0101_A_ INSPECT FLIGHT DECK TIE DOWNS REV A.docx

USNS SPEARHEAD

(JHSV 1)

INSPECT FLIGHT DECK TIE DOWNS

1.0 ABSTRACT

1.1 This item describes inspection of the Flight Deck Tie-Downs.

2.0 REFERENCES

2.1 JHSV-1 FD Tiedown Fitting Maint Orig

2.2 Flight Deck Tie Down Numbering Scheme NAVSEA 588-001

2.3 SPEARHEAD Checklist Flight Deck Tie Down Record

2.4 ALCOA Flight Deck Tie Down DWG. 05003554

2.5 Work Instructions for USNS Spearhead FDTD Fittings 20130212.pdf

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location

3.1.1 Flight Deck 02-55-0

3.2 Quantity

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE

4.1 Alcoa Cross Bar Removal Tool

5.0 NOTES

5.1 The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTR’s.

5.2 The contractor and all subcontractors, regardless of tier are advised to review other work items under this contract to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

5.3 The contractor shall furnish the services of an Alcoa Manufacturer’s Representative to supervise and document all steps of the SOW.

6.0 QUALITY ASSURANCE REQUIREMENTS

6.1 The contractor shall record the findings as stated in this SOW.

7.0 STATEMENT OF WORK REQUIRED

7.1 Prior to start of work obtain the latest version of 2.3 Flight Deck Tie Down Record for use throughout this SOW.

7.2 Perform the following inspections of 73 FDTDs using reference 2.1 as guidance. The MSC Rep will determine which FDTDs will be inspected using references 2.2 and 2.3 as guidance.

7.2.1 CROSSBARS: The crossbars shall be visually checked for deformation and checked for excessive wear using a Go-No-Go gage of type identified in maintenance requirement card (MRC) C1 8VVK N, enclosure(4). If visual indications exist where it appears crossbar material has been removed through corrosion or damage and has been painted over, then the paint in the vicinity of the reduced cross-sectional area shall be stripped prior to the Go-No-Go test.

7.2.2 FASTENER TORQUE: Each of the bolted fasteners of the crossbars to the cup should have a visible paint marking to identify the final bolt orientation at installation. A visible inspection of these markings shall be performed to ensure the fastener has maintained torque and has not loosened. Any bolted fastener with cracked, misaligned, or missing markings shall be checked for tension using a torque wrench. The torque wrench shall be set to 57 ft-lbs for the perimeter bolts and 95 ft-lbs for the center bolt. A maximum rotation of 1/24 turn (15 degrees) from the initial position of the torque wrench is allowable. Record the location of each bolt that exceeds maximum allowed rotation with respect to the orienting dimple on the cup.

7.2.3 TOPSIDE WELD: The welded interface of the tiedown fitting cup to the top of the Flight Deck planking shall be inspected. To determine that weld integrity has been retained, either magnetic particle testing, liquid penetrant testing, or visual inspection using 5X magnification, in accordance with NAVSEA Technical Publication T9074-AS-GIB-010/271, is acceptable. If the top weld fails the inspection, the cup’s bottom weld seam must also be inspected. This inspection will require removal and replacement of structural fire protection installed on the underside of the flight deck, 15’6” above the main deck, to gain access to the weld interface with the bottom skin of the flight deck planking. Removal of structural fire protection to inspect the underside of weld shall be by an approved Change Order.

7.2.4 TIEDOWN FITTING CUP: Visual inspection of cleaned top surfaces of the tiedown fitting cup for evidence of cracking, corrosion, or pitting should be made and results recorded.

7.2.5 CROSSBAR and FASTENERS: The interface of the crossbars to the cup shall be visually examined for any pitting of material due to dissimilar metal corrosion. Any visible dissimilar metal corrosion shall be cause for disassembly of the tiedown fitting to examine for any further corrosion in the area of the inserts into the fitting cup.

7.3 Provide the services of an Alcoa Manufacturer OEM to supervise and document the removal and installation of 30 FDTD crossbars.

7.4 Provide the parts listed in paragraph 3.2 to use during the crossbar inspections. Turn over any parts not used to the MSC Rep.

7.5 Remove 10 each FDTD crossbars and renew coating in accordane with ref 2.4. Reinstall and touch up any flight deck lines and coatings which extended to the cross bars.

7.6 Remove 30 FDTD crossbars using reference 2.1 and 2.5 as guidance.

7.6.1 Prior to disassembly, check the bolt torque.

7.6.2 Disassembly entails the removal of the five crossbar bolts and crossbar to permit a visual inspection of the ten sealing gaskets for cracks, cuts and permanent compression set.

7.6.3 Visually inspect the five threaded holes for corrosion or debris that would indicate seawater, fuel or other liquids have breached a seal.

7.6.4 Regardless of condition, the replacement of all five of the round gaskets directly under the bolt heads must be made every time the tiedown fitting is disassembled.

7.6.5 If any of the rectangular gaskets are damaged or deemed suspect, replace them and record their location with respect to the orienting dimple on the cup. No gaskets shall be re-used.

7.6.6 Corroded or damaged fasteners shall be replaced at ALCOA and MSCREP discretion.

7.6.7 Photographs shall be taken of the disassembled fasteners, seals, crossbars and if removed, the recoil inserts.

7.6.8 If corrosion is identified beyond 2 threads of the bolt, the bolt and the recoil insert should be replaced. If a visual inspection of the threaded inserts reveals the presence of the recoil “tang” at the bottom of the insert, it shall be removed and the bottom of the fastener shall be further examined for thread damage. If 1 full thread or more of the bottom of the bolt is damaged due to the presence of the recoil “tang”, that bolt shall be replaced.

7.6.9 Replacement of fastener bolts or recoil inserts requires a pull test. These tiedowns shall be marked out of service until their components are replaced.

7.6.10 If no corrosion or evidence of liquid intrusion is found and the required torques are achieved during reassembly utilizing the original fasteners, pull testing is not required. This would also include cases where only the cross bar is replaced.

7.7 Install the same 30 FDTD crossbars using reference 2.1 and 2.5 as guidance.

7.7.1 It is imperative that the sequencing and fastener torque during reassembly be conducted as per the following sections:

7.7.1.1 Torque the center bolt to 68 Nm (50 ft-lbs), then torque the perimeter bolts to 41 nm (30 ft-lbs) by first torqueing two bolts opposite each other and then the other two bolts opposite each other.

7.7.1.2 Continue with a final torque in the same sequence as above with a torque value of 136 Nm +/-6.8 (100 ft-lbs, +/-5.0) for the center bolt and 81 Nm +/-5.04 (60 ft-lbs+/-3.0) for the perimeter bolts.

7.7.2 For efficiency of future inspection, it is also imperative that bolts are paint marked to indicate final position after achieving the required torque.

7.8 Repairs or pull tests required due to the inspections will be the subject of a change order.

7.9 Perform topside weld repairs in two (2) tie down locations, tie down numbers C-8 and B-9. Remove underside fire protection panels and inspect underside weld. Prior to welding submit ABS welder qualifications and weld procedure to MSCREP.

7.9.1 Perform pull test in and post pull test inspection accordance with reference 2.1.

7.10 Record the results of the inspections on reference 2.3. Provide an electronic copy of the completed spreadsheet and photographs to the MSC Rep.

7.11 Manufacturer’s Representative:

William H. Grassel Senior Technical Specialist Alcoa Defense Alcoa Technical Center 100 Technical Drive Alcoa Center, PA 15069-0001 724-337-5813

8.0 General Requirements: None additional.

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