MORGENTHAU_(WHEC_378W)_UPDS_FQ1_JMR_16R0.pdf

USCGC MORGENTHAU (WHEC 722)

SPECIFICATION FOR UNPLANNED DOCKSIDE REPAIRS

FY2016

Developed By: Justin M Ryan

(Rev-0, 30 November 2015)

USCGC MORGENTHAU (WHEC-378W) UNPLANNED DOCKSIDE AVAILABILITY FY2016

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property ................................................................................. vi Consolidated List of Critical Inspection Items ........................................................................................... vii Principal Characteristics ............................................................................................................................ viii General Requirements WORK ITEM 1: Ship Service Diesel Generator, Generator Rotor and Stator Removal and Reinstallation15 WORK ITEM 2: Ship Service Diesel Generator, Overhaul iii (Rev-0)

REVISIONS RECORD

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

DATE REV# WORK

ITEM#

CHANGES MADE

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

iv (Rev-0)

CONSOLIDATED LIST OF REFERENCES

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

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

• MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

• Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

• Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws::

www.gpoaccess.gov

The Government is aware of the following internet web links where contractors may procure commercial specifications:

• American Welding Society (AWS): http://www.awspubs.com/index.php

• ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

• NFPA: http://www.nfpa.org

• SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS

Coast Guard Drawing 378-FRAM-W 111-2, Rev -, Shell Expansion Aft Coast Guard Drawing 378-FRAM-W 117-6, Rev -, Web Frames 234, 241, & 248-1/2 Coast Guard Drawing 378-FRAM-W 122-4, Rev -, Transverse Bulkheads 192, 202-1/2 & 256 Coast Guard Drawing 378-FRAM-W 635-1, Rev M, Insulation a&D Coast Guard Drawing 378-FRAM-W 801-1, Rev F, Booklet of General Plans Coast Guard Drawing 378-FRAM-W-801-001, Rev F, Booklet of General Plans

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Jun 2006, Coatings and Colors

Manual Coast Guard Technical Publication (TP) 3263A, 15-SEP-93, Ship Service Diesel Generator - Model 8-

645E2 - (Part 1) Coast Guard Technical Publication (TP) 3263B, 15-SEP-93, Ship Service Diesel Generator - Model 8-

645E2 - (Part 2) 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 3041 (SFLC Std Spec 3041), 2014, Shipboard

Electrical Cable Test http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace v (Rev-0)

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 3101 (SFLC Std Spec 3101), 2014, Overhaul AC Synchronous Machines

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

Surface Forces Logistics Center Standard Specification 8636 (SFLC Std Spec 8636), 2014, Temporary Hull Accesses

OTHER REFERENCES

American National Standards Institute (ANSI/EASA) AR100-2015, Recommended Practice for the

Repair of Rotating Electrical Apparatus The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2004, Solvent Cleaning The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 3), 2004, Power Tool Cleaning vi (Rev-0)

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

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

WORK

ITEM

MTI ITEM

DESCRIPTION

NSN/PN QTY ESTIMATED

COST

($/UNIT)

2 N Brushes, electrical generator 01-143-7554/5829438P1 6 $14.76

*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 vii (Rev-0)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

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

Work Item Title

This section is not applicable to this package.

viii (Rev-0)

PRINCIPAL CHARACTERISTICS

378 WHEC (W-CLASS: MORGENTHAU)

PHYSICAL CHARACTERISTICS

Length overall 378' 3" Length between perpendiculars 350' 0" Maximum beam (@ 13' 6" dwl) 42' 0" Beam @ main deck 42' 0" Depth 26' 3/8" Main deck camber 6" in 21' 0" Minimum berth depth 30' 0" Height of highest projection 116' Draft, fwd @ full load 14.78' Draft, aft @ full load 15.61' Draft, fwd @ minimum operating 14.63' Draft, aft @ minimum operating 15.33' Full load displacement 3313 long tons Minimum operating displacement 2762 long tons Light ship displacement 2433 long tons

HULL

Frame spacing 1' 0" Material Deckhouse, fwd of frame 96 HY-100 Steel Main deck frames 183 to 242-1/2 and fwd of FR 96

HY-80 Steel

01 level frames 183 to 316 HY-80 Steel Lower hull around bow thruster, port and starboard strakes A-3 and A-4, frames 56 to 96

HY-80 Steel

Masts and superstructure above the 01 deck

Type 3456 Aluminum

Remaining ASTM A-131

MACHINERY

Type of propulsion CODOG Two diesel engines Fairbanks More 12-cylinder opposed piston 38-TD-8-1/8; 7000 SHP total Two gas turbines Pratt and Whitney FT4A-2; 36,000 SHP total Two controllable pitch propellers Escher Wyss 4 blade, 13' 0" diameter; 149 RPM max on Diesel engines; 235 RPM max on Gas turbines Two reduction gears Western Gear Electrical characteristics Two 550KW-AC Type, 450V, 60 Hz, 3 Phase, 720 RPM GM 8-645 diesel driven ship's service generators (located in the Engine Room) 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 ix (Rev-0)

TANK CAPACITIES

Diesel oil 192,858 gal. (95%) Fresh water 17,695 gal. (100%) JP-5 fuel 27, 603 gal. (95%)

1 (Rev-0)

00000_1115_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.

2 (Rev-0)

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

3.2 Contractor-provided fire extinguishers. The Contractor shall provide portable fire extinguishers.

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 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.

3.5.1 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 (Rev-0)

3.5.1.1 USCG Generator status. The activity Generator Status for the Coast Guard Facility is _________.

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.

4 (Rev-0)

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.”

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.

5 (Rev-0)

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

VESSEL NAME HULL # WORK

ITEM # WORK ITEM TITLE

LOCATION OF WORK (INCL. FRAME #’S) AREA (SQFT)

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

Ensure all coatings are in compliance with 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.

6 (Rev-0)

Name of QP-1/NACE Inspector Signature Cert. # Date / Time

7 (Rev-0)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

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

DATE &

TIME

ACTIVITY

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

LOCATION

(Frame & Deck, relation to equipment, etc.)

TEMPERATURE

% REL.

HUMID-ITY

DEW PT. SURFACE AMBIENT

ΔT

| DP - Surface

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE /

TIME

8 (Rev-0)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

LOCATION OF WORK (FRAME REFERENCES) AREA (SQFT)

SURFACE PREPARATION METHOD

PROFILE ACHIEVED (mils)

Min Max Mean SSPC-SP-10/NACE No. 2

SSPC-SP 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: ______________

9 (Rev-0)

10 (Rev-0)

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

SURFACE PREPARATION METHOD

PROFILE ACHIEVED (mils)

Min Max Mean SSPC-SP-10/NACE No. 2

SSPC-SP 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.

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

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

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

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

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

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

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

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

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

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

_____ mils _____ mils _____ mils _____ mils _____ mils

11 (Rev-0)

12 (Rev-0)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15

DATE TEST LOCATIONS CONDUCTIVITY

(MICROSIEMENS/CM)

13 (Rev-0)

14 (Rev-0)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

COATING MFG PRODUCT NAME BATCH # INDUCTION

COATING SYSTEM

SEQUENCE

(PRIMER/TOUCHUP/3RD

COAT, ETC.)

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

SPOT 1 2 3 4 5 AVERAGE

VALUE

*BASE METAL READING

(BMR)

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

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation 3 Before Adjustments After Adjustments

Avg.

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation 3 Before Adjustments After Adjustments

Avg.

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation 3 Before Adjustments After Adjustments

Avg.

APPLICATION METHOD (AIRLESS, CONVENTIONAL

SPRAY, ROLLED)

AVERAGE DFT

15 (Rev-0)

SYY_NNN_ESWBS_AUT_MMYY_HULL#

WORK ITEM 1: Ship Service Diesel Generator, Generator Rotor and Stator Removal and Reinstallation

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to remove the starboard side diesel generator assembly, generator section only, from the cutter to an electrical contractor for rewinding.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 378-FRAM-W 111-2, Rev -, Shell Expansion Aft Coast Guard Drawing 378-FRAM-W 117-6, Rev -, Web Frames 234, 241, & 248-1/2 Coast Guard Drawing 378-FRAM-W 122-4, Rev -, Transverse Bulkheads 192, 202-1/2 & 256 Coast Guard Drawing 378-FRAM-W 635-1, Rev M, Insulation a&D Coast Guard Drawing 378-FRAM-W 801-1, Rev F, Booklet of General Plans

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3263B, 15-SEP-93, Ship Service Diesel Generator -

Model 8-645E2 - (Part 2) 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 3041 (SFLC Std Spec 3041), 2014, Shipboard Electrical Cable Test 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 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures Surface Forces Logistics Center Standard Specification 8636 (SFLC Std Spec 8636), 2014, Temporary Hull Accesses

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OTHER REFERENCES

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2004, Solvent Cleaning The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 3), 2004, Power Tool Cleaning

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Alignment Tech Rep. The Contractor shall provide the services of a Qualified Technical Representative who is familiar with the alignment of General Electric Single Bearing Generators to accomplish the following on site:

• Assist with verifying the alignment of the generator to the diesel engine before commencing work and after completion of all work.

3.1.2.1 Ensure the Tech Rep has experience with the system/equipment stated above and demonstrated on their work history.

3.1.2.2 Submit the name and work history of the Tech Rep to the COR at the Arrival Conference.

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.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the below-listed:

• Miscellaneous ventilation ducting.

• Two (2) sections of deck drain piping.

• Bulkhead Insulation in way of proposed access cut for generator removal.

• Sewage Transfer piping between fore and aft sewage.

• Cradle assembly to transport and protect generator rotor when disassembled.

• Degaussing Cables.

• FCU Drain Line.

• Overhead Lights.

• Diesel Engine Blower and intake ducting.

• Soak Back Lube Oil Pump.

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• Various Cabinets and Storage Lockers.

• Cable way: Associated with the console batteries.

• Lead based paint on Engine Room Bulkhead behind insulation.

3.1.4.1 Disconnect and remove ventilation ducting as required to remove the generator stator and rotor.

Restore ventilation ducting upon completion of work.

3.1.4.2 Crop and remove deck drain piping in way of bulkhead penetration. Restore deck drain piping upon completion of work.

3.1.4.3 Remove and dispose of bulkhead insulation in way of access cut for generator removal. Restore insulation upon completion of work. Follow guidance in CG Dwg 378 FRAM W 635-1.

3.1.4.4 Sewage transfer piping removal. Sewage transfer piping which is in way of bulkhead access cut which will be made to allow removal of the generator stator assembly is critical for proper ability to operate the ship’s sewage plant and transfer sewage off the vessel. Disruption of the continuity of the sewage transfer piping must be minimized. The contractor shall perform the following work:

3.1.4.4.1 The contractor shall on the sewage transfer piping perform all work on the sewage system after normal working hours for the cutter, between the hours of 2200 and 0600. Coordinate with ship’s force personnel to ensure that sewage usage is secured during the time the contractor is working. Ensure that work is completed prior to 0600 to allow ship’s force to commence meal preparation in the morning.

3.1.4.4.2 Target the sewage transfer piping where the bulkhead penetration for generator removal will occur.

3.1.4.4.3 Crop and remove the piping. Install flange connections on the piping on either end where the sewage piping was removed.

3.1.4.4.4 Fabricate and install a temporary bypass around the location where the bulkhead access cut is to be performed to allow for removal of the generator assembly. The bypass must be long enough to allow the generator stator to pass through the bulkhead access cut. The bypass may be installed using flexible hose with gasketed flange connections at either end to ensure that sewage does not leak while in use. The flexible connection must be long enough to be away from the access cut, but short enough not to interfere with sewage transfer between the fore and aft sewage stations.

NOTE:

Figures depicting interferences are contained in Section, 4 NOTES

3.1.4.5 Fabricate a wooden cradle to support and protect the rotor assembly while transporting it to the electrical sub-contractor for cleaning and inspection. Accompanied by the Coast Guard Inspector, inspect the cradle assembly before removing the generator rotor.

3.1.4.6 Degaussing cables are located along the bulkhead of the Engine Room Upper Level. The proposed access cut will be made above the degaussing cables. Protect the degaussing cables from heat damage by using insulated blankets in way of welding when access cut is being made and when access is being reinstalled.

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3.1.4.7 Crop and remove fan coil drain line in way of access cut. Provide a temporary drain line for the fan coil unit in the area to drain to the bilge during all generator work. Reconnect the existing drain after completion of all work.

3.1.4.8 Disconnect and remove electrical lighting and wiring in the overhead above the generator as required to allow installation of padeyes for lifting the generator. Reinstall electrical lighting and wiring upon completion of all work.

3.1.4.9 Diesel engine blower and intake ducting. Disconnect and remove the SSDG Diesel Engine Blower and intake ducting. Cover all openings to prevent entry of contamination into the blower or the diesel engine during time that blower is removed. Set aside the blower and intake ducting for reinstallation upon completion of all work. Reinstall the blower and intake ducting upon completion of all work. Follow guidance in CG Tech Pub 3263 for blower removal.

3.1.4.10 Diesel Engine Soak Back Oil Pump. Electrically and mechanically disconnect and set aside the soak back oil pump to allow removal of the generator stator. Cap all lines. Return and reinstall the soak back oil pump upon completion of all work.

3.1.4.11 Various Cabinets and Storage Lockers. Disconnect and remove the acid storage locker and three small additional storage cabinets in way of the access cut. Set them aside in the Engine Room for later reinstallation. Return and reinstall the cabinets upon completion of work.

3.1.4.12 Cableway for console batteries. Disconnect and move cableway as required to complete access cut. Reinstall cableway upon completion of work.

3.1.4.13 Lead Base Paint. Coordinate removal of lead based paint on bulkheads for cropping and reinstalling access cover. Follow guidance in Section 3.1.5.

3.1.5 Preservation, lead based paint (LBP) abatement, interior. The Contractor shall accomplish LBP abatement requirements, as specified in SFLC Std Spec 000, Appendix A or B, for the surfaces damaged during welding. Surfaces to be abated also include all structural members associated with/adjacent to designated surfaces, in addition to lighting fixtures, pipe runs, and junction boxes where ever existing paint coating was damage due to welding and must be repaired.

NOTES

Abatement specific requirements in Appendix A or B of SFLC Std Spec 0000 include, but are not limited to the following:

+ Additional protective measures.

+ HAZMAT removal/surface preparation.

+ Post-surface preparation clearance sampling and inspection.

+ Lead dust clean up.

+ Waste disposal.

3.1.5.1 Post-abatement clearance, inspection, and cleaning – order of performance. After completion of surface preparation and removal of generated debris, perform the below-specified tasks, in the specific order provided.

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3.1.5.2 Substrate inspection. Perform visual inspection, accompanied by the CG Inspector, of all prepared surfaces. Submit a CFR.

3.1.5.3 Lead dust cleaning and wipe sampling. After satisfactory results of visual inspection, perform all tasks associated with lead dust cleaning and wipe sampling.

3.1.5.4 Surface coating. After satisfactory result of lead dust concentrations have been achieved, prime and coat all affected surfaces using the coating specified for bulkheads under insulation in SFLC Std Spec 6310, Appendix B (Cutter and Boat Interior Painting Systems).

3.1.6 Electrical requirements. The Contractor shall accomplish all electrical work in accordance with SFLC Std Spec 3042, and test cables in accordance with SFLC Std Spec 3041.

3.2 Background information. The starboard side ship’s service generator has developed a direct short in the internal windings. It is the intent of the Coast Guard to remove the generator stator assembly and the generator rotor to an electrical repair shop for rewinding and repairs. This work will require an access cut to be made in the starboard side of the cutter and rigging and crane services to remove the generator components.

The cutter is moored starboard side to the pier, at Sand Island in Honolulu HI. There is approximately 6 to 8 feet. of clearance between the side of the cutter and the pier to allow removal of the generator from the cutter.

The starboard side ship’s service generator is located in the Engine Room (5-192-01-E) upper level starboard side aft, next to the control booth.

3.3 Temporary access cut. The contractor shall perform the following work:

3.3.1 Following guidance in SFLC Std Spec 8636, determine the location and size for an access cut in the starboard side shell to remove the generator assembly from the cutter. Use CG Dwg 378 FRAM W 111- 2, CG Dwg 378 FRAM W 117-6, CG Dwg 378 FRAM W 122-4, and CG Dwg 378 FRAM W 801-1 to help determine the location for the access cut.

3.3.2 Provide a sketch of the proposed location for the access cut to the Coast Guard Inspector for review. Mark the location for the access cut on the bulkhead in the engine room. Access cut should be above the level of the control booth and should be a minimum thirty (30) inches above the water line.

3.3.3 Following guidance in SFLC Standard Specification 8638, crop an access for removal of the generator stator and rotor from the cutter. Retain access patch for later reinstallation.

3.3.4 Provide a weather protective covering in way of access cut to prevent entry of weather into the cutter.

3.3.5 After the generator assembly has been returned to the cutter and reinstalled, reinstall the access cut following the guidance in SFLC Std Spec 8636. Use 100% continuous welds.

3.3.6 Dye penetrant test all new welds. Conduct external hose test along new weld seam in accordance with SFCL Std Spec 0740. Demonstrate to the Coast Guard Inspector that all new weld seams are tight.

3.4 Generator rotor removal. The contractor shall perform the following work:

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3.4.1 Remove rotating equipment guards and generator covers to allow access to generator coupling and generator rotor assembly.

3.4.2 Following guidance in Maintenance Instruction 1765 contained in CG Tech Pub 3263B, and as directed by the Alignment Technical Representative, measure and record the alignment between the generator and the ship’s service diesel engine. Measure and record the thrust alignment and the radial and angular alignment of the generator assembly. Measure and record air gap readings around the generator rotor on both the forward and aft ends of the generator. Submit a CFR of all readings before commencing any additional disassembly work on the generator. Perform all alignment checks in the presence of the Technical Representative and the Coast Guard Inspector.

3.4.3 Following guidance in paragraph 1-4-1-8 of the550-KW Generator Section of CG Tech Pub 3263B, and SFLC Std Spec 3042,disconnect and remove the generator assembly from the cutter.

3.4.3.1 Disconnect and cap all electrical leads to the generator assembly, including line leads, excitation leads, space heater leads and temperature detector leads. Label the leads with the correct phase orientation to ensure that they are reconnected properly.

3.4.3.2 Disconnect the water inlet and the water outlet piping to the air cooler and the oil inlet and oil outlet piping from the bearing bracket. Drain all piping and cap end fittings to prevent contamination.

3.4.3.3 Number and mark each of the bold-down bolts and the dowels which secure the generator to the air cooler and the foundation.

NOTE

As shown in the assembly drawing in CG Tech Pub 3263B, the generator stator assembly is doweled to the air cooler/foundation to ensure alignment between the generator and the engine.

3.4.3.4 Remove the brush rigging and the collector. Remove the brushes.

3.4.3.5 Rig and support the forward end of the rotor when disconnecting the rotor from the coupling. Rig and support the aft end of the rotor while removing the bearing and the bearing housing.

3.4.3.5.1 Provide and install temporary padeyes as required to support the rotor and to rig the stator housing off the cutter during the course of this work. Load test padeyes to 200% of expected working load prior to use. Remove padeyes upon completion of work.

3.4.3.6 Remove oil shields and the bearing housing. Uncouple the generator rotor from the diesel engine.

NOTE

Figure 1-6-1 in the Generator Section of CG Tech Pub 3263B indicates that there may be sufficient room to remove the generator rotor without turning the stator assembly on the foundation. USCG does not know if this is possible.

3.4.3.7 Disconnect and remove the hold-down bolts and dowels from the generator foundation. Collect any shims from any of the hold down bolts and maintain each shim with its associated hold down bolt.

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3.4.3.8 Rig the stator assembly and swivel the stator if required to remove the rotor assembly. Protect the rotor and ensure that it does not contact the stator during this procedure.

3.4.3.9 Disassemble the rotor support bearing on the aft end of the rotor.

3.4.3.9.1 While the bearing is disassembled, clean and inspect the bearing housing and the bearing shells.

Note any indication of electrolysis or damage to the bearing babbit. Submit a CFR.

3.4.3.10 Rig the generator rotor out of the stator housing and onto the pier. Place the rotor assembly in the previously prepared cradle and transport the rotor to the electrical sub-contractor’s facility for cleaning and inspection which will be covered in a separate work item of this specification package.

3.4.3.11 Accompanied by the Coast Guard Inspector and the electrical sub-contractor, inspect the generator rotor and stator assembly. Determine the amount of damage to the stator assembly and the repair work required to repair the ground in the generator stator. Submit a CFR with repair recommendations.

3.5 Generator stator removal. The contractor shall perform the following work:

3.5.1 Rig and remove the generator stator assembly to the pier. Transport the stator assembly to the electrical sub-contractor’s facility for required repairs.

3.6 Generator air cooler. The contractor shall perform the following work:

3.6.1 Label and mark all the foundation bolts and dowels which hold the generator air cooler/generator foundation to the generator skid assembly.

3.6.2 Remove all the foundation bolts and dowels.

3.6.3 Transport the air cooler assembly to the contractor’s shop.

3.6.4 Clean the air side and water side of the air cooler assembly. Inspect the air cooler assembly in the presence of the Coast Guard Inspector to ensure that it is clean.

3.6.5 Hydrostatically test the water side of the air cooler assembly to 75 psig. Ensure that there are no leaks.

3.6.6 Test the air side of the air cooler assembly to 10 psig. Ensure that there are no leaks.

3.6.7 Document any leaks. If there are leaks or cracks in the cooler assembly, a contract modification may be issued to perform repairs.

3.6.8 Reassemble the air cooler assembly. Install new zinc anodes in the heads.

3.6.9 Submit a CFR noting completion of repairs.

3.6.10 Return the air cooler assembly to the ship and reinstall the assembly on the generator skid assembly. Ensure that the hold down bolts and dowels and any shims are returned to their original location.

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3.7 Return generator stator and rotor assembly to the cutter. The contractor shall perform the following work:

3.7.1 After completion of required repairs to the generator rotor and stator, the contractor shall return the rotor and stator assemblies to the cutter and rig the equipment back aboard the cutter.

3.7.2 Return the stator to the foundation and reassemble the rotor in the stator assembly. Support the rotor in the stator assembly and ensure that the rotor does not contact the stator windings during reassembly.

3.7.3 Swivel the stator assembly back to its original location on the foundation.

3.7.4 Reassemble the generator rotor bearing and reconnect the rotor to the engine coupling.

3.7.5 Following the guidance in CG Tech Pub 3263, MI 1765, recheck the alignment of the generator rotor to the engine and of the stator assembly to the foundation. Shim and adjust the stator and bearing housing as required to obtain proper alignments. Perform all alignment checks in the presence of the Technical Representative and the Coast Guard Inspector.

3.7.5.1 Measure and record thrust and radial and angular alignment. Record air gap reading on the forward and aft end of the rotor at 4 locations around the rotor, top bottom, left and right sides. Compare the values obtained to the values previously measured. Submit a CFR.

NOTE

Generator alignment tolerances given in Fig. 19 (MI 1765 in CG Tech Pub 3263B) are limits established for factory assembled equipment. Accuracy in leveling the power plant during installation can affect alignment enough to put it outside these limits. Therefore, if angular and radial alignment are both within a total indicator reading of 0.76 mm (0.030”) after installation, it is not necessary to disturb the alignment.

If either reading exceeds this limit, generator shall be realigned back to the factory limits.

3.7.6 After verifying all alignments, drill and ream out the dowel assemblies in the stator to foundation housing. Provide and install new dowel pins.

3.7.7 Reinstall all foundation bolts and shims. Provide and install new shims as required to obtain correct radial and axial alignment between the generator and the engine.

3.7.8 Torque all foundation bolts to values found in the technical manual.

3.8 Generator reassembly. The contractor shall perform the following work:

3.8.1 Reassemble the generator. Reinstall all brushes and brush rigging. Install all guards and equipment covers.

3.8.2 Reconnect all electrical connections. Ensure phase sequence is correct. Use previously installed tags to verify proper wiring connections.

3.8.3 Reconnect all lube oil and cooling water piping.

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3.9 Generator testing.

3.9.1 Megger the generator rotor and stator and record as installed readings. Submit a CFR.

3.9.2 With the aid of ship’s force, test operate the generator assembly. During testing, vent water from the cooler heads to ensure proper flow. Ensure that the cooler is not leaking from the tell-tail drains.

3.9.3 Verify oil flow through the generator bearing.

3.9.4 Test operate the generator for a period of four (4) hours under load. Ensure that the generator bearing temperatures remain stable and that there is lube oil flow to the bearing.

3.10 Restoration. The contractor shall perform the following work:

3.10.1 After the access cut is reinstalled, power tool clean the internal bulkhead areas near the access cut which were damaged by welding. Feather all edges.