Crane_Specification _posted.doc

American Aero Oceanmaster CG-300 Crane

SPECIFICATION FOR OVERHAUL AND REPAIR

FY2015

Developed By: Thurston B. Sumner III and Paul W Beausejour (Rev-0, 4 March 2015)

TABLE OF CONTENTS

iiiRevisions Record ivConsolidated List of References viConsolidated List of Government-furnished Property viiConsolidated List of Critical Inspection Items viiiPrincipal Characteristics

1General Requirements

10WORK ITEM 1: CG-300 Equipment and Components, Inspect and Service

21WORK ITEM 2: CG-300 Upper Works Equipment and Components, Inspect and Service

40WORK ITEM 3: CG-300 Boom, Inspect and Service

43WORK ITEM 4: Technical On-Site Support and Diagnostics, Provide

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 FL 9210-1, Rev -, Weatherford Marine CG 300 Crane

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST)_M10360.3 (series), Coatings and Color Manual

Coast Guard Technical Publication (TP) 1952B, SWBS 589, Section A, Sep 2008, Construction Crane, Oceanmaster CG300

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2014, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, And Installation

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2014, Inspect, Repair, And Test Auxiliary Machine Systems

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

ASTM International (ASTM) 6966, 2008, Standard Practice for Collection of Settled Dust Samples Using Wipe Sampling Methods for Subsequent Determination of Metals

Code of Federal Regulations (CFR) Title 29, Part 1910, Jul 2008, Occupational Safety and Health Standards

Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) C6183, 2007, Cork and Rubber Composition Sheet; For Aromatic Fuel And Oil Resistant Gaskets The Society for Protective Coatings (SSPC) Surface Preparation Specification No.11 (SSPC-SP 11), 2004, Power Tool Cleaning to Bare Metal

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 task order contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)):

Principal Characteristics

Principal Characteristics

American Aero Oceanmaster CG300 Marine Crane

CRANE

PRIME MOVER

PUMPS

00000_0215_FLT

REC_00000_FLT_ MATOC Dockside (1014) General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel equipments repairs performed at a commercial contractor’s facility for Coast Guard vessels.

1.2 Term interchangeability. The terms 'Contractor', 'CG Yard', 'NAVSTA EVERETT', 'shipyard', 'Base', and 'Coast Guard Industrial' are used interchangeably in this specification. Where the primary service provider is Coast Guard personnel, references to contractor and other noted descriptors within this specification or within drawings, publications, SFLC Standard Specifications or other commercial and military references are deemed the same as prime service provider.

2. REFERENCES

Coast Guard Drawings

None

Coast Guard Publications

Coast Guard Commandant Instruction (COMDTINST)_MI0360.3 (series), Coatings and Color Manual

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

Other References

ASTM International (ASTM) 6966, 2008, Standard Practice for Collection of Settled Dust Samples Using Wipe Sampling Methods for Subsequent Determination of Metals

Code of Federal Regulations (CFR) Title 29, Part 1910, Jul 2008, Occupational Safety and Health Standards

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

Code of Federal Regulations (CFR) Title 33 CFR, Jul 2013 Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, 2013, Protection of the Environment Code of Federal Regulations (CFR) Title 49, Oct 2013, 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 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.

3.3 Preservation requirements. The Contractor shall accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec 6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

3.3.2 Coating colors and system color schemes. Ensure that all colors and color coat/paint schemes are in accordance with (COMDTINST)_MI0360.3C , Chapter 11 (Cutter and Boat Colors Exterior and Interior).

NOTE

Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes (provided in Chapter 5 of COMDTINST MI0360.3) are strictly prohibited.

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

3.5 Environmental protection requirements. The Contractor shall adhere to the following environmental protection requirements in accordance with the SFLC Stand Spec 0000:

3.5.1 Contractor operated (non USCG) facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix A, Requirements for Environmental Protection at Contractor Operated (Non USCG) Facilities, as applicable, during the performance of this availability. Contractor shall plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor shall comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.2 Test and procedures. The Contractor shall be required to promptly conduct tests and procedures for the purpose of assessing whether operations are in compliance with applicable Environmental Laws. Analytical work shall be done by qualified laboratories; and where required by law, the laboratories shall be certified.

3.5.3 Regulatory notifications. The Contractor shall be responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The Contractor shall submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications shall be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

3.5.4 Environmental manager. The Contractor shall appoint in writing an Environmental Manager for the project, and shall be responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager shall ensure compliance with Hazardous Waste Program requirements, including hazardous waste handling, storage, manifesting, and disposal; implement the Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to adequately accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas; ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the Environmental Records binder and required documentation, including environmental permits compliance and close-out.

3.5.5 HW disposal. Contractor shall comply with SFLC Std Spec 0000 Appendix A, Requirements For Environmental Protection At Contractor Operated (Non USCG) Facilities for HW disposal.

3.6 Local Policy. None.

3.7 SFLC standard specification approved changes. The Contractor shall be aware that the following are approved changes to published SFLC 2014 Edition Standard Specifications and supersede published content: None.

4. NOTES

4.1 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 6310 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 SFLC Std Spec 6310, 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-containing 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-11, SP-10, SP WJ-2…).

Verify surface anchor profile using ASTM D4417-Methods B or C against SFLC Std Spec 6310. 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 WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

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 WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

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.

ADJUSTMENTS

Avg.

ADJUSTMENTS

Avg.

58900_CG300EqpmntCmpnts_TBS_0215_IBCT

WORK ITEM 1: CG-300 Equipment and Components, Inspect and Service

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect and service designated associate equipment and components contained within the Kit Box.

1.2 Government-furnished property.

($/UNIT)

2. REFERENCES

Coast Guard Drawings

None

Coast Guard Publications

Coast Guard Technical Publication (TP) 1952B, Section A, Construction Crane, Oceanmaster CG300

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2014, Inspect, Repair, And Test Auxiliary Machine Systems

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

Other References

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following task(s) in Table 1:

· Task # 1.

· Task # 2.

· Task # 4.

· Task # 5.

· Task # 6.

· Task # 7.

· Task # 8.

· Task # 10.

· Task #11.

· Task #12.

· Task #13.

· Task #29.

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures-general. The Contractor shall furnish and install all protective coverings to seal off and protect all components and equipment against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment and components to original condition of cleanliness.

NOTE

Plastic bags may be used only when arrangement or configuration prevents the use of the other sealing methods specified above.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.2 Inspection and service particulars. The Contractor shall perform the tasks specified in Table I, in accordance with SFLC Std Spec 5000 and CG TP 1952. Renew all gaskets, O-rings, seals, plugs, cotter pins, and fasteners during reassembly.

NOTE

Contractor has the option to renew vs. Disassemble and Inspect if it is more cost advantageous at no additional cost to the Government

TABLE 1 – Recurring TASKS

ADDITIONAL REQUIREMENTS

In accordance with TP-1952B

2. Load post kit disassembly, inspect, and renew. Inventory shall be secured within kit as applicable with new type 316L Stainless Steel Fasteners.

3. Complete pre-shipment inspection and inventory, secure kit box top with new type 316L Stainless Steel Fasteners and rubber tie downs.

4. Kit shall be made ready for CG procured shipping and loaded as required.

3.2.4 (Preservation) Submit a CIR.

3.2.3 (Disassemble and Inspect)

3.2.4 (Preservation)

C2.4 (Valves and Manifolds) Submit a CIR.

Adjust Counterbalance manifold setting in accordance with CG TP 1952B.

3.2.4 (Preservation)

C2.4 (Valves and Manifolds) Submit a CIR.

3.2.4 (Preservation)

C2.4 (Valves and Manifolds) Submit a CIR.

3.2.4 (Preservation)

C2.4 (Valves and Manifolds) Submit a CIR.

3.2.4 (Preservation) Submit a CIR.

Submit a CFR.

3.2.4 (Preservation) Submit a CIR.

Contractor shall ensure swing drive plate is machined to fit CG-300 crane.

3.2.4 (Preservation) Submit a CFR.

3.2.4 (Preservation) Submit a CFR.

3.2.5 (NDE)

3.2.4 (Preservation) Submit a CFR.

3.2.5 (NDE)

Submit CFR.

3.2.2 (Service and inspect)

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.5 (NDE)

Submit a CFR.

3.2.4 (Preservation)

C2.4 (Valves and Manifolds) Submit a CIR.

C2.5 (Gages)

B2.9 (Label Plates) Perform weight testing.

See Table 2 below for requirements.

Submit CFR.

Submit two copies of final reports - one to the COR, and the other, to be shipped with the Kit Assembly.

Reports shall include but are not limited to:

· Kit Inventory, Weight and Speed Test Results.

· Wire Rope Certification, Gauge and Meter Certification, and Fastener Certifications.

NOTE

Contractor personnel will complete all weight tests.

TABLE 2 – WINCH TEST WEIGHTS

Main Hoist Test Weights

3.3 Additional maintenance requirements. The Contractor shall perform tasks in Table 3 when authorized by the KO. Submit CFR to document all inspections and recommended additional repairs. Combine or group CFR, as required, to minimize administrative burden and maximize efficiency.

Tasks will be exercised via authorized and released Change Requests (CR), when determined to be necessary by inspection results.

TABLE 3 – ADDITIONAL MAINTENANCE Requirements

ADDITIONAL REQUIREMENTS

TASK

C2.4 (Valves and Manifolds)

4. NOTES

This section is not applicable to this work item.

58900_CG300UpprWrks_TBS_0215_IBCT

WORK ITEM 2: CG-300 Upper Works Equipment and Components, Inspect and Service

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect and service the Upper Works for the Oceanmaster CG300 Marine Crane.

1.2 Government-furnished property.

($/UNIT)

Coast Guard Drawing FL 9210-1, Rev -, Weatherford Marine CG 300 Crane

Coast Guard Publications

Coast Guard Technical Publication (TP) 1952B, SWBS 589, Section A, Sep 2008, Construction Crane, Oceanmaster CG300 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2014, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, And Installation

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2014, Inspect, Repair, And Test Auxiliary Machine Systems

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

Other References

Society of Automotive Engineers (SAE) Aerospace Material Specification (AMS) C6183, 2007, Cork and Rubber Composition Sheet; For Aromatic Fuel And Oil Resistant Gaskets

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following locations:

· Table 1,Task # 1.

· Table 1,Task # 2.

· Table 1,Task # 3.

· Table 1,Task #9.

· Table 1,Task #10.

· Table 1,Task # 12.

· Table 1,Task # 14.

· Table 1,Task #15.

· Table 1,Task # 16.

· Table 1,Task # 17.

· Table 1,Task # 18.

· Table 1,Task # 19.

· Table 1,Task #20.

· Table 1,Task #21.

· Table 1,Task # 22.

· Table 1,Task #23.

· Paragraph 3.3.1 (Visual inspection, operational testing and diagnostics).

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures-general. The Contractor shall furnish and install all protective coverings to seal off and protect all components and equipment against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment and components to original condition of cleanliness.

NOTE

Plastic bags may be used only when arrangement or configuration prevents the use of the other sealing methods specified above.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.2 Inspect and service task particulars. The Contractor shall perform the tasks specified in Table 1, in accordance with SFLC Std Spec 5000 and CG TP 1952, as applicable.

TABLE 1 – Recurring TASKS

ADDITION REQUIREMENTS

TASK

3.2.5 (NDE)

3.2.4 (Preservation)

1. Disassemble and remove entire cab to all allow for inspection and complete preservation of all previously-painted components.

Submit a CIR.

2. During reassembly, renew of as applicable, the following cab assembly components shown on Coast Guard Fleet Drawing FL-9210-1 and the drawings in CG TP 1952B but not limited to the below items:

· Fluid, Fluid filters, strainers, and associated mounting hardware.

· Diesel engine components: including the hot starts, flanged exhaust flex pipe (3-inch stainless steel), muffler, engine mounts, and associated mounting hardware.

· Seat assembly and associated mounting hardware.

· All hydraulic fittings.

· Cab deck plates

· All pins, sheaves, keepers, shafts, plates, spacers, rollers, and associated mounting hardware.

· All gaskets, O-rings, seals, plugs, cotter pins, stuffing tubes, chaffing gear, and fasteners.

3.2.5 (NDE)

Submit a CIR.

In accordance with TP-1952B, Ensure boom stops have a clearance notch is machined on both sides of the boom stop bases to allow adequate clearance of the operator cab (left side) when lowered to 0 degrees and the topping lift wire rope clears (Right Side).

3.2.5 (NDE)

3.2.4 (Preservation)

D2.4.1 Open Gearing Lubrication Submit a CIR.

Rotate bearing during lubrication to ensure proper application.

Reinstall the ball ring assembly with new internal and external certified bolts and Type 316L Stainless Steel washers in accordance with TP 1952B (Bolt Torque and Installation Procedure).

Components shall be renewed prior to the closing of tanks as applicable.

All renewals shall be in accordance with CG TP-1952

C2.5.2 (Calibration)

Submit a CIR.

Refer to SFLC Std Spec 3042.

Renew all stuffing tubes.

Renew all labels.

3.2.3 (Disassemble and Inspect)

Submit a CIR.

3.2.3 (Disassemble and Inspect)

C2.4 (Valves and Manifolds) Submit a CIR.

Adjust Counterbalance manifold setting in accordance with CG TP 1952B.

B2.3 (Winches) Perform weight testing listed in Table 5.

Submit a CFR.

3.2.4 (Preservation)

C2.4 (Valves and Manifolds) Submit a CIR.

3.2.4 (Preservation)

C2.4 (Valves and Manifolds) Submit a CIR.

3.2.4 (Preservation)

C2.4 (Valves and Manifolds) Submit a CIR.

3.2.4 (Preservation) Submit a CIR.

3.2.4 (Preservation) Submit a CIR.

Ensure swing drive plate is machined to fit CG-300 crane.

3.2.4 (Preservation) Submit a CIR.

3.2.4 (Preservation) Submit a CIR.

3.2.5 (NDE)

3.2.4 (Preservation) Submit a CIR.

D2.1 (Fastener assemblies)

D2.1 (Fastener assemblies)

D2.1 (Fastener assemblies)

3.2.4 (Preservation)

2. Overhaul the designated doors and associated door frames as shown on Drawings CG3002B and CG3002B1 contained in TP 1952, in accordance with the door manufacturer’s instructions.

· Overhaul includes but not limited to renewing latches, gaskets, and sealing material. Door gaskets shall be MIL-PRF-900, Mar 1991, Rubber Gasket Material, 45 Durometer Hardness

· Upon completion of overhaul, perform chalk test in accordance with SFLC Std Spec 0740.

Submit a CFR

1.Tank Capacity: 80 Gallons – each tank.

2. Tank content disposal:

· Dispose of residual tank contents and all cleaning fluids in compliance with all applicable Federal, state, and local laws, ordinances and regulations

· Document a complete chain of custody record of the removed tank contents and generated wastes, from the vessel to the point of final destination or delivery.

· Submit document to the COR upon completion of work.

3. Cleaning requirements:

· Remove tank cover(s) and clean tank interior surfaces free of all foreign materials, such as sediment or sludge, taking care not to damage the coating system (if applicable)

· Remove cleaning media and residues continuously during the washing process.

· Remove any residual wash media; and wipe up residual moisture with clean lint-free cloths

· Provide new oil for testing and properly drain to meet shipping requirements for over the road transportation.

4. Inspection: Visually inspect all tank interior surfaces, including, but not limited to bulkheads, floor and overhead plating, structural members, manhole cover surfaces, fasteners and gasket seating surfaces.

Submit a CFR including the following, as applicable:

· Tank structural condition.

· Inaccessible areas.

· Condition of tank coating, including measurements taken, percentage, location, and type of coating failure.

· Tank level indicator (TLI) and/or float switch condition, as applicable.

· Sounding tube and striker plate condition.

· Suction and discharge piping condition.

· Fastener material and condition (correct fastener material is stainless steel).

5. Tank closing:

· Ensure that the tank(s) remain open for approximately 24 hours after completion of all authorized repair and preservation procedures.

· Notify the COR at least 24 hours prior to closing the tank(s).

· After satisfactory inspection by the Coast Guard Inspector and completion of all authorized repairs, close tank manhole cover(s) with new gasket material conforming to AMS-C-6183.

· Renew all tank plugs

Ensure all gear boxes are filled in accordance with CG TP 1952B.

B2.9 (Label Plates) Perform weight testing See Table 5 for requirements.

Mount crane on suitable test stand to complete tests outlined in Table 5. Reference paragraph 3.2.

Complete all tests in the presence of a CG inspector. If any inspection or test fails to meet the requirements herein, take corrective procedures and/or furnish materials to correct each deficiency.

Submit a CFR.

Disassemble and ready the crane assembly for shipment and load crane assembly on CG-provided over the road shipping transportation.

Provide two copies of the Final reports - one to the COR and the other, to be shipped with the crane Reports shall include but are not limited to:

· Crane Serial#, Weight and Speed Test Results, Wire Rope Certification,

· Gauge and Meter Certification, Crane Engine Log w/ Current Hours, hose log and Fastener Certification.

Unload crane assembly for CG procured shipping and stage for the next overhaul.

Contractor personnel will complete all weight tests.

TABLE 2 – WINCH TEST WEIGHTS (Test STand)

Main Hoist Test Weights

TABLE 3 – GAuge Renewals

TABLE 4 – Door PARTICULARS

3.2 Crane test. The Contractor shall perform the below tasks, using the test loads listed in Table 5. Submit a CFR.

3.2.1 Swing Bearing Wear Inspection. Take dial indicator readings at the 12, 3, 6, and 9 o’clock positions with the boom at 80 degrees and then again at 15 degrees.

NOTE

1. No weight attached for this test.

2. Max bearing deflection is .095”.

3.2.2 Timed speed test. Conduct timed speed test for all winches using a standardized test load of 8,250 (+200/0) lbs, as follows:

· Attach a ten foot length of…