CGC_JUNIPER_(WLB_201)_SPEC.docx

USCGC JUNIPER (WLB 201)

SPECIFICATION FOR UNPLANNED DOCKSIDE REPAIRS

FY2016

Developed By: Jonathan C Copley (Rev-0, 21 March 2016)

TABLE OF CONTENTS

USCGC JUNIPER (WLB-225A) UNPLANNED DOCKSIDE AVAILABILITY FY2016

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.

USCGC JUNIPER (WLB-225A) UNPLANNED DOCKSIDE AVAILABILITY FY2016

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 225-WLB 549-1, Rev D, Onboard Lubrication Requirements Coast Guard Drawing 225-WLB 556-1, Rev G, Hydraulic System Diagram

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Jun 2006, Coatings and Colors Manual Coast Guard Technical Publication (TP) 3553, 07-JAN-97, Manufacturer's Instruction Book-SWBS Group(s) 551-556 Coast Guard Technical Publication (TP) 3557, Apr 2010, Crane, Buoy Coast Guard Technical Publication (TP) 4634, 20-APR-07, Hydraulic Power Unit (HPU) - Model 39496 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 5000 (SFLC Std Spec 5000), 2014, Auxiliary Machine Systems Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None

USCGC JUNIPER (WLB-225A) UNPLANNED DOCKSIDE AVAILABILITY FY2016

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.

USCGC JUNIPER (WLB-225A) UNPLANNED DOCKSIDE AVAILABILITY FY2016

This section is not applicable to this package.

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

This section is not applicable to this package.

Principal Characteristics

225' WLB (A-CLASS)

Physical

Hull

Frame spacing

Machinery

Tank CAPACITIES

00000_0316_FLT

REC_00000_FLT_Commercial Project @ CG Facility (1212) General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed by commercial contractors at a Coast Guard 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) M10360.3 (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 None

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 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 two Coast Guard fire watch personnel.

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

3.3 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 M10360.3, Chapter 6 (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 6 of COMDTINST M10360.3) 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 USCG facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, 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.

3.5.1.1 USCG Generator status. The activity Generator Status for the Coast Guard Facility is “Large Quantity Generator. “

3.5.1.2 Plans and permits. The CG Facility has unit specific permits including the following:

Spill Prevention Control and Countermeasures (SPCC) Plan: Unit has a SPCC Plan which requires certain unit-specific procedures be followed for the storage, inspection, and transfer of petroleum products in containers 55 gallons or greater.

National Pollutant Discharge Elimination System (NPDES) Storm Water (SW) Permit: Unit has an NPDES SW permit which requires unit-specific procedures be followed for the storage and inspection of equipment and materials which may contribute contaminants to storm water discharges.

Air Emission Permit: Unit has a Air Emission Permit which requires unit-specific procedures be followed for the emissions of VOCs and hazardous air pollutants.

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 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 B, Requirements For Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.5.6 Additional Requirements. The Contractor shall be aware of the following:

3.5.6.1 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 COR or KO-approval.

3.5.6.2 Local environmental regulations at the Government facilities may be more stringent. As with all environmental regulations, the Contractor shall prepare for and comply with local and state regulations.

3.5.6.3 Coast Guard facilities do not maintain Facilities Response Plans (FRPs) per 33 CFR 154. Contractor shall furnish the FRP when required for over-the-water liquids transfers to and from vessels, and is required for oil/fuel transfers to/from vessels for 250 barrels (10,500 gallons) or more.

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:

3.7.1 SFLC Standard Specification 6310, Requirements for Preservation of Ship Structures.

3.7.1.1 SFLC Std Spec 6310, page C-2, Section C1.5.1. Change from "lead-containing paint as 0.06%" to "lead-containing paint as 0.009%".

3.7.1.2 SFLC Std Spec 6310, page 4, Section 2 References, Group- Other References. Add “The Society for Protective Coatings (SSPC) Paint Application Guide No. 11, 2008, Protecting Edges, Crevices, and Irregular Steel Surfaces by Stripe Coating”

3.7.1.3 SFLC Std Spec 6310, page Appendix C-6, add "Hempel Hempadur Multi-Strength GF 35870" with FED-STD-595 color "Black/Red" under ANTI-ABRASION COATING, ICE BREAKING CAPABLE VESSELS, <235’.

3.7.1.4 Standard Spec 6310, page Appendix A-7, Under "UNDERWATER (U/W) BODY/BOOT-TOP", Add line Column 1: Option for U/W Body and Boot-Top, Steel Hulls, <154', in Salt Water. Column 2: Blank. Column 3: SSPC-SP 10/NACE NO. 2 using grit conforming to MIL-A-22262 / (1.5-3.5) - or - SSPC-SP WJ-2(M)/NACE WJ-2(M). Columns 4 and 5: Same as "U/W Body and Boot-Top, Aluminum Hull, High Speed (>30 knots)".

3.7.2 SFLC Standard Specification 0000 General Requirements.

3.7.2.1 SFLC Std Spec 0000, paragraph 1.3 ‘Acronyms and term definitions’, page 5, “PCL (Paint Containing Lead)” definition replaced by, “Any paint or coating containing lead in excess of 0.009 percent by weight (1.0 mg/cm2 or 90 ppm). Lead Based Paint (LBP) is an interchangeable term with PCL.”

3.7.2.2 Change Std Spec 0000 paragraph 3.2.4.2.3(QP 1 inspector or tech rep duties) bullet, “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph 3.1.19 of SFLC Std Spec 6310 (Critical drying time requirements)).” to “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph 3.1.17 of SFLC Std Spec 6310 (Critical drying time requirements)).”

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:

Abrasive 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 Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

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:

Abrasive 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):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Mean Reading (mils)

Mean Reading (mils) IAW ASTM DD4417).

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY Measurements IAW SSPC-GUIDE 15.

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):

Avg.

Location (Frame Reference):

Avg.

Location (Frame Reference):

Avg.

55601_ANK_0316_225WLB_201

WORK ITEM 1: Crane and Buoy Deck Hydraulic System Flush

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to hydraulic flush the entire forward hydraulic system including port and starboard HPUs and reservoirs.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 225-WLB 556-1, Rev G, Hydraulic System Diagram Coast Guard Drawing 225-WLB 549-1, Rev D, Onboard Lubrication Requirements 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 Coast Guard Technical Publication (TP) 3557, Apr 2010, Crane, Buoy Coast Guard Technical Publication (TP) 4634, 20-APR-07, Hydraulic Power Unit (HPU) - Model 39496 Coast Guard Technical Publication (TP) 3553, 07-JAN-97, Manufacturer's Instruction Book-SWBS Group(s) 551-556 Other References None.

3. REQUIREMENTS

3.1 General. The Contractor shall refer to the references specified herein when performing this work item.

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

None.

3.1.3 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.

3.1.3.1 Protective measures - hydraulic system(s). The Contractor shall maintain existing hydraulic system cleanliness; take all necessary precautions to prevent the introduction of contaminants into the hydraulic system. Whenever disconnecting or removing components from the hydraulic system, completely seal all openings to the rest of the system, immediately, using either caps (for externally threaded connection points), bolt-on blanks, or taped-on discs/covers (durable plastic or sheet-metal no less than 1/16-inch thick).

3.1.3.2 Protective measures – pier side. The Contractor shall provide and maintain proper containment of all equipment, oil, filters, associated equipment, and hazmat located on the pier in accordance with SFLC Std Spec 0000, Appendix B. This includes, but is not limited to, safe storage receptacles, containment equipment, and other protective measures. 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.

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 Hydraulic main system turbulent flush. The contractor shall perform a turbulent system flush, using a portable HPU with 3 Micron filtration, of main hydraulic system. KTR shall jumper around all sub-system components. Using the flow rates outlined in the table1 below perform the flush to remove all contaminates. The contractor shall repeat the flush as necessary to achieve ISO cleanliness code of 19/17/14, in accordance with (SFLC Std Spec 5000), Paragraph C2.1. through the use of filtration and changing the contaminated oil as necessary. The contractor shall conduct routine Clear and Bright test. Upon satisfactory Clear and Bright test, the contractor shall send out oil samples in accordance with paragraph 3.2.6. The contractor shall then drain and discard all contaminated hydraulic oil, approximately 1600 gallons (800 gallons each reservoir), in accordance 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. The contractor shall then refill the system with, approximately 1600 gallons (800 gallons each reservoir), of new, clean, filtered oil.

3.2.1 Hydraulic sub-system flush. Contractor shall supply and use a portable HPU with 3 Micron filtration to flush each subassembly through each individual associated directional control valve. Flushing shall continue on each sub-assembly until a Clear & Bright sample is obtained, a sample for laboratory analysis will then be obtained and sent for testing.

3.2.2 Inspection. With a lint-free rag, clean each reservoir and suction strainer of all sludge and deposits. The Contractor shall 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:

· Reservoir structural condition.

· Inaccessible areas.

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

· reservoir 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).

3.2.3 Reservoir closing. The Contractor shall ensure that the reservoirs 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 reservoirs After satisfactory inspection by the Coast Guard Inspector and completion of all authorized repairs, close reservoir manhole cover(s) with new gasket material conforming to AMS-C-6183.

3.2.4 Contractor shall ensure the following Table 1 minimum flow rates are maintained for each circuit. If multiple loops are flushed concurrently each loop shall be provided with a flow measuring device. These flow rates represent minimum flows needed to achieve a turbulent flow condition and maximize benefits of flushing effort. The Contractor shall provide calibrated flow meters. Prior to flushing the certification of calibration shall be shown to the CG Inspector.

TABLE 1. MINIMUM FLOW RATE FOR standard FLUSHING WITH FLUID

NOTES

1. This table is based on the “interior” diameter of the piping, and not on the nominal pipe size. Flow rates represent minimum flows needed to achieve a turbulent flow condition and maximize benefits of flushing effort. Flow rates are based on a flow velocity of about 25 ft/second.

2. If there is a conflict between the pressure and flow rate requirements of this specification, the minimum flow rates shall be governing, unless the design pressure of the piping is exceeded.

3. The use of by-pass (flow control) valves is not allowed downstream of the flow meters.

4. Where a section of piping is fabricated with a larger diameter pipe and is welded to smaller diameter pipe use the smaller pipe minimum flow rate for flushing.

3.2.5 Whenever a noticeable increase in the pressure drop across strainers is observed, the strainers should be cleaned and bag renewed. This may occur as frequency as 15 min intervals.

3.2.6 During flushing, constant monitoring of the flushing oil must be maintained in order to determine the contamination level. Filtering shall continue until the fluid entering the return flow filter meets the particle population ISO cleanliness code of 19/17/14, in accordance with ISO 4406. All flushing fluid shall pass through the return filter after passing through each system flushing circuit. All samples shall be taken at a point just prior to this filter.

3.2.7 Take a representative sample of oil from the hydraulic system of the hydraulic system. Send samples out for laboratory analysis. Analysis shall include viscosity, moisture, total acid number, particle size and population in sufficient detail to determine ISO cleanliness code of 19/17/14, in accordance with (SFLC Std Spec 5000), Paragraph C2.1.3. Submit CFR.

3.2.8 The Contractor shall re-install any disturbed hydraulic system equipment and components in accordance with Std spec (SFLC Std Spec 5000) and TP-3557.

3.2.9 Provide and renew supply and return filters and breathers in accordance with SFLC Std Spec 5000 and TP-3557.

3.2.10 Provide and renew 1600 gallons hydraulic oil (800 gallons each reservoir) in accordance with SFLC Std Spec 5000 , paragraph C2.1, and CG Dwg 225-WLB 549-1. Ensure filter the new fluid through one or more three-micron absolute, non-bypass type filter during refilling.

3.3 The Contractor shall conduct an operational test and weight test in the presence of the CG Inspector. Submit a CFR.

4. NOTES

This section is not applicable to this work item.

58901_ANK_0316_225WLB_201

WORK ITEM 2: Buoy Deck Equipment and Hydraulic System DCV Inspect and Service

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect and service all the buoy deck equipment DCVs.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 225-WLB 556-1, Rev G, Hydraulic System Diagram Coast Guard Drawing 225-WLB 549-1, Rev D, Onboard Lubrication Requirements 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 Coast Guard Technical Publication (TP) 3557, Apr 2010, Crane, Buoy Coast Guard Technical Publication (TP) 4634, 20-APR-07, Hydraulic Power Unit (HPU) - Model 39496 Coast Guard Technical Publication (TP) 3553, 07-JAN-97, Manufacturer's Instruction Book-SWBS Group(s) 551-556 Other References None.

3. REQUIREMENTS

3.1 General. The Contractor shall refer to the references specified herein when performing this work item.

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

None.

3.1.3 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.

3.1.3.1 Protective measures - hydraulic system(s). The Contractor shall maintain existing hydraulic system cleanliness; take all necessary precautions to prevent the introduction of contaminants into the hydraulic system. Whenever disconnecting or removing components from the hydraulic system, completely seal all openings to the rest of the system, immediately, using either caps (for externally threaded connection points), bolt-on blanks, or taped-on discs/covers (durable plastic or sheet-metal no less than 1/16-inch thick).

3.1.3.2 Protective measures – pier side. The Contractor shall provide and maintain proper containment of all equipment, oil, filters, associated equipment, and hazmat located on the pier in accordance with SFLC Std Spec 0000, Appendix B. This includes, but is not limited to, safe storage receptacles, containment equipment, and other protective measures. 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.

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 The Contractor shall operate and inspect all buoy deck equipment in accordance std spec (SFLC Std Spec 5000), paragraph 3.2.1. Submit CFR.

3.2.1 Upon completion of the Buoy Deck equipment and Hydraulic system flush, the Contractor shall operationally test all DCVs in accordance with Std spec (SFLC Std Spec 5000) paragraph 3.2.2 and submit CFR.

3.2.2 The Contractor shall operationally test and weight all deck handling equipment in accordance with CG TP-3557 and Std spec (SFLC Std Spec 5000). The Contractor shall conduct operational test and weight test with each port and starboard HPU. Submit CFR.

3.2.3 Take a representative sample of oil from the hydraulic system of the hydraulic system. Send samples out for laboratory analysis. Analysis shall include viscosity, moisture, total acid number, particle size and population in sufficient detail to determine ISO cleanliness code of 19/17/14, in accordance with (SFLC Std Spec 5000), Paragraph C2.1.3. Submit CFR.

3.2.4 Fabricate and install test weight label plates in accordance with Std spec (SFLC Std Spec 5000), paragraph B2.9.

3.3 Partially preserve all deck equipment and hydraulic system exterior surfaces, include all new components and disturbed surfaces in accordance with Std spec (SFLC Std Spec 5000) paragraph 3.2.4.

3.4 After installation of all equipment, parts, and hoses, wrap each hose fitting with a petroleum wax saturated tape coating such as “Densil (Densyl) Tape or equivalent, conforming to ANSI/AWWA C217. See SFLC Std Spec 5000, paragraph C3.2.

4. NOTES

4.1 Buoy Crane Test Weights.

Test Weights – Aux Hoist

Test Weights – Main Hoist

4.2 Hydraulic Inhaul Winch and Chain Stopper Test Weights.

Main Hoist Test Weights

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