 (Ambient condition parameters), cannot be met for successful application and curing of “critical-coated” surface coating systems, the Contractor shall provide the following, at no additional cost to the Government:

· Suitable tenting, as applicable, for exterior surface preservation.

· Suitable ambient condition control equipment, which may include, but not be limited to the below-listed, to create and maintain ambient conditions recommended by the coating system’s manufacturer, and facilitate successful coating application and curing.

· AC system.

· Heaters.

· Blowers.

· Dehumidifiers.

A2.1.5.2 Submit an ambient condition control plan to the COR within 24 hours prior to initiating ambient condition control process

NOTE

The Contractor is expected to be aware of the advent of environmental conditions that are adverse to preservation of critical-coated surfaces and include all costs in

3.5.10 Pre-surface preparation requirements – additional to paragraph A2.1.7 (Pre-surface preparation requirements).

“A2.1.7.4 Coupon test. 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:

A2.1.7.4.1 Conduct a performance test on all abrasive blasting operations on a Contractor- provided test coupon, prior to starting abrasive blasting operations on the vessel. Use a new metal plate, of the same metal type and material properties as the area to be blasted, steel or aluminum plate, as applicable. For steel plates, the new plate shall have the mill scale intact and the plate will be in a Rust Grade "A" condition, per the SSPC-VIS 1 visual standard cards. No existing anchor profile, other than the surface irregularities from the manufacturing process are permitted on the test coupon. 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. The test coupon shall be affixed so as to not permit excessive movement during the performance test.

CAUTION!

Do not affix the coupon to the vessel nor shall the blast media from the performance test strike the vessel during the test A2.1.7.4.2 Ensure that the abrasive blasting operation test on the test coupon is with the very same setup that will be used to blast the vessel. The setup shall include, but not be limited to:

· The abrasive media to be used (material and media size).

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

· Delivery rate and pressure settings.

A2.1.7.4.3 Blast an one-square foot area on one side of the test coupon to the abrasive surface preparation standard specified in the applicable work item and perform an anchor profile test of the blasted surface in accordance with ASTM D4417, method A or C. Notify the COR in advance of the abrasive blasting operation test, to permit the witnessing of the test by appropriate Coast Guard personnel. Submit a CFR documenting the results of the abrasive blasting operation test. CFR shall include at a minimum, the following:

· Area of the vessel that the verified setup will be used to abrasive blast with.

· The abrasive media used.

· 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.

NOTES

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

2. The reverse side of the test coupon may be used for the subsequent test, provided that the conditions in paragraph A2.1.7.4 (Coupon test) are met.

A2.1.7.4.3 Repeat the abrasive blasting operation test in the following instances:

· The setup, as defined in paragraph A2.1.7.4.1 is 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 COR.

NOTE

A performance test of the abrasive blasting operations on a test coupon and measuring the anchor profile prior to performing the operation on the cutter, in order to confirmed that the anchor profile range that the operation is going to produce. An abrasive blasting operation test is prudent, as there are enough variables in the equipment setup and media properties that the resulting anchor profiles from one contractor to the next vary significantly.

3.5.11 Post-surface preparation requirements - additional to paragraph A2.1.8 (Post-surface preparation requirements).

A2.1.8.8 Substrate profile measurements - during and post-surface preparation. 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 for complete preservation of a ”critical-coated” surface:

A2.1.8.8.1 During surface preparation by abrasive blasting or waterjetting operations, spot check the existing anchor profile per 500-square feet, in order to 'project' the need to manage the excessive anchor inspect for both excessive and insufficient anchor profiles . When the Contractor elects to prepare a substrate by waterjetting, the Contractor shall inspect the substrate for areas of insufficient or excessive anchor profile, both visually and in accordance with ASTM D4417, Method A or C. Submit a CFR detailing the location, square footage, measured anchor profiles, and the anchor profile range required for the applicable coating system.

A2.1.8.8 2 Post completion of surface preparation, measure the profile of the resultant bare surfaces, in accordance with ASTM D4417, Method A or C.”

3.5.12 Caution verbiages – additional to paragraph A2.1.18 (Critical drying and cure time requirements).

“CAUTIONS!

1. Hard cure times or cure time prior to immersion for any “critical coated system” shall be met as published on the Product Data Sheets available online. No early undocking or relaxation of these published requirements is permitted without prior approval from the KO. Coating system manufacturer’s Sales or Technical Representatives may not relax these requirements. Painting and curing of all tank coating systems (except for tanks that are inboard and not touching the skin of the vessel (side and/or bottom) shall occur while the cutter is out of the water.

2. CAPAC systems shall not be energized until full cure of all underwater paint systems has occurred.”

3.5.13 Preservation Plan.

“A2.2 Preservation Plan (PP). The contractor shall submit a PP to the COR at the arrival conference, to allow for review of all work items pertaining to the preservation of the vessel. At a minimum, PP shall include the following and be broken down by work item:

· Coatings to be applied – listed by manufacturer and product identification numbers.

· Target wet and dry film thickness values.

· Authorized reducers/solvents - including maximum percent by volume for reducers/solvents.

· Colors by FED-STD-595 color number.

· Application method for each coat.

· Application pressure and nozzle size requirements listed on the manufacturer’s product data sheet(s).

· Minimum recoat windows for applying subsequent coats, maximum recoat windows to apply subsequent coats, adjusted for anticipated temperatures.

· Any special instructions or environmental limits listed by the coating manufacturer.

· Intended final cure times prior to immersion or full duty rating (as applicable).”

3.5.14 Changes to paragraph B2.2.3.3.1.

“B2.2.3.3.1 Do not release lead or lead-contaminated materials into the environment. Conduct periodic air monitoring (as appropriate) for lead in the worker’s breathing zone, during the course of any abatement work involving lead containing materials, to prevent exposure at or above the PEL. Submit results of all air monitoring samples to the COR, within 24 hours of completion of sampling.”

3.5.15 Booming requirements during the offload or on-load of petroleum products.

“B2.2.10 Booming requirements during the offload or load of petroleum products. The Contractor shall provide a containment boom system and boom off the cutter during all petroleum cargo on-loads and offloads. The cutter shall be boomed off by the contractor during both shipyard functions and the final bunkering of the cutter by ship's force. The contractor is responsible to provide the labor to deploy and recover the boom during all operations, including operations conducted by ship's force. The containment boom shall at a minimum, fullly encapsulate the cutter from the pier wall in front of the cutter to the pier wall at the stern of the cutter. When moored alongside a pier that does not provide a fully intact pier wall that will contain a spill, the containment boom shall wrap completely around the cutter on all sides to provide spill containment. For tug and barge configurations, the containment boom shall encapsulate both the cutter and the barge, as applicable.”

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)

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.

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.

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.

| DP - Surface |

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

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: ______________

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

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.

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

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY Measurements IAW SSPC-GUIDE 15

(microsiemens/cm)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

Dry Film Thickness (DFT) Measurements IAW SSPC-PA 2

*BASE METAL READING (BMR)

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

Location (Frame Reference): ___________________

Overall Avg. DFT

ADJUSTMENTS

Avg.

Overall Avg. DFT

ADJUSTMENTS

Avg.

Overall Avg. DFT

ADJUSTMENTS

Avg.

Snn-nnn_24100_JAH_1110_378W_7xx

BOUTWELL WORK ITEM 1: NO. 1 Main Reduction Gear Overhaul and Accessory Drive Renewal1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew bearings in the No. 1 Main Reduction Gear and to renew the accessory drive gear.

1.2 Government-furnished property.

($/UNIT)

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

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

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

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 378-FRAM-W 801-1, Rev -, Booklet of General Plans Coast Guard Drawing 378-FRAM-E 85-1, Rev -, Booklet of General Plans Coast Guard Drawing 378-FRAM-W 602-100, Rev -, Visual Identification Coast Guard Publications Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Coast Guard Technical Publication (TP) 3255I, 11-MAY-00, Manufacturer's Instruction Book, SWBS Group(s) 234 Coast Guard Technical Publication (TP) 3256B, Manufacturer's Instruction Book, SWBS Group(s) 241 Coast Guard Technical Publication (TP) 3257, Manufacturer's Instruction Book, SWBS Group(s) 241-242 Other References The Society for Protective Coatings SSPC-SP 1, 11/1/2004; Solvent Cleaning The Society for Protective Coatings SSPC-SP 3, 11/1/2004; Power Tool Cleaning Naval Ship's Technical Manual (NSTM) Chapter 241, Mar 2004, Propulsion Reduction Gears, Couplings, Clutches, And Associated Components

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph(s). These checks must be completed as noted in the below sections of the specification:

· 3.11 Preliminary Shaft Alignment Check. Must be completed within 2 days of start of contract.

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

· Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

· Assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

3.1.2.1 The Contractor shall ensure that the Tech Rep is a certified representative of Philadelphia Gear Corporation.

3.1.2.2 The Contractor shall submit the name of the Tech Rep to the COR at the Arrival Conference.

3.1.3 Protective measures.

3.1.3.1 The contractor will take all special protective measures required, including tarping and masking to ensure that contaminants are not introduced into the reduction gear casing.

3.1.3.2 In accordance with SFLC Standard Spec 0000 paragraph 3.3.3, the contractor will provide adequate protection to all deck covering or deck surfaces in areas where the work under items of these specifications is being accomplished and on all main access routes to these areas.

3.1.3.3 See additional measures for contamination protection noted in Section 3.6 below.

3.1.4 Interferences. None

3.2 General Information

During a recent inspection, it was noted that the accessory drive spur gear on the No. 1 Main Reduction Gear was damaged and needed to be changed out. Additionally, the bearings and gears of each of the accessory drives (tachometer drive, gear driven water pump drive, gear driven oil pump drive, and gear driven servo pump drive) will be disassembled and overhauled. All Babbitt journal bearings supporting all shafts will be removed and inspected as a part of this work.