SOW_CGC_MORRO_BAY.docx

56122_CKN_0216_140

Steering Gear System Piping, Renew

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew the vessel's hydraulic steering system piping and install hydraulic hoses in Aft Steering, Compartment 2-80-0-E.

1.2 Government-furnished property. None

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 140 WTGB 561-004, Rev C, Hydraulic Steering System Arrg – Jastram Coast Guard Drawing 140 WTGB 185-007, Rev C, Fdns Incidental to Jastram Steering Equip Installation Coast Guard Publications Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2014, Auxiliary Machine Systems Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes Coast Guard Technical Publication (TP) 3482, Mar 2001, SWBS 561, HYDRAULIC POWER UNIT - INSTRUCTIONS 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 paragraph(s):

· 3.1.2 Visual inspection.

· 3.4 Removal of hydraulic piping.

· 3.8 Steering System Hydraulic Power Unit Hose Installation

· 3.9 Install support brackets.

3.1.2 Tech Rep. The Contractor shall provide the services of a Qualified Technical Representative who is familiar with the Jastram Steering Equipment to accomplish the following on site in the execution of work identified in section 3.8 of this specification:

· Advise on manufacturer's proprietary system information.

· Hydraulic hose installation.

· Ensure compliance with manufacturer's procedures and standards during system disassembly, inspection, and reassembly as applicable.

3.1.3 Visual inspection. The Contractor shall visually inspect all fitting and piping associated with the system. Submit a CIR identifying any inconsistencies not identified in this specification.

3.1.4 Protective measures - general. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces in the vicinity of the work area 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, components, and spaces to original condition of cleanliness.

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

Overhead and Bulkhead sheathing and insulation Tight working spaces Overhead lighting Adjacent fuel and ballast tanks

3.2 Operational test - initial. Prior to commencement of work, the Contractor shall witness Coast Guard Personnel perform an initial operational test of the steering system to demonstrate existing operational condition. Submit a CFR.

3.3 Hydraulic oil disposal. The Contractor shall drain all hydraulic fluid (approximately 145 gallons) from the steering system into a suitable container and dispose of in accordance with all Federal, state, and local regulations.

3.4 Removal of hydraulic piping. The Contractor shall disconnect and remove the hydraulic piping, as shown on Coast Guard Drawing 140 WTGB 561-004, examine all parts and present the initial finding of failure. Submit a CIR. The Contractor shall be aware that sheet 1 of the drawing references removals of a system that has been replaced; this sheet does not apply to this work item.

3.4.1 All hydraulic connections shall be capped to prevent entry of contaminant.

3.4.2 All removed components shall be labeled or otherwise identified to avoid interchanging any parts during reassembly.

3.5 Steering oil reservoir. The Contractor shall clean the steering oil reservoir (145 gallon capacity) with a lint-free cloth.

3.5.1 Open the reservoir cover. Visually inspect the interior of reservoir for any defects.

3.5.2 After inspecting the reservoir, renew the gasket for the cover and reinstall the reservoir cover.

3.6 Renewal of hydraulic piping. Renew the hydraulic piping and fittings according to Coast Guard Drawing 140 WTGB 561-004, using the standard 37 degree flare fittings with seal inserts.

3.7 Install hydraulic hoses. Fabricate, certify and install twelve 12 new hydraulic hoses per DWG 140 WTGB 561-004 Rev C.

3.8 Steering System Hydraulic Power Unit Hose Installation. The contractor shall submit a CIR with recommendation on modifying six (6) hydraulic pipes on the Steering System HPU to accommodate the installation of hydraulic hoses.

3.8.1 A Jastram or RG Group Technical Representative shall be on site to provide guidance on the location and installation of these hoses. The Coast Guard can provide a recommended Technical Representative upon request. Comment by MDBelt: Should we provide POC/contact details and should this be listed in 3.8.1 or in 3.1.2?

3.8.2 The exact dimensions of the hoses shall be identified with the recommendation of the technical representative. For estimating purposes, the contractor shall anticipate:

· 2 each 1” x 18” hose with Female JIC and 90 Degree Female JIC Long Drop fittings

· 2 each 3/4” x 24” hose with Female JIC and 90 Degree Female JIC Long Drop fittings

· 2 each 3/8” x 12” hose, both ends with Female JIC fittings

3.9 Replace support bracket. Replace support brackets and renew isolation insert and hardware, according to Coast Guard Drawing 140 WTGB 561-004. Ensure spacing meets the requirements of General Note 2 of the drawing. Submit a CIR with recommended pipe support hangar arrangement to include size and locations. The Coast Guard inspector will be available to assist in identification of proper pipe hangar locations. The Contractor shall be aware that this item will include hot work and that a marine chemist and daily competent person certifications will be required.

3.10 Install of foundation for Double Acting Relief & Bypass (DARB) Valve. Fabricate and install foundation for Double Acting Relief & Bypass Valve. See Details 35A and 35B of Coast Guard Drawing 140 WTGB 185-007. The Contractor shall be aware that this item will include hot work and that a marine chemist and daily competent person certifications will be required.

3.11 Repair Interferences. The contractor shall paint all surfaces disturbed by hotwork. Insulation and sheathing removed in the way of hotwork shall be restored in kind. Removed materials may be reused if in good condition with the concurrence of the Coast Guard Inspector.

3.12 Reinstallation. The Contractor shall reinstall any removed components of the steering hydraulic system as shown on Coast Guard Drawing 140 WTGB 561-004. Ensure appropriate thread-loc compound is used if identified in manufacturer recommendations.

3.13 Hydraulic fluid renewal. The Contractor shall renew the system hydraulic fluid in accordance with SFLC Std Spec 5000, Appendix C, Paragraph C2.1 (Fluids). New oil shall be Shell Tellus S2V 32 Hydraulic Oil. If this oil is not available, the contractor shall contact the Coast Guard Inspector and recommend an equivalent oil. Renew all filters.

3.14 Hydraulic fluid filtering. The Contractor shall filter the system hydraulic fluid in accordance with SFLC Std Spec 5000, Appendix C, Paragraph C2.1 (Fluids).

3.15 Hydrostatic test. After all authorized repairs, the Contractor shall hydrostatically test all new and disturbed piping and components of the steering system in accordance with SFLC Std Spec 0740, Appendix C, Hydrostatic Test. Ensure zero leakage from or permanent deformation of pressure-containing parts by repairing all leaks, deformations, and discrepancies. Submit a CFR.

3.16 Operational test – post repairs. After completion of work, the Contractor shall thoroughly test, in the presence of the Coast Guard Inspector and demonstrate the steering system to be in satisfactory operating condition. Submit a CFR.

3.16.1 Test the steering system in all modes of operation to ensure the rudder travels smoothly throughout the full range of travel without chattering or binding and at the required rate of train.

3.16.1.1 Start and obtain suction on #1 steering pump. Swing rudder and check reservoir level. Add fluid as necessary. Visually inspect and correct any leaks.

3.16.1.2 Repeat procedures of section 3.16.1.1 using the #2 steering pump.

3.16.1.3 Repeat procedures of section 3.16.1.1 using both steering pumps simultaneously.

3.16.2 Check that the rudder angle indicator in the pilothouse matches the indicator on the rudder post to ensure that the feedback linkage was not disturbed. Correct any discrepancies noted.

3.16.3 After successful dockside testing of the steering system, an underway test of the system shall be performed. The Contractor should plan for a 4 hour underway period from the time of departure until the time of return to the pier. Following underway testing, submit a CFR identifying underway test results, including any system deficiencies with recommended method of repair if applicable.

4. NOTES

4.1 Hydraulic cylinder information.