Attachment_2-_Work_Specification.pdf

USCGC HICKORY (WLB 212)

SPECIFICATION FOR UNPLANNED DOCKSIDE REPAIRS

FY2017

Developed By: Bronson L Suyat

(Rev-0, 29 August 2017)

USCGC HICKORY (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: No. 1 Ship Service Diesel Generator, Overhaul Rotor WORK ITEM 2: No. 1 Ship Service Diesel Generator, Overhaul Stator WORK ITEM 3: No. 2 Ship Service Diesel Generator, Inspect 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 201-2, Rev C, Access Removal Routes

COAST GUARD PUBLICATIONS

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

Manual Coast Guard Technical Publication (TP) 3537B, Manufacturer's Instruction Book – SWBS Group(s) 310 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0450, 2014, Electrical Power for

Contractor’s Tools & Equipment Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3100, 2014, Inspect, Test and

Recondition AC Synchronous Machines In-Place Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3101, 2014, Overhaul AC

Synchronous Machines 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

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

Repair of Rotating Electrical Apparatus 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 ***RECTIFIER

ASSEMBLY

NSN: 5999-01-293-2369

PN: 5N-9421

1 ea. 2,624.49

*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

3 No. 2 Ship Service Diesel Generator, Inspect 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 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

• Provide portable fire extinguishers for Coast Guard fire watch personnel. Coast Guard fire watch is in lieu of contractor personnel during the hours of 0800-1600, Monday through Friday, and limited to two Coast Guard fire watch personnel.

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

3.3 Preservation requirements. The Contractor shall accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec 6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

3.3.2 Coating colors and system color schemes. Ensure that all colors and color coat/paint schemes are in accordance with COMDTINST M10360.3, Chapter 6 (Cutter and Boat Colors Exterior and Interior).

NOTE

Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes (provided in Chapter 6 of COMDTINST M10360.3) are strictly prohibited.

3.4 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740.

3.5 Environmental protection requirements. The Contractor shall adhere to the following environmental protection requirements in accordance with the SFLC Stand Spec 0000:

3.5.1 USCG facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, during the performance of this availability. Contractor shall plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor shall comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.1.1 USCG Generator status. The activity Generator Status for the Coast Guard Facility is Small quantity exempt.

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 (Rev-0)

3.5.2 Test and procedures. The Contractor shall be required to promptly conduct tests and procedures for the purpose of assessing whether operations are in compliance with applicable Environmental Laws. Analytical work shall be done by qualified laboratories; and where required by law, the laboratories shall be certified.

3.5.3 Regulatory notifications. The Contractor shall be responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The Contractor shall submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications shall be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

3.5.4 Environmental manager. The Contractor shall appoint in writing an Environmental Manager for the project, and shall be responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager shall ensure compliance with Hazardous Waste Program requirements, including hazardous waste handling, storage, manifesting, and disposal; implement the Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas;

ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the Environmental Records binder and required documentation, including environmental permits compliance and close-out.

3.5.5 HW disposal. Contractor shall comply with SFLC Std Spec 0000 Appendix B, Requirements For Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

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

3.5.6.1 No Contractor or Subcontractor shall have the authority to sign a Hazardous Waste Manifest using the Coast Guard facility’s EPA Generator ID Number or remove contract generated hazardous waste from the Coast Guard facility without COR or KO-approval.

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

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

3.6 Local Policy. None.

3.7 SFLC standard specification approved changes. The Contractor shall be aware that the following are approved changes to published SFLC 2014 Edition Standard Specifications and supersede published content:

4 (Rev-0)

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

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

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

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

3.7.1.4 Standard Spec 6310, page Appendix A-7, Under "UNDERWATER (U/W) BODY/BOOT-TOP", Add line Column 1: Option for U/W Body and Boot-Top, Steel Hulls, <154', in Salt Water. Column 2: Blank. Column 3:

SSPC-SP 10/NACE NO. 2 using grit conforming to MIL-A-22262 / (1.5-3.5) - or - SSPC-SP WJ-2(M)/NACE WJ-2(M). Columns 4 and 5: Same as "U/W Body and Boot-Top, Aluminum Hull, High Speed (>30 knots)".

3.7.2 SFLC Standard Specification 0000 General Requirements.

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

3.7.2.2 Change Std Spec 0000 paragraph 3.2.4.2.3(QP 1 inspector or tech rep duties) bullet, “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph

3.1.19 of SFLC Std Spec 6310 (Critical drying time requirements)).” to “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph 3.1.17 of SFLC Std Spec 6310 (Critical drying time requirements)).”

4. NOTES

4.1 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 6310 to be completed and submitted during preservation of “critical-coated surfaces”, are provided at the end of this document.

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.

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

6 (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 |

7 (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:

8 (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).

9 (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)

10 (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

11 (Rev-0)

31124_ RAD_0817_212

WORK ITEM 1: No. 1 Ship Service Diesel Generator, Overhaul Rotor

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to repair, ashore in a suitable repair facility, the rotor of No. 1 Ship Service Diesel Generator, which suffered metal to metal contact on the exciter and exciter stator causing 4 bolts to shear and damaged the key way on rotor shaft. Metal shavings are present throughout the generator stator and rotor windings and windings are grounded.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y ***RECTIFIER

ASSEMBLY

NSN: 5999-01-293-2369

PN: 5N-9421

1 ea. 2,624.49

*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 201-2, Rev C, Access Removal Routes

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3537B, Manufacturer's Instruction Book –

SWBS Group(s) 310 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0450, 2014, Electrical Power for Contractor’s Tools & Equipment Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3101, 2014, Overhaul AC Synchronous Machines

OTHER REFERENCES

American National Standards Institute (ANSI/EASA) AR100, 2015, Recommended

Practice for the Repair of Rotating Electrical Apparatus

12 (Rev-0)

3. REQUIREMENTS

3.1 General. Repair the rotor of No. 1 Ship Service Diesel Generator in accordance with SFLC Std Spec 3101, using ANSI/EASA AR100-2015 instead of AR100-2010 as referenced. The recommended rigging path, when known, is shown in the drawing referenced above. Generator data is shown in Table 1 below.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

3.1.2.1 Provide the services of a Technical Representative (Tech Rep), who is familiar with AC synchronous machine repair. Both the Tech Rep and the Coast Guard Inspector shall be present to witness the performance of all tests, inspections, and cleaning operations performed under this specification.

3.1.2.2 The Tech Rep shall be employed by a shop that is a member of the Electrical Apparatus Service Association (EASA) and that shop shall adhere to the association’s standards, including

ANSI/EASA AR100.

3.1.2.3 Submit a copy of the Tech Rep’s résumé and a list of references to the COR at the Arrival Conference.

3.1.3 Protective measures. 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, 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. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph

3.3.5 (Interferences).

3.2 Removal. Disassemble the generator and rig out the rotor to be worked ashore in accordance with Section A.2.1 of Appendix A of SFLC Std Spec 3101. See CG Drawing 225B-WLB 201-2 for the rigging path to buoy deck through hatches and watertight doors; no removal of bolted (BERP) or welded (WERP) equipment removal plates is anticipated. Using the installed buoy crane, the cutter crew will lift the rotor from the buoy deck and set it on the bed of the Contractor’s truck ashore, transfering it back to the buoy deck after overhaul.

3.3 Initial inspection. Perform the initial inspection and tests of section 3.3 of SFLC Std Spec 3101. Submit a CFR.

3.4 Shop work. For bidding purposes, assume that all six rotor poles must be rewound ashore in a suitable repair facility; the Government may request an equitable adjustment if the actual scope of repairs performed is reduced based on inspection results. Perform the shop work appendices of SFLC Std Spec 3101 as follows:

13 (Rev-0)

3.4.1 Rewinding. Rewind all rotor poles per Appendix C. Varnish may be applied to new windings using the vacuum pressure impregnation (VPI) method. Insulation treatment shall be of temperature Class H or better.

3.4.2 Miscellaneous repairs. Renew the shaft per paragraph D2.1 of SFLC Std Spec 3101, including necessary repairs to keyway and fabrication of a new key. Also inspect permanent magnet keyway and make repairs if needed. Renew frame and bearing housings, and bearings per paragraphs D2.3 and D2.4 respectively, of SFLC Std Spec 3101. None of the other miscellaneous repairs of Appendix D are expected to be needed, but may become the subject of a changed order if deficiencies are found during the initial inspection. When authorized, such repair shall be performed in accordance with the applicable Appendix D section listed in Table 2 of SFLC Std Spec 3101.

3.5 Balancing. Dynamically balance each rotor assembly per Section 3.4.4 of SFLC Std Spec 3101. Submit a CFR.

3.6 Reassembly. Reassemble each machine per Section 3.4.5 of SFLC Std Spec 3101. For exciter armature (rotor – L2) bolts on Caterpillar SR4 generators, apply thread locking compound per Caterpillar service manual Form No. SENR3985, contained within the generator technical publication, and tighten 5/16 inch bolts to 26 lb-ft and ⅜ inch bolts to 41 lb-ft.

3.7 Shop acceptance testing. Accomplish the shop acceptance tests of Section 3.5 of SFLC Std Spec 3101. Submit a CFR.

3.8 Final assembly. Complete reassembly work per Section 3.6 of SFLC Std Spec 3101.

3.9 Packaging. Package each reassembled machine per Section 3.7 of SFLC Std Spec 3101.

3.10 Reinstallation. Reinstall the generators or assemblies that were worked ashore in accordance with Section A.2.2 of Appendix A of SFLC Std Spec 3101.

3.11 Final acceptance testing. Accomplish the final acceptance tests of Section A.2.3 of Appendix A of SFLC Std Spec 3101. Submit a CFR.

TABLE 1 – GENERATOR DATA

QUANTITY CHARACTERISTICS MANUFACTURER LOCATION

450 kW, 450 VAC, 60 Hz, 3 phase, 1200 RPM, 0.8 power factor Caterpillar Engine Room

4. NOTES

4.1 Additional pad eyes will most likely be needed for removal.

4.2 This generator is (rotor only) removable from the vessel without making a hull cut.

14 (Rev-0)

4.3 Contractor should be aware that a marine chemist will be needed to certify the space, per SFLC General Specification 0000, prior to commencing hot work.

15 (Rev-0)

31125_ RAD_0817_212

WORK ITEM 2: No. 1 Ship Service Diesel Generator, Overhaul Stator

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to to rewind, ashore in a suitable repair facility, the stator of No. 1 Ship Service Diesel Generator, which suffered metal to metal contact on the exciter and exciter stator causing 4 bolts to shear and damaged the key way on rotor shaft. Metal shavings are present throughout the generator stator and rotor windings.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 225B-WLB 201-2, Rev C, Access Removal Routes

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3537B, Manufacturer's Instruction Book –

SWBS Group(s) 310 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0450, 2014, Electrical Power for Contractor’s Tools & Equipment Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3101, 2014, Overhaul AC Synchronous Machines

OTHER REFERENCES

American National Standards Institute (ANSI/EASA) AR100, 2015, Recommended

Practice for the Repair of Rotating Electrical Apparatus

3. REQUIREMENTS

3.1 General. Overhaul the stator of No. 1 Ship Service Diesel Generator ashore in a suitable repair facility in accordance with SFLC Std Spec 3101, using ANSI/EASA AR100-2015 instead of AR100-2010 as referenced. The recommended rigging path, is shown in the drawing referenced above. Generator data is shown in Table 1 below.

3.1.1 CIR.

16 (Rev-0)

None.

3.1.2 Tech Rep.

3.1.2.1 Provide the services of a Technical Representative (Tech Rep), who is familiar with AC synchronous machine repair. Both the Tech Rep and the Coast Guard Inspector shall be present to witness the performance of all tests, inspections, and cleaning operations performed under this specification.

3.1.2.2 The Tech Rep shall be employed by a shop that is a member of the Electrical Apparatus Service Association (EASA) and that shop shall adhere to the association’s standards, including

ANSI/EASA AR100.

3.1.2.3 Submit a copy of the Tech Rep’s résumé and a list of references to the COR at the Arrival Conference.

3.1.3 Protective measures. 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, 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. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph

3.3.5 (Interferences). For bidding purposes, anticipate hot work will be required to remove and reinstall some of the interferences. Known interferences include, but are not limited to the below-listed (see Section 4 below for more details):

• No. 1 SSDG Engine jacket water expansion tank

• Fire tight door at frame 67

• Ladder

• Fuel oil filter assemblies/ gauges and hoses

• #1 SSDG Exhaust piping

• MDE Ventilation ducting

• SSDG air filter housings

• Lighting

• Smoke detectors

• Fire main piping and hose stations

3.2 Removal. Remove the generator assemblies to be worked ashore in accordance with Section A.2.1 of Appendix A of SFLC Std Spec 3101. See CG Drawing 225B-WLB 201-2 for rigging path to weather including any bolted (BERP) or welded (WERP) equipment removal plates that must be removed. Using the installed buoy crane, the cutter crew will lift the stator from the buoy deck and set it on the bed of the Contractor’s truck ashore, transfering it back to the buoy deck after overhaul.

3.3 Initial inspection. Do not perform the initial inspection and tests of Section 3.3 of SFLC Std Spec 3101, as these were performed under definite work item No. 1 Ship Service Diesel Generator, Overhaul Rotor.

17 (Rev-0)

3.4 Shop work. Perform the shop work appendices of SFLC Std Spec 3101 as follows:

3.4.1 Rewinding. Rewind the stator per Appendix C. Varnish may be applied to new windings using the vacuum pressure impregnation (VPI) method. Insulation treatment shall be of temperature Class H or better.

3.4.2 Miscellaneous repairs. None of the miscellaneous repairs of Appendix D are expected to be needed, but may become the subject of a changed order if deficiencies are found during the initial inspection performed under work item No. 1 Ship Service Diesel Generator, Overhaul Rotor. When authorized, such repair shall be performed in accordance with the applicable Appendix D section listed in Table 2 of SFLC Std Spec 3101.

3.5 Packaging. Package each reassembled machine per Section 3.7 of SFLC Std Spec 3101.

3.6 Reinstallation. Rig the stator back into the Main Machinery Room. The remaining reinstallation work is performed under definite work item No. 1 Ship Service Diesel Generator, Overhaul Rotor.

3.7 Final acceptance testing. Accomplish the final acceptance tests of Section A.2.3 of Appendix A of SFLC Std Spec 3101. Submit a CFR.

TABLE 1 – GENERATOR DATA

QUANTITY CHARACTERISTICS MANUFACTURER LOCATION

450 kW, 450 VAC, 60 Hz, 3 phase, 1200 RPM, 0.8 power factor Caterpillar Engine Room

4. NOTES

4.1 This work item was written with the knowledge that damage has been sustained to the exciter stator. Where “stator” is written, consider it to include the entire stator assembly: both the exciter stator and the main stator. These stators are identified in Figure 4 as parts 14 and 15.

4.2 Additional pad eyes will most likely be needed for removal.

4.3 Contractor should be aware that a marine chemist will be needed to certify the space, per SFLC General Specification 0000, prior to commencing hot work.

4.4 The No. 1 SSDG generator is located on the port side of the Main Machinery Room Upper (mezzanine) Level (4-66-0-E) as shown in Figures 1 through 3 below. No. 1 SSDG is forward of No. 2 SSDG. Both are outboard of the mezzanine railing. Known interferences to the work include the No. 2 Main Diesel Engine jacket water expansion tank, fire fighting station, fuel oil purifier head tank, and mezzanine railings.

4.4.1 The generator stator may be removed from the vessel through existing Bolted Equipment Removal Plate (BERP) and Welded Equipment Removal Plate (WERP) openings. The

18 (Rev-0) recommended load path, shown on CG Drawing 225-WLB 201-2, is up through Crew’s Mess and forward to the Buoy Deck.

4.4.2 Doors and hatches are shown in CG Drawing 225-WLB 167-1. A 60” x 36” watertight hatch is located at the top of the ladder adjacent to No. 1 SSDG and can be used to rig out the rotor to the Buoy Deck through existing openings. A 96” x 46” Bolted Equipment Removal Plate (BERP), located in the Mess Deck immediately above the forward opening in the mezzanine deck, may also be unbolted for rigging out the rotor and stator. The two quick acting watertight doors (QAWTDs) at frames 57 and 66 leading from the Buoy Deck to the Mess Deck are 36” × 72” and are each outfitted with a 46” × 80” Welded Equipment Removal Plate (WERP) that can be cut along the weld seam to create an opening large enough to rig out the entire generator. See CG Drawings 225-WLB 201-1, 225-WLB 310-202, and 225-WLB 601-2 for more information.

FIGURE 1 – PORT SIDE OF MAIN MACHINERY ROOM UPPER LEVEL (4-66-0-E)

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FIGURE 2 – NO. 1 SHIP SERVICE DIESEL GENERATOR (FORWARD END)

FIGURE 3 – NO. 1 SHIP SERVICE DIESEL GENERATOR (AFT END)

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FIGURE 4 – SSDG INTERNAL ARRANGEMENT AND

FIGURE 5-SSDG CROSS-SECTION AND DIMENSIONS

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31126_ RAD_0817_212

WORK ITEM 3: No. 2 Ship Service Diesel Generator, Inspect

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect and test in place the rotor and stator windings of No. 2 Ship Service Diesel Generator (SSDG). SSDG is believed to be in good condition. Bearings were renewed in April of 2015, bearing and bearing housing needs to be inspected for wear.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 225B-WLB 201-2, Rev C, Access Removal Routes

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3537B, Manufacturer's Instruction Book –

SWBS Group(s) 310 Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0450, 2014, Electrical Power for Contractor’s Tools & Equipment Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 3100, 2014, Inspect, Test and Recondition AC Synchronous Machines In-Place

OTHER REFERENCES

American National Standards Institute (ANSI/EASA) AR100, 2015, Recommended

Practice for the Repair of Rotating Electrical Apparatus

3. REQUIREMENTS

3.1 General. Inspect, recondition, and test in place the No. 2 Ship Service Diesel Generators (SSDG) in accordance with SFLC Std Spec 3100, using ANSI/EASA AR100-2015 instead of AR100-2010 as referenced. Generator data is shown in Table 1 below.

22 (Rev-0)

TABLE 1 – GENERATOR DATA

QUANTITY CHARACTERISTICS MANUFACTURER LOCATION

450 kW, 450 VAC, 60 Hz, 3 phase, 1200 RPM, 0.8 power factor Caterpillar Engine Room

3.1.1 CIR. Submit a CIR for the inspections listed in the following paragraph(s):

None.

3.1.2 Tech Rep. Provide the services of a Technical Representative (Tech Rep), who is familiar with AC synchronous machines and shall be present during the performance of this work. The technical representative shall be employed by a shop that is a member of the Electrical Apparatus Service Association (EASA) and that shop shall adhere to the association’s standards, including ANSI/EASA AR100. Both the technical representative and the Coast Guard Inspector shall be present to witness the performance of all tests, inspections, and cleaning operations performed under this specification.

3.1.2.2 The Tech Rep shall be employed by a shop that is a member of the Electrical Apparatus Service Association (EASA) and that shop shall adhere to the association’s standards, including

ANSI/EASA AR100.

3.1.2.3 Submit a copy of the Tech Rep’s résumé and a list of references to the COR at the Arrival Conference.

3.1.3 Protective measures. 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, 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. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph

3.3.5 (Interferences).

3.2 Requirements. Accomplish all work detailed in SFLC Std Spec 3100, with the exception of the following (unless a Change Request has been authorized and released by the KO):

3.2.1 Bearing wear. Measure and record bearing wear in accordance with SFLC Std Spec 3100, Section 3.2.3.6, Bearing wear. Inspect bearing housing for defects. Submit CFR.

3.2.2 Collector rings. Do not measure and record collector ring wear and concentricity in accordance with SFLC Std Spec 3100, Section 3.2.3.7, Collector ring wear and concentricity.

3.2.3 Rotor extraction. Remove the rotor for cleaning within the compartment in accordance with SFLC Std Spec 3100, Section 3.2.3.8, Rotor removal.

3.3 Insulation treatment. Do not touch up thin and bare spots on the cleaned windings with an air drying varnish in accordance with SFLC Std Spec 3100, 3.3.2, Insulation treatment.

23 (Rev-0)

3.4 Utility services. The use of Coast Guard utility services, both afloat and ashore, for performance of this work item is restricted as follows:

3.4.1 Electrical power. Electrical power for temporary tools and equipment used to accomplish this work item shall comply with SFLC Std Spec 0450.

3.4.1.1 Dockside equipment. Power solely for dockside tools and equipment may be taken from the dockside electrical power distribution system in accordance with Appendix A (preferred) of SFLC Std Spec 0450 or from the shipboard electrical power distribution system in accordance with Appendix D of SFLC Std Spec 0450.

3.4.1.2 Shipboard equipment. Power solely for shipboard tools and equipment may be taken from the ship service electrical distribution system in accordance with Appendix B (preferred) of SFLC Std Spec 0450 or from the dockside electrical power distribution system in accordance with Appendix C of SFLC Std Spec 0450.

3.4.3 Compressed air. Compressed air for tools and generator hand cleaning may be taken from the ship service air system. Air that is to be blown into a generator shall be filtered for particulate, water, and oil prior to discharge.

4. NOTES

This section is not applicable to this work item.