58300_JAH_1111_282_SINGLE_POINT_DAVIT_(GEN)_LEVEL_2_INSPECT_AND_TEST.doc

58300_JAH_0317_282

WORK ITEM 1: SINGLE POINT DAVIT (GEN) LEVEL 2 INSPECT AND TEST

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew davit's wire rope, perform service, inspect, and test the Allied D5700CT Single Point Davit (SPD), Control Console, Hydraulic Power Unit (HPU), and structure for integrity. Perform all of the work in this specification item on the port side single point davit. The starboard side single point davit has been removed.

1.2 Government-furnished property.

($/UNIT)

1 ea.

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing 282-WMEC 601-2, Rev G, CGC ALEX HALEY General Arrangements

Coast Guard Publications

Coast Guard Technical Publication (TP) , 05-SEP-13, Single Point Boat Davit – Model D5700CT – Multiple Class Cutters Coast Guard Technical Publication (TP) 2754, 22-JUN-84, Hydraulic Power Unit (HPU) - Multiple Class Cutters 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

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

Other References

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

3.1.2 Tech Rep. The Contractor shall provide the services of qualified Tech Rep, who is familiar with the Allied Single Point Davit equipment/system, to accomplish the following tasks – on site:

· Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

· Assist with proper repair methods, 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 The Contractor shall ensure that the Tech Rep is a certified representative of Allied Marine.

3.1.2.2 The Contractor shall submit the name of the Tech Rep to the COTR at the Arrival Conference.

3.1.3 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, 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:

· OTH RHI Boat

3.2 General. The Contractor shall perform the work listed on the port single point davit.

3.2.1 In the presence of the Coast Guard Inspector, inspect and test all affected equipment and systems to document original condition. Submit a Condition Found Report (CFR) noting any discrepancies in equipment and system operation. Use CG Tech Pub 3485C for guidance. Equipment including but not limited to winch, cylinder and all safety components. Davit location is shown in CG Dwg 282 WMEC 601-2. Starboard side davit has been removed.

3.2.2 Wash down and thoroughly clean the entire davit and associated components with fresh water and detergent. visually inspect, and operational test the Allied D5700CT Single Point Davit (SPD) including the Control Console and Hydraulic Power Unit (HPU) onboard the cutter. The contractor shall submit a Condition Found Report (CFR) to the Coast Guard Inspector with the inspection and test results identifying any deficiencies that may require immediate attention for continued safe operation of the davit. The report shall also identify and recommend any maintenance required to the davit and its components to extend operation until the next scheduled overhaul (2 years).

3.2.3 Ensure that runoff drain does not drain into the body of water.

3.2.4 Don’t remove any bushing for inspection. Inspect all bushings in-place. After each inspection, test, reading, etc the Contractor shall submit a CFR.

NOTE

It may be necessary to refer to Coast Guard Technical Publications while conducting inspection and tests on the SPD. For brevity, this specification will call out “Section,” “Chapter” or “paragraph” without mention of a reference. It will be assumed that it is referring to CG Tech Pub 3485C for SPD and CG Tech pub 2754 for HPU.

3.2.5 The Coast Guard will launch the Over The Horizon Rigid Hull Inflatable Boat (OTH RHI Boat) or Cutter Boat -Large.

3.2.6 CB-L Boat Inspection And Stowage – Hoist the boat out of the water and place it on the boat GFP trailer which will enable the Coast Guard to inspect and perform minor maintenance. Locate the boat in the cradle near the cutter. Weigh the CB-L in the presence of the Coast Guard Inspector (fully outfitted approximately 4150 lbs), record the weight and provide a written report including weight, outfit and fuel level to the Coast Guard Inspector. Ensure no liquid in the bilge.

<<Cutter, is there a trailer that Contractor can use? And Verify the boat weight.>>

3.3 The Contractor shall secure, and isolate all affected mechanical, piping, and electrical systems in accordance with the General Requirements.

Perform the work listed below on the port single point davit.

3.4 Davit Inspection. The Contractor shall perform the following work:

3.4.1 Verify that the load rating is clearly identified on the SPD and that a test plate is present and identifies that last date of testing.

3.4.2 Perform a “walk around” visual inspection of the davit structure, jib and pedestal for cracks., deformation, and corrosion. Visually inspect welds on davit structure, jib, and pedestal for cracks, damage or corrosion. Check that all bolts are secured and properly torqued in accordance with CG Tech Pub 3485B.

3.4.3 Perform a visual inspection of all hoisting fittings on the davit (release hook or release mechanism) and ensure that the release latch locks and releases freely without binding. Inspect sheave for wear with groove gage and pivot pins and bushings for wear in accordance with enclosed Figure “Sheave Inspection.” Inspect sheave housing for cracked welds and damage or deterioration. Inspect anti-two block switch assembly for damage, frayed wires or loose connections.

3.4.3.1 Quick release hooks must be recertified every 5 years. Submit a CFR if the quick release hook on the davit is in need of recertification.

3.4.4 Foundation Cap Screw Renewal. The contractor shall perform the following work:

Ship’s force reports that the cap screws which hold the davit inner race bearing to the davit foundation are heavily rusted. Cap screws cannot be torque checked due to heavily rusted heads. Ship’s force suspects many of the cap screws are seized in place. See part 31on figure 7A-2 Davit Assembly in CG Tech Pub 3845C.

3.4.4.1 Perform the swing bearing wear check on the davit assembly, following guidance in CG Tech Pub 3845C, ,paragraph 6.3.1.10.1. Record the bearing deflection value and submit a CFR. Make a recommendation on the CFR to renew the swing bearing if the deflection value exceeds 0.035”.

3.4.4.2 Remove each of the rusted cap screws holding the davit assembly to the swing bearing inner race. These are PC 28 on Table 7A-2 of CG Tech Pub 3845. Remove the cap screws one at a time to prevent davit from shifting. Provide and install new cap screws bolts in way of the old cap screws.

3.4.4.2.1 Ship’s force has reported that several of the cap screws are seized in placed and the Contractor shall include in the price of his bid that significant excess work, including possible drilling out of several cap screws may be required to remove them.

3.4.4.2.2 If any hot-work required to remove the cap screws, all hot work shall be done in accordance with SFLC Std Spec 0740.

3.4.4.3 After each of the cap screws have been replaced with new, torque all of the cap screws in accordance with CG Tech Pub .

3.4.4.4 After the new cap screws have been installed and torque, paint the tops of each cap screw with one coat of epoxy paint to match the existing color of the davit.

3.4.5 Lubricate grease all davit fittings in accordance with Chapter 4 of the CG Tech Pub.

3.5 Wire Rope Removal. The Contractor shall remove and dispose of wire rope and end fitting from the davit by paying out the entire length from the drum in accordance with all federal, state, and local laws and regulations. Remove down stop control assembly. Remove wire rope from the drum by tapping out the cable wedge at the bitter end connection. Retain quick release hook or hook release mechanism [for OTH RHI BOAT’s with lifting frame] for reuse.

3.6 Boom Cylinder. The Contractor shall visually inspect cylinder pins, and bushings for wear. Inspect for leakage in the vicinity of the stem and packing gland and service in accordance with CG Tech Pub 3485B.

3.6.1 Cylinder Test. In the presence of the Coast Guard Inspector. Pressurize both sides of the cylinder to 3,000 psig and hold for 10 minutes to test for leakage, no pressure drop allowed. No leakage is allowed.

3.7 Swing Assembly. The Contractor shall visually inspect the swing gear and pinion for excessive wear and damage. Check that the pinion gear caps and cap screws are secured. Check oil level in gear reducer by removing plug on top of the gearbox. Oil level will be visible through hole. Change oil in accordance with CG Tech Pub 3485B.

3.7.1 Inspect swing motor and stop valve for leakage.

3.8 CT Winch Assembly. The Contractor shall wire brush winch drum and inspect surface for cracks, wear, damage or corrosion. Oil level will be visible through holes. Change oil in accordance with CG Tech Pub 3485C.

3.9 Hydraulic Power Unit (HPU). The Contractor shall perform the following work:

3.9.1 Check fluid level in tank is full (100 gallons capacity) and submit a CFR. Renew tank vent filter. Renew pressure filter.

3.9.2 Inspect welds of HPU frame and welding of frame to deck for cracks or corrosion. Inspect motor and pump shock mounts for wear or loose hardware. Check the electric motor insulation resistance reading.

3.9.3 Start HPU or activate Ship’s central hydraulic system. Verify that davit supply pressure is 2500 psig maximum. Verify that operating pressure at control console is 2500 psig. Check pressure settings from table 1 2 and ,make adjustments in accordance with section 6.2 of CG Tech Pub 2754. Check full load motor amperage draw, voltage, and frequency and submit a CFR. Relief valve is set at 2750/2900 psig (see the NOTE below). Check the setting of the SPD relief valve (located in the hydraulic control valve assembly) paragraph 6-2.1. Adjust as required.

NOTE

Instructions for relief valve adjustments can be found in Dwg #11247 Note 11, sheet 1 of 3. The system pressure should be set using warm oil, not cold oil. 250 psi differential is minimal, at best.

3.9.4 Visually check for leaking connections, worn or damaged hoses and fittings, or any other defect.

3.9.5 Take a representative oil sample from the single point davit hydraulic system at a return line location designated by Coast Guard Inspector and send it out for particle and water analysis. Analysis shall include particle size and populations and a classification in accordance with ISO 4406, code 19/16. Submit report on results within the first week of the availability.

3.9.6 Check that low level alarm, immersion heater, temperature sensing probe, controller, and thermostat are functioning.

3.10 Control Console. The Contractor shall remove the cover at the front of the console and visually inspect hydraulic lines for leakage, damage or corrosion. Inspect for loose hardware.

3.10.1 Accumulator. Ensure that pressure gage and discharge valve are operational. Inspect for corrosion and check precharge in accordance with CG Tech Pub .

3.10.2 Verify that CT mode indicator lights on control console are operational.

3.10.3 Control Levers. Inspect control levers for jib and swing operations and ensure that they return to center “neutral” position and operate freely.

3.10.4 Inspect Joystick control lever for freedom of movement. Check for loose connections and hardware. Remove joystick cover and inspect control box assembly for loose connections and loose hardware. Also check for presence of moisture. Inspect cover gasket.

3.10.5 Emergency Winch Control Lever. Check for loose connections and loose hardware.

3.10.6 Control Valve Assembly. Check for leaks.

3.11 Wire Rope Renewal. The Contractor shall renew wire rope and end fitting with pre-lubricated 5/8”Dia., 6x37, 75’, Extra Improved Plow Steel (XIPS), preformed, and IWRC in accordance with NSTM Chapters 613 and 589. Lubricant shall meet MIL-G-18458. Wire rope shall meet or exceed API Specifications 9A. Renew wire rope cable wedge (drum attachment). Ensure kinking or bird caging does not occur on wire rope during renewal. Lead wire rope through anti-two block weight prior to installing end fitting. Maintain 100 pounds of tension on the hook when spooling wire rope on the drum. Inspect down stop assembly for wear, (worn roller or cam), damage and deterioration. Ensure that spring has adequate tension to maintain pressure of the roller on the drum surface.

3.11.1 Prior to purchasing new wire rope for the davit, verify the end fitting on the existing wire rope. During the previous availability it was noticed that end fitting shown in the technical manual do not match the end fittings on the existing wire rope. Ensure that correct end fittings are purchased.

3.12 The Contractor shall lubricate grease fittings in accordance with Chapter 4.

3.13 The Coast Guard is responsible for breasting out the cutter if required and making the necessary adjustments to gangways, shore ties and mooring lines as required for testing. Notify the Coast Guard Inspector at least 72 hours before testing and shall coordinate all cutter movement with the Coast Guard.

3.14 Pre-Test Inspection. The Contractor shall prior to operating the davit perform the following inspections:

3.14.1 Restore all affected equipment and systems in accordance with the General Requirements.

3.14.2 Perform a careful inspection of all hoisting fittings and slings to determine any apparent weakness in the fittings or in their attachment to the boat, and to determine whether all parts appear to be in operable condition.

3.14.3 All davit testing shall be in accordance with manufacturer’s instructions. Test OTH RHI Boat rigging and SPD:

(a) No load test

(b) Static Load Test the Davit, 150% of rated load = 8,550 lbs

(c) Dynamic Load Test the Davit, 125% of rated load at no specific speed = 7,125 pounds

(d) Rated load test at rated speed with 5700 lbs

(e) Constant Tension Feature Testing with 2500 lbs

(f) Static Load Testing OTH RHIB rigging gear consisting of the sling to 6500 lbs

NOTE

OTH Single Point Davit Tests are conducted with independent test weights or water bag. The boat is NOT used. The Contractor shall provide water bag.

3.15 Static Testing. The Contractor shall test the static strength of the SPD by attaching 8,550 lbs of Contractor furnished weights (or water bag) to the hook. Ensure that the weight will not strike the cutter or damage it in any way. Hold the weight for at least 10 minutes in this condition. No visually observable creep/slip shall be allowed. The Contractor shall provide 8,550 lbs test weight.

3.15.1 Use a crane to place the weight on the davit hook. It will not bear weight during testing, but shall remain on the hook for the duration of the static weight test. Upon the completion of static test, remove all weights

3.15.2 Post Test Inspection. Following each test, an inspection shall be made in the presence of the Coast Guard Inspector to ensure that no parts have been strained and to verify that all parts are in proper condition. Typical defects to look for are:

a. Elongated, deformed or cracked shackles

b. Cracks or deformation of bolt holes or bolts

c. Deformed or cracked welds

d. Loss in strength due to corrosion or deterioration

e. Elongated or frayed wire rope

f. Loosening of wire rope fittings

g. Absence of lubrication on cables, rollers and sheaves

h. High strands, bird caging or kinks in wire rope

3.16 Dynamic Testing. After successful static testing, the Contractor shall operationally test the SPD to 125 percent of hoisting capacity (7125 lbs). Ensure that the Contractor furnished weight will not strike the cutter or damage it in any way. Check winch for rated speed at rated load and check rated hydraulic oil flow and pressure in accordance with the manufacturer recommendation.

NOTE

7125 lbs is the maximum operational test load for the 5700CT SPD.

3.16.1 Test the winch operation by raising and lowering the weight. Raise and lower the weight through at least 3 cycles. Ensure wire rope reeves fair on the winch drum and all mechanisms are set properly.

3.16.1.1 Lower the weight. Stop and raise the weight 6“. Hold for 5 minutes without slippage.

3.16.1.2 Raise the weight and breast the davit in and out.

3.16.1.3 Stow weight and repeat steps above, 3 times.

3.16.2 Test the swing drives by holding the weight against the cutter’s rail after first protecting the rail with chafing gear.

3.17 Rated Load Test. The Contractor shall perform the following work:

3.17.1 Operationally test the SPD to 100 percent of hoisting capacity (5700 lbs) at rated speed. Test the winch operation by raising and lowering the weight. Raise and lower the weight through at least 3 cycles. Ensure wire rope reeves fair on the winch drum and all mechanisms are set properly.

3.17.1.1 Lower the weight. Stop and raise the weight 6“. Hold for 5 minutes without slippage.

3.17.1.2 Raise the weight and breast the davit in and out.

3.17.1.3 Stow weight and repeat steps above, 3 times.

3.18 CT Operational Test. The Contractor shall perform the following work: Simulate “wave action” for CT Test. To simulate “wave action,” the Contractor shall hook the test weight by a crane and lifting/lowering as a wave would using a test weight/water bladder.

3.18.1 No Load Run Thru Test:.

NOTE: The winch should have at least 2500 lbs. of tension on the hook to perform its functions.

3.18.2 Disconnect the OTH RHI Boat’s sling from the SPD and operate the davit through 3 complete cycles. Ensure that each mode of operation (Hoisting/lowering, CT operation, articulation of jib and stewing are satisfactory. Also test the anti-two block and down stop functions by hoisting and lowering the hook to actuate the systems. Swing SPD to max rotating limits to actuate swing stops. Refer to chapter 5 for troubleshooting if any problems arise during tests.

3.18.3 Under no circumstances shall the control console be left unattended while the tests are being conducted.

3.18.4 In the presence of the Coast Guard Inspector, the contractor shall test the davit as specified below:

3.18.5 Operational Test. The Contractor shall perform the following work:

3.18.5.1 Attach the OTH RHI Boat’s sling to the SPD (Release Hook) and operate the davit with the OTH RHI Boat thru one complete cycle from the stowed position and back performing all modes of operation.

3.18.5.2 Constant Tension Feature Test. The Contractor shall perform the following work:

CAUTION!

While conducting this test, exercise care not to inadvertently move the joystick to “max” tension mode with an unloaded hook. This will cause the hook to quickly raise up at max speed and actuate the anti-two block switch.

NOTE

Use a forklift to simulate waves.

3.18.5.3 As the OTH RHI Boat is lowered to the water, depress the button to select constant tension mode. When the OTH RHI Boat is waterborne, the boom pressure sensing switch will close by release of OTH RHI Boat weight and switches the system to the constant tension mode (within one second). Allow the OTH RHI Boat to ride the waves with the CT mode engaged. The joystick control should be set for max CT tension. If this does not occur, the switch settings will require adjustment as outlined in Chapter 5.

3.18.5.4 With the OTH RHI Boat in the water, move the joystick lever to min CT tension, and release the hook from the boat sling by manually pulling the hook down to obtain slack in the cable. The hook will remain at that position because the force required to overhaul the brake drum is less than 50 lbs. If this cannot be accomplished, the settings will require adjustment as outlined in Chapter 5.

3.18.5.5 Cancel CT mode, and raise the unloaded hook up to the davit head. Lower the hook back down to the water and allow it to stop within the crew’s reach. The crewman should manually overhaul wire rope fall and pull the hook down for hookup with the boat sling. Once the hook is engaged, move the joystick to max CT tension and allow the OTH RHI Boat in the water. When the boat crew acknowledges readiness and the OTH RHI Boat reaches the crest of the wave, cancel the CT mode and raise the OTH RHI Boat from the water to the stowed position onboard the cutter.

CAUTION!

If constant tension mode is cancelled while the OTH RHI Boat is tending down a swell, The davit will shock load, creating the potential for davit failure.

3.19 Static load testing OTR RHI Boat rigging gear consisting of the sling. The Contractor shall add test weights to the OTH RHI Boat , using portable test weights (i.e. sand bags, or small water bag), equivalent to 50% of the boat weight and outfits, a total of 6500 lbs. The davit winch and rigging shall be used to lift the loaded boat several inches clear, to hold the test weight for 10 minutes, and to lower the boat back to the cradle, under control. Remove the test weights. Visually inspect the OTH RHI Boat rigging gear and sling and verify no permanent deformation or damage. Submit a CFR.

3.20 Emergency Operation Simulation. The Contractor shall, with the OTH RHI Boat in the stowed position, cut off all electrical power to the HPU and SPD. Conduct emergency OTH RHI Boat handling operations in accordance with CG Tech Pub 3485C.

3.21 Test Report. The Contractor shall submit a Condition Found Report (CFR) of all, tests and inspections to the Coast Guard Inspector within 24 hours.

3.22 Provide and attach an engraved brass label plate showing the Rated working Load, Dynamic Load Test, and Static Test Load, place and date of test. The Coast Guard Inspector will designate the location for this plate.

3.23 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed interior surfaces to match existing adjacent surfaces, in accordance with SFLC Sts Spec 6310 Appendix B (Cutter and Boat Interior Painting Systems). Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

3.23.1 Restore all interferences to their original condition in accordance with the General Requirements.

4. NOTES

This section is not applicable to this work item.

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