CGC_ALDER_UPDS_SPEC_ATTACHMENT_-_2.pdf

USCGC ALDER (WLB 216)

SPECIFICATION FOR UNPLANNED DOCKSIDE REPAIRS

FY2017

Developed By: Jonathan C Copley

(Rev-0, 03 January 2017)

USCGC ALDER (WLB-225B) UNPLANNED DOCKSIDE AVAILABILITY FY2017

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property .................................................................................. v Consolidated List of Critical Inspection Items ............................................................................................. vi Principal Characteristics ............................................................................................................................. vii General Requirements WORK ITEM 1: Buoy Crane (Appleton EB-480-60-40), Inspections, Repairs, and Component Renewals1 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 225B WLB 556-001, Rev F, Hydraulics System Diagram Coast Guard Drawing 225B WLB 573-001, Rev J, Buoy Handling System Arrangement

COAST GUARD PUBLICATIONS

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

Manual Coast Guard Technical Publication (TP) 3557, Section 573-C, Jul 2005, Manufacturer's Instruction Book-

SWBS Group 568-573, Buoy Crane – Model EB-480-60-40 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 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)

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)

1 Y Turntable bearing NSN: N/A

PN: YMD-8255 1 ea 54,325.00

1 Y Swing drive gear speed reducer

NSN: 3010-01-507-1237

PN: YMD-8256 1 ea 17,723.29

1 N Turntable bearing bolt NSN: 3950-01-516-5810 PN: YMD-8953 115 ea 35.00

1 Y **Swing Brake, Wet Type

NSN: 3040-01-536-3596

PN: YMD-9629 1 ea 686.53

1 Y **Parts Kit, Hydraulic Motor

NSN: 4320-01-475-1857

PN: YMD-6847-R 1 ea 40.78

1 Y **Swing drive hydraulic motor

NSN: 4320-01-365-3021

PN: YMD-8258 1 ea 2,555.05

1 N **Luff cylinder pin NSN: 5315-01-632-8114 PN: MMD-3214 4 ea 1,872.00

1 N **Luff cylinder bushing

NSN: 3120-01-424-1044

PN: MMD-2020 8 ea 112.89

1 N **Heel pin NSN: 5315-01-631-1699 PN: MMD-2873 2 ea 1,250.00

N **Snap ring

NSN: 5340-01-F16-4852

PN: SH-700-STPA (Smalley

Steel Ring Co) 4 ea 125.00

1 N **Thrust washer NSN: 3120-01-632-7953 PN: MMD-1363 4 ea 504.00

*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 vi (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

1 Buoy Crane (Appleton EB-480-60-40), Turntable Bearing and Swing Drive Gear Assembly, Renew vii (Rev-0)

PRINCIPAL CHARACTERISTICS

225' WLB (B-CLASS)

PHYSICAL

Length overall 225' 0" Length between perpendiculars 206' 0" Maximum beam 46' Designed draft 13' 0" Full load displacement 1905.6 Long Tons SW Light ship displacement 1500.7 Long Tons SW Minimum operating displacement 1869.2 Long Tons SW Mast height (above 12' waterline) 67' 5" Anchor Two 4000 lb standard Navy stockless anchors, 8 shots each, port and starboard, 1-

3/8 die lock chain

HULL

Bilge keels (port & starboard) Frames 42-79 Frame spacing FR 0 to 12 21" FR 12 to 30 22" FR 30 to 102 24"

MACHINERY

Main propulsion Diesel Reduction Diesel engines Two Caterpillar 3608, TA, 3100 BHP each @ 900 RPM Number of propellers 1 Number of blades 4 Diameter 10' Pitch Controllable

RPM 254

Ship's service diesel generators Two Caterpillar 3508 TA, 450 KW Emergency diesel generator One Caterpillar 3406 DITA, 280 KW Shore tie Two 450 VAC, 400 Amp, 3-wire Shaft bearing, forward Cooper Bearing 01-BCP-1400-EX-TL Shaft bearing, aft Water Lubricated Cutless Bearing

TANK CAPACITIES

Diesel oil 76,498 gal.

Fresh water capacity 8056 gal.

Hydraulic oil capacity 2785 gal.

Lube oil storage 764 gal.

Grey water tank 2700 gal.

Sewage holding tank 1700 gal.

1 (Rev-0)

00000_1216_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.

Or

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

Or

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.

A-Team Note: Determine whether the Contractor or the Coast Guard will provide fire watches; then select applicable paragraph 3.2 above (fire watch, fire extinguisher s, or a combination of both requirements), and delete the others. Under normal circumstances, for all cutters, fire watch personnel for contract work will be provided by ship's force with the contractor providing fire extinguishers. For situations involving a small cutter crew (such as WLIC and WLR tenders) and an inordinate amount of hot work or multiple shift work, the A-team may consider the requirement for contractor provided fire watch personnel or a combination of both fire watch and fire extinguishers.

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

3 (Rev-0)

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).

4 (Rev-0)

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)).”

5 (Rev-0)

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.

6 (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.

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 |

8 (Rev-0)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

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: 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 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 Replica Tape Here

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:

9 (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: 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).

10 (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)

11 (Rev-0)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

COATING MFG PRODUCT NAME BATCH

INDUCTION

TIME

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.

1 AVG. BMR DEVIATION

1 AVG. BMR DEVIATION

APPLICATION METHOD (AIRLESS, CONVENTIONAL SPRAY,

ROLLED)

AVERAGE DFT

1 (Rev-0)

S2016030_58900_MWC_0117_216

WORK ITEM 1: Buoy Crane (Appleton EB-480-60-40), Inspections, Repairs, and Component Renewals

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to accomplish the following tasks, pierside at the vessel’s homeport:

• Removal of the boom assembly and attached components (main boom, extension boom, swivel head assembly, crane block, overhaul ball, telescoping cylinder, main winch, auxiliary winch, etc)

• Removal of the turret assembly, cab assembly, and operator’s platform (and associated components)

• Removal and inspection of five (5) swing drive gear speed reducers

• Renewal of four (4) swing drive assemblies (hydraulic motor, brake, and speed reducer)

• Reinstallation of one (1) swing drive gear speed reducer; renewal of corresponding hydraulic motor & brake

• Renewal of one (1) turntable bearing

• Reinstallation, reassembly, and testing of the buoy crane

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y Turntable bearing NSN: N/A PN: YMD-8255 1 ea 54,325.00

Y Swing drive gear speed reducer

NSN: 3010-01-507-1237

PN: YMD-8256 4 ea 17,723.29

N Turntable bearing bolt NSN: 3950-01-516-5810 PN: YMD-8953 115 ea 35.00

Y Swing Brake, Wet Type NSN: 3040-01-536-3596 PN: YMD-9629 5 ea 686.53

Y **Parts Kit, Hydraulic Motor

NSN: 4320-01-475-1857

PN: YMD-6847-R 1 ea 40.78

Y Swing drive hydraulic motor

NSN: 4320-01-365-3021

PN: YMD-8258 5 ea 2,555.05

N **Luff cylinder pin NSN: 5315-01-632-8114 PN: MMD-3214 4 ea 1,872.00

N **Luff cylinder bushing NSN: 3120-01-424-1044 PN: MMD-2020 8 ea 112.89

N **Heel pin NSN: 5315-01-631-1699 PN: MMD-2873 2 ea 1,250.00

N **Snap ring

NSN: 5340-01-F16-4852

PN: SH-700-STPA (Smalley Steel Ring Co)

4 ea 125.00

2 (Rev-0)

N **Thrust washer NSN: 3120-01-632-7953 PN: MMD-1363 4 ea 504.00

N **Bushing NSN: 5365-01-632-8144 PN: MMD-2875 4 ea 620.00

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

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

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

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 225B WLB 556-001, Rev F, Hydraulics System Diagram Coast Guard Drawing 225B WLB 573-001, Rev J, Buoy Handling System Arrangement

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3557, Section 573-C, Jul 2005, Manufacturer's

Instruction Book-SWBS Group 568-573, Buoy Crane – Model EB-480-60-40 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

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections required in the following Table 2 tasks:

• Task# 1.

• Task# 2.

• Task# 5.

• Task# 6.

3.1.2 Tech Rep. The Contractor shall provide the services of an OEM authorized/ licensed Tech Rep for the Appleton Marine® crane (Model EB-480-60-40) to accomplish the following on site:

• Provide manufacturer's proprietary system/ equipment information, software, and tools.

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

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé.

3 (Rev-0)

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 near 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). Maintain existing hydraulic system cleanliness and take all necessary precautions to prevent the introduction of contaminants into the hydraulic system.

Immediately after disconnecting or removing components from the hydraulic system, seal all openings to the rest of the system using caps for externally threaded connection points, bolt-on blanks, or taped-on discs/covers made of durable plastic or sheet-metal that is no less than 1/16-inch thick.

NOTE

Be aware that 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).

3.1.5 Protective measures for equipment removals. The Contractor shall provide all required staging and support materials (i.e. blocking, cribbing, tarps, storage containers, etc) to ensure removed components are adequately protected. Additionally, ensure the surrounding shore-side work area (pier and adjacent parking lot surfaces) are protected to ensure no damage occurs as a result of temporary staging of removed components.

3.1.6 Major component weights. Refer to Table 1 for a list of weights for the major components. For additional component weights, refer to CG TP-3557, Figure 7-1.

NOTES

1. The weights below represent the major components of the crane to assist in removal planning efforts. For additional component weights, refer to CG TP- 3557, Figure 7-1.

2. The homeport pier is rated for vertical loads as follows:

- 400 PSF maximum uniform live load

- Truck loading in accordance with AASHTO “Standard Specifications for Highway Bridges” for an HS20 truck or equivalent loading.

- 50 ton capacity hydraulic truck crane lifting the rated load (10,000 lbs minimum) with an 80-ft minimum boom length at a 50-ft minimum operating radius

3. Due to the pier constraints and the component removals required, a shipcheck is highly encouraged in support of developing work plan to accomplish.

TABLE 1 – MAJOR COMPONENT WEIGHTS

COMPONENT APPROX WEIGHT (LBS)

Turntable Bearing 4773

Swing Gear Drive Assembly 1480 Main Boom 18700

4 (Rev-0)

Extension Boom 8250 Luffing Cylinder 4600

Extension Cylinder 4200 Cylinder Support 425

Swivel Head 1312 Swivel Head Bearing 406

Main Winch 3500 Aux Winch 1225

Wire Rope (Main) 610 Wire Rope (Aux) 215

Crane Block 548 Overhaul Ball 258

Turret 16435 Hydraulic Swivel 250

Hydraulic Control Valve Assembly 300

Platform 900 Gear Guard 280

Swivel Driver 105 Swivel Support 360

Manifold Support 350

3.2 Tasks. The Contractor shall perform the tasks specified in Table 2 for the buoy crane, in accordance with SFLC Std Spec 5000, and using Coast Guard Drawing 225B WLB 573-001 and CG TP-3557, SWBS 573C as guidance.

TABLE 2 - TASKS

# TASK

TYPE

QTY COMPONENT

OR ASSEMBLY

APPENDIX AND

PARA. FROM SFLC

STD SPEC 5000

OTHER

Disassemble, Remove, and

Inspect

Boom assembly and attached components

3.2.3 (Disassemble and Inspect)

Unship the boom assembly and attached components (main boom, extension boom, swivel head assembly, crane block, overhaul ball, telescoping cylinder, main winch, auxiliary winch, etc) Submit a CIR.

Disassemble, Remove, and

Inspect 1 Turret assembly 3.2.3 (Disassemble and

Inspect)

Unship the turret assembly, cab assembly, and operator’s platform (and associated components) Submit a CIR.

3 Renew 1 Turntable bearing Renew w/ GFP.

4 Renew 4 Swing Drive Gear Speed Reducer Renew w/ GFP.

5 (Rev-0)

# TASK

TYPE

QTY COMPONENT

OR ASSEMBLY

APPENDIX AND

PARA. FROM SFLC

STD SPEC 5000

OTHER

Disassemble, Remove, and

Inspect 5 Swing Drive

Assembly

D2.4 (Open gearing and gear reducers)

1. Remove the units (hydraulic motor, brake, and speed reducer) from the crane and transport to a suitable repair facility.

2. Inspect the hydraulic motors, brakes, pinion gears, planetary gear reducers, and controls.

NOTE: Inspections are in support of designated one (1) swing drive assembly for repair/reuse.

Submit a CIR.

6 Inspect 1 Hydraulic Swivel 3.2.3 (Disassemble and Inspect) Submit a CIR.

7 Reinstall 1 Swing Drive Assembly

Reinstall the speed reducer designated by CG (refer to Task #5), using new hydraulic motor and brake

(GFP)

Reassemble, Groom, and Lubricate

1 Buoy Crane 3.2.6 (Groom and lubricate)

Upon completion of all work, reassemble the crane.

Groom and lubricate IAW

TP-3557.

Clean, Inspect, and Lubricate

1 Swing Bearing Assembly Rotate the crane during lubrication. Submit CFR.

9 Final test 1 Buoy Crane Assembly B2.4 (Boom and Crane)

Perform operational and weight testing. Refer to Paragraph 6-6 of TP-3557.

See Table 3 for test weights.

Submit a CFR.

10 Fabricate and Install 1 Label plate B2.9 (Label plates)

TABLE 3 - TEST WEIGHTS

TEST WEIGHTS – AUX HOIST

Static Test 15,000 (+5% - 0%) lbs Dynamic 12,500 (+5% - 0%) lbs

Rated 10,000 (+0% - 5%) lbs at rated speed

TEST WEIGHTS – MAIN HOIST

Static Test 60,000 (+5% - 0%) lbs Dynamic 45,000 (+5% - 0%) lbs

Rated 40,000 (+0% - 5%) lbs at rated speed

NOTE

Coast Guard Personnel will operate equipment.

6 (Rev-0)

3.3 Special requirements for various components. If a Change Request has been authorized for additional work on any of the components listed in Table 2 below, the Contractor shall refer to the corresponding appendix or paragraph of SFLC Std Spec 5000, as applicable.

TABLE 4 – SPECIAL REQUIREMENTS

COMPONENT

APPENDIX &

PARAGRAPH IN

SFLC STD SPEC

Fluids C2.1

Hose assemblies C2.2 Piping and tubing C2.3

Valves and manifolds C2.4 Gages C2.5

Gas charged accumulators C2.6 Heat exchangers and fluid coolers C2.7

Systems C2.8 Fastener assemblies D2.1

Wire rope assemblies D2.2

Brakes and clutches D2.3

Open gearing and gear reducers D2.4

3.4 Crane components change-out. The Contractor shall be aware that the Government reserves the right to furnish new crane components for installation in-place of the ones removed. When the Government exercises this right, the Contractor shall turn over the removed componentto the Coast Guard PA as an MTI item.

4. NOTES

This section is not applicable to this work item.