0102-RevB_A_Tank_Preservation.doc

USNS RAPPAHANNOCK

T-AO 204

HULL STRUCTURE

23 February 2018

TANK PRESERVATION

1.0 ABSTRACT

1.1 This item describes the surface preparation and re-coating of the seven (7) tanks listed in paragraph 3.1.

2.0 REFERENCES/ENCLOSURES

2.1 References:

2.1.1 Surface Preparation Specifications, Steel Structures Painting Council, Systems and Specifications, Volume 2.

2.1.2 NAVSEA Dwg. 101-6581216, "General Arrangement of Tanks and Flats, Fwd Fr 60" for Double Hull Tankers.

2.1.3 NAVSEA Dwg. 101-6581214_A, "General Arrangement Double Bottom, T-AO 201, 203, 204.

2.1.4 NAVSEA Dwg. 801-6580574, "Capacity Plan, T-AO 203 Only"

2.1.5 NAVSEA Dwg. 633-6580109, Zinc Anodes in Ballast Tank and Bilge Spaces"

2.2 Enclosures:

2.2.1 MSCFSC Standard Item No. 010, Revised 22 March 2010, Tank, Void and Cofferdam Preservation

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity: Seven (7) Tanks:

(gallons) Footage

S.W. Ballast Tank #7P S.W. Ballast Tank #9P 5-43-2 5-51-2 168,563 25,500 177,693 25,900

JP-5 Tank #7C JP-5 Tank #8C Cargo Potable Water Tank (P) Cargo Potable Water Tank (S) Cargo Oily Waste Tank 4-43-0 4-47-0 2-102-4 2-102-7

3-40-0 578,443 33,000 578,443 33,100 51,994 8,800 51,994 8,800 64,744 9,300

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material

4.2.1 Ballast / JP-5 / Oily Waste Tanks (117,500 total sq. feet)

Amercoat 240 Buff

650 gallons

Amercoat 240 Red Oxide

250 gallons

Amercoat 240 Off-White

650 gallons

Amercoat T-10 Solvent

50 gallons

4.2.2 Cargo Potable Water Tanks (17,600 sq. ft. total)

Amercoat 133 Red

90 gallons

Amercoat 133 White

90 gallons

Amercoat T-10 Solvent

10 gallons

4.3 Government Furnished Services

4.3.1 GFS: Paint manufacturer's technical representative.

5.0 NOTES

5.1 Emptying, cleaning, gas freeing, and closing of the tanks listed in para. 3.1 are covered by work item 021.

5.2 All work on this item shall be conducted under the direct supervision of the MSC paint representative.

5.3 If addition of water to cargo tanks is required to maintain suitable trim on the vessel, disposal of the slops is to be borne by the contractor and included in this item.

5.4 Coordinate this work with work item 104.

6.0 QUALITY ASSURANCE REQUIREMENT: NOT USED

7.0 STATEMENT OF WORK

7.1 Cleaning and Preparations

7.1.1 Remove interferences obstructing work for the tanks listed in para. 3.1. Reinstall interferences after completing work.

7.1.2 FOR ALL TANKS (listed in par. 3.1) refer to enclosure 2.2.1 par. A., B. & C. using the type of liquids carried in each tank.

7.1.2.1 All bellmouth suctions shall be unbolted from the suction valve, rigged aside, and a bolted blank installed on the valve. Vent lines shall be broken at the first joint off the tank and blanked. Lines which are of all welded construction or which do not have a mechanical joint within one (1) foot of the tank shall be plugged on the inside of the tank. Reinstall bellmouths and lines removed after completion of work.

7.1.2.2 Valve stems and reach rod universal joints within the tank shall be greased and wrapped to protect same from blasting and coating. Remove all protection after completion of work.

7.1.2.3 In areas to be painted, record all ship's markings (if any). After painting, replace markings as original (area, size, and color).

7.1.2.4 Ballast tanks: Remove zincs using 2.1.5 for guidance. Provide report of condition of zincs; including sizes, quantities, locations and condition of each stud. For estimating purposes, plan to provide and replace a total of twenty (20) studs. Reinstall zincs after completing work. NOTE: If new zincs are required, CAT B work item 916 will be turned on by a change order.

7.1.3 Clean and prepare the tanks listed in paragraph 3.1 for blasting in accordance with enclosure 2.2.1, Section A.

7.1.4 Upon completion of Coating application, reinstall access cuts (if any were made by the contractor) and reinstall interferences. Close out tanks (ship’s force to inspect each tank prior to final closure). Closure of tanks is covered by work item 021.

7.1.5 Prepare required reports in accordance with Section A of enclosure 2.2.1.

7.2 Surface preparation

7.2.1 Abrasive Blast the tanks listed in Para 3.1, in accordance with enclosure 2.2.1, Section B, to SSPC-SP10 / NACE 2 (Near White Metal Blast Cleaning).

7.2.2 After blasting, the ABS surveyor and Port Engineer to inspect the tanks for conditions and any possible repairs. For estimating purposes, contractor shall plan for a grand total of the following to be accomplished:

a. Gauge a total of 80 feet of longitudinals/plate in in areas as designated by ABS.

b. Crop out and replace a total of 60 feet of longitudinals (and angle irons) in areas designated by ABS.

c. Weld thirty (30) feet of missing / deteriorated welds in in areas designated by ABS.

d. For ballast tanks, fabricate and replace a total of two (2) ladders.

e. Replace a total of fifteen (15) rungs on various access tank ladders.

f. Cut out (and cap open ends) of degaussing piping in ballast tanks. Approx. 300 feet total. NOTE: After cutting, but before repairs of degaussing piping are accomplished, the ABS surveyor must inspect piping and agree with repair plan.

NOTE: If necessary, a change order will be issued to reflect actual size/quantity of repairs required.

7.2.3 Type of repair material required:

HR Plate; ½ inch R/L, VSP Square HR Angle; 7 inch X 4 inch X ½ inch X R/L

7.2.4 If any steel repairs are accomplished after the tanks are re-coated, ensure that the tank coatings are protected from all damage during welding repair work. Contractor will be responsible to correct any paint damage during repairs. This includes damage from weld splatter which would require proper cleaning and recoating.

NOTE: For any coating area damaged from weld burn thru (i.e. on the exterior (shell) of the ship, in an adjacent tank or adjacent space), the contractor shall repair those damaged surfaces and follow painting guidelines in para. 7.3.

7.25 All new steel shall be abrasive blasted in accordance with enclosure 2.2.1, section B, to SSPC-SP10 / NACE 2 (Near White Metal Blast Cleaning).

7.3 Coating Application

7.3.1 Under the guidance of the MSC paint rep, apply GFM Coating system, in accordance with enclosure 2.2.1, as per Manufacturer instructions and product data sheets. All new and disturbed areas to be prepared and coated.

7.3.1.1 One full coat of Amercoat 240 Buff at 5-6 mils DFT (100%) over the entire interior of the tanks.

7.3.1.2 Apply one stripe coat Amercoat 240 Red Oxide at 5-6 mils DFT over corners, knife edges, cut out holes, joints, weld seams and hard to spray areas.

7.3.1.3 Apply one full coat of Amercoat 240 Off-White at 5-6 mils DFT (100%) over the entire interior of the tanks.

7.4 Manufacturer's Representative: Government will provide paint rep.

8.0 GENERAL REQUIREMENTS: None

1. ABSTRACT

This standard item provides requirements for tank, void and cofferdam preservation. This item includes UNIVERSAL REQUIREMENTS, which apply to all work covered in this standard work item, and menu-type COMPONENT REQUIREMENTS that detail the work required for specific tank, void and cofferdam preservation applications . This standard item will be incorporated into a MSFSC vessel work package by reference.

2. References:

Note: Reference documents include a mix of public and private information. To the maximum extent possible, all reference information is included in the reference folder which is provided with the MSFSC Standard Work Item package. Private documents, such as SOLAS, ASME or SSPC, are not provided but are considered to be common ship repair industry documents which are available through subscription to the publishing organizations.

SSPC (Society for Protective Coatings)

SP – Surface Preparation Standards and Specifications

PA – Paint Application Standards, Guides and Specifications

NAVMED P-5010-6, Water Supply Afloat

3. ITEM LOCATION/DESCRIPTION

Locations are as specified in the base item.

4. GOVERNMENT FURNISHED MATERIAL/ EQUIPMENT/ SERVICE: None

5. Notes: None

6. QUALITY ASSURANCE REQUIREMENTS: None

7. STATEMENT OF WORK REQUIRED

A. Universal Requirements

Open manholes for tanks, voids and cofferdams as designated in the base work item. Cleaning and gas free certification requirements for the subject tanks are covered under other work items in the base work package(WI 021 Clean and Gas Free Tanks, Voids and Cofferdams, WI 020 Gas Free Certificates).

In conjunction with initial water washing, contractor shall be responsible to pump out liquids, and remove all mud, dirt and debris using contractor furnished pumps and hoses, as may be necessary to clean the tanks, voids and cofferdams as designated in the base work item.

For ventilation and access during blasting and coating operations, contractor may elect to make a maximum of two (2) temporary access cuts. Prior to making any cut(s), the contractor shall submit a sketch to the MSCREP and the local ABS Surveyor which shows the location and size of each proposed cut and the relationship of the proposed cut(s) to adjacent structural members and weld seams. MSCREP and ABS approval shall be obtained prior to making the cut(s).

Provide and erect all necessary staging required to access all applicable surfaces as may be identified in the base work item.

Provide and maintain adequate lighting and ventilation. Lighting shall be sufficient for preparation, inspection and application requirements. Ventilation shall be of sufficient size to maintain a clear atmosphere during blasting and painting operations.

During sandblasting and painting activities, use of dehumidification equipment is discretionary on the part of the contractor. However, it is expected that the entire tank, void or cofferdam will be presented for inspection after sandblasting at one time. Piece-meal presentation will not be accepted. If used, as a minimum, the DH shall: Effect a complete air change in the space at least once every one-half (1/2) hour; Maintain the relative humidity in the space within the limits set by the paint manufacturer for the coating being applied; Maintain a minimum of 5o F. differential between the substrate temperature of the space and the dew point, with the dew point being the lower temperature; Ducting shall be run so as not to create hazards to personnel transiting the areas through which the ducting is run; Ducting shall further be maintained airtight and in good repair such that it does not contribute to contamination of the vessel's interior or equipment with abrasive blast grit, dust or paint.

Prior to start of surface preparation and painting, the contractor shall take precautions to protect the vessel from contamination. The following actions, at a minimum shall be taken: All suction and vent lines shall be broken at the first joint off the tank and blanked. Lines which are of all welded construction or which do not have a mechanical joint within one (1) foot of the tank, cofferdam or void shall be plugged on the inside of the tank, cofferdam or void; Valve stems and reach rod universal joints within the tank, cofferdam or void shall be greased and wrapped to protect same from blasting and coating; As necessary, based upon the location of ventilation and dehumidification exhausts, grease and wrap valve stems and exposed portions of hydraulic cylinders. Install filters on air intake vents. Install covers on fuel tank vents; Appropriate measures shall be taken to ensure that the vessel's interior and its equipment is not subject to contamination from blasting grit, dust or paint spray; In the area to be blasted, record the location, size and color of all ship's markings; Protective covering shall be inspected at regular intervals, but not less than at the start of each work shift. Degraded protective covering shall be repaired prior to the restart of work. Contamination of the vessel and its equipment shall be reported to the MSCREP verbally, immediately upon its discovery, followed by a written report within four (4) hours of the verbal notification. The contractor shall be responsible for cleaning the contaminated equipment and showing that the contamination has not caused damage to same. Cost to repair equipment damaged by such contamination shall be borne by the Contractor.

Temporarily remove zinc anodes in way of surface preparation and paint application. If zincs are welded in lace vice bolted, contractor shall apply protective coverings over those zincs. Before removal, contractor shall prepare a report documenting location, condition and mounting method for each zinc in the space. Reinstall upon completion of all coatings work.

After surface preparation, all surfaces shall be blown down using clean dry air and/or vacuumed to remove all dust, dirt and debris.

With exception of potable water tanks, thinning of the paint will be allowed for viscosity control if determined to be necessary by the paint manufacturer's representative. In no case shall the paint be thinned in excess of 5% by volume. Thinner utilized for viscosity control shall be new and of the type recommended by the manufacturer’s product data sheet. Thinning of paint for potable water tanks shall not be done without the expressed written authorization of the MSCREP.

Paint material shall be stored within the Paint Manufacturer's recommended temperature range. When paint material is being applied, ensure that the material's temperature is within the Manufacturer's recommended range, but in any case, not less than 70o F.

Ensure the following conditions are met prior to painting: Surfaces shall be clean, dry, and free of oil, grease or residue from surface preparation; Air and metal surface temperatures shall be within the range published by the paint manufacturer; The ambient air and substrate temperatures register at least 5o F. above the dew point temperature; The relative humidity is within the range set by the manufacturer’s product data sheet. In the event that there is no range established by the manufacturer, the relative humidity shall be no higher than 85 percent; No coating shall be applied at temperatures below 35o F. without prior written approval of the MSCREP; Material Safety Data Sheets for the product(s) being applied are on the job site and have been reviewed by the personnel involved.

Prior to application of any coating, the area to be painted shall be inspected and approved by the MSCREP and the Paint Representative. Inspection shall include surface preparation including cleanliness and surface profile as determined by Keane-Tator Comparator (or equal) examination and/or replica tape, DFT readings of prior coats, etcetera, as applicable depending upon the current stage of coating application. This inspection includes not only the initial coat of paint, but all subsequent coats as well. DFT readings of the prior coat of paint shall be presented to the MSCREP at the time of inspection for coating. Spot readings shall be taken at a rate of five per 1,000 square feet. DFT gages shall be calibrated, spot readings shall be taken and DFT tolerances shall be in accordance with SSPC-PA2, Measurement of Dry Coating Thickness With Magnetic Gages.

Immediately prior to coating the surface shall be re-tested for non-visual surface contaminates at random locations to ensure that surfaces have not been re-contaminated. If contamination is found, additional tests shall be made as necessary to determine the extent of contamination and to prove the success of remediation. Results of this testing shall be presented to the MSCREP at time of inspection for coating application. The maximum allowable contamination concentrations shall be less than 10 ug/cm2 of chloride contaminants as determined by field or laboratory analysis using reliable, reproducible test equipment.

Stripe coating, where called-out, shall be performed by brush, roller, paint mitt or other mechanical means that will ensure that the paint is applied to the areas where needed. In no case will spray application of a stripe coat be allowed.

Upon completion of coating activities, fit and weld the removed access plates to the satisfaction of the ABS Surveyor. Close the tank, void or cofferdam and apply a 1 1/2 psi air test to prove the installed plates are tight. Upon completion of the air test, re-open the tank, void or cofferdam.

Upon completion of the air test, remove all blanks and plugs and make-up all lines as original. Re-install all interferences. All replacements shall be proven operationally. Clean welds and disturbed areas in accordance with SSPC-SP3, Power Tool Cleaning, and coat the access plate(s) weld seams and all other areas disturbed by re-installations with two (2) coats of epoxy. Edges of disturbed areas shall be feathered-in. Touch-up coats shall be applied in the same order as the original coatings. Where only the top coat of the system has been damaged, affected areas shall be sanded to abrade the surface, feathered-in and touched-up with the topcoat only.

Prior to closure, a final inspection of the tank, void or cofferdam interior shall be conducted by the MSCREP. Upon acceptance by the MSCREP, re-install the manhole cover(s) with new gaskets.

The contractor shall prepare a paint report and submit same to the MSCREP within three (3) days of completing the coating application. The report shall include the following data: The date, time and location of each coating application; The air and substrate temperatures, relative humidity and dew point temperature at the time of each coating application; Dry film thickness readings at a rate of five (5) spot readings per 1,000 sq. ft. of surface for each coat of paint. DFT gages shall be calibrated and spot readings shall be taken in accordance with SSPC-PA2, Measurement of Dry Coating Thickness With Magnetic Gages; The manufacturer, Product Identification Number and Batch Numbers for each coat of paint applied; Surface profile measurements; Results of testing for non-visual surface contaminants (soluble salts).

Upon completion, all protective covering shall be removed and the vessel shall be cleaned of all residues resulting from the surface preparation and painting operations. Compartment(s) shall be left clean and ready for use.

B. Tank, Void or Cofferdam Painting – Surface Preparation Methods

The specific type of surface preparation shall be identified in the base work item. Where spot blasting or spot mechanical cleaning is specified, the edges of adjacent intact paint shall be feathered-in.

1) Bare Metal Using Abrasive Blast

Perform a HP water wash of the entire tank interior using fresh water at 2,500 to 3,000 psi to remove slime, dirt, mud, soluble salts and other foreign matter. Particular attention shall be given to the undersides of stiffeners, ledges, snipes, limber holes in longitudinals, crevices and areas of rust, rust scale, blistered, cracked, peeling or flaking coatings. Accomplish the requirements of Surface Preparation Standard SSPC-SP1, Solvent Cleaning, to remove all dirt, oil, grease, soluble salts or other organic matter. Biodegradable cleaners or other eco-friendly methods/agents shall be used to the greatest extent possible. Upon completion of all water washing chloride testing shall be performed at random locations. The maximum allowable contamination concentrations shall be less than 10 ug/cm2 of chloride contaminants as determined by field or laboratory analysis using reliable, reproducible test equipment.

The entire interior of the tank, void or cofferdam, including all structural members, internal piping, reach rods and reach rod support brackets, interior of the manhole covers, interior of removed access cuts, etcetera, shall be abrasive blasted in accordance with Surface Preparation Standard SSPC-SP10/NACE 2, Near White Metal Blast Cleaning.

Prior to the start of abrasive blasting the blast media shall be tested to ensure that it is not contaminated with chlorides, as determined by field or laboratory analysis using reliable, reproducible test equipment.

Upon completion of abrasive blasting, all spent grit, dust and dirt generated by this work item shall be removed. All internal surfaces shall be blown-down with dry, oil free air at a maximum pressure of 10 psi and/or vacuumed clean.

2) Mechanical Cleaning

The entire interior of the tank shall be HP fresh water washed to remove dirt, rust and rust scale, loose, flaking, peeling or otherwise deteriorated coatings and salts. Equipment utilized shall maintain a discharge pressure of 2,500 to 3,000 psi. In conjunction with the HP water washing accomplish the requirements of SSPC-SP1, Solvent Cleaning, to remove all dirt, oil, grease, soluble salts or other organic matter. Biodegradable cleaners or other eco-friendly methods/agents shall be used to the greatest extent possible. Upon completion of all water washing, chloride testing shall be performed at random locations. If contamination is found, additional tests shall be made as necessary to determine the extent of contamination and to prove the success of remediation. The maximum allowable contamination concentrations shall be less than 10 ug/cm2 of chloride contaminants as determined by field or laboratory analysis using reliable, reproducible test equipment. All surfaces shall be allowed to thoroughly air dry.

All areas of rust, rust scale or coatings which are cracked, blistered, peeling, flaking or otherwise deteriorated shall be prepared in accordance with the Surface Preparation Standard SSPC-SP11, Power Tool Cleaning To Bare Metal. Ensure that a minimum surface profile of 1 mil is attained. All tightly adherent paint edges shall be feathered-in.

Upon completion of surface preparation all dust and dirt generated by this work item shall be removed. All internal surfaces shall be blown-down with dry, oil free air, at a maximum pressure of 10 psi and/or vacuumed clean.

C. Coating Application

Apply the MSC approved paint system as detailed in the base work item, to the interior surfaces of the tank. The dry film thickness for each coat of paint shall be as noted in the base work item.

1) Tanks, Voids and Cofferdams Other Than Potable Water Tanks

Dry voids and cofferdams that have been blasted to Near White Metal in their entirety may be coated as follows:

1. Apply one (1) full coat of inorganic zinc silicate to all interior surfaces. Ensure complete coverage in snipes, limber holes, plate edges, corners, crevices, threaded surfaces, weldments and other difficult to coat areas.

2. Apply a mist coat of epoxy at 1-2 mils DFT to all zinc coated surfaces.

3. Apply a stripe coat of epoxy to the entire interior of the space.

4. Apply a full coat of epoxy to the entire interior of the space.

Alternatively, all tanks, voids and cofferdams Other Than Potable Water Tanks that have been blasted to Near White Metal may be coated as follows:

1. Apply one (1) full coat of epoxy paint.

2. Apply one (1) stripe coat of epoxy to all corners, crevices, plate edges, snipes, limber holes, threaded surfaces, pitted surfaces, weldments or other difficult to coat areas.

3. Apply a second full coat of epoxy paint.

2) Mechanically Prepared (SP-11) Tanks, Voids and Cofferdams Other Than Potable Water Tanks Spot prepared tanks, voids and cofferdams Other Than Potable Water Tanks shall be coated as follows:

1. Apply two (2) spot coats of epoxy paint to all prepared areas.

3) Potable Water Tank Coating- Initial Application

Potable Water tanks prepared for coating by dry abrasive blasting to Near White Metal shall be coated as follows:

Apply the MSC approved paint system identified in the base work item, to all interior surfaces of the tank. The dry film thickness for each coat of paint shall be as noted in the base work item. Stripe all limber holes, snipes, corners, weldments, pitted areas, threaded surfaces or other areas that are not conducive to proper coverage by spray application.

Immediately prior to the start of spray application, the spray pump(s), lines and gun(s) shall be flushed-out with new thinner of the type recommended by the paint manufacturer. This flushing shall be witnessed by the manufacturer’s tech rep and the MSCREP.

Each coat of paint in the system shall be allowed to cure a minimum of 48 hours, under the dehumidification conditions set forth in the Universal Requirements above, prior to the start of the successive coat.

After access plates have been reinstalled and touch-up coats and final application of the coating, the tank shall be allowed to cure, with DH operating in accordance with the requirements of paragraph 7, for a minimum of seven (7) days before introducing water to the tank.

The tank and associated disturbed piping and equipage shall be super chlorinated in accordance with the guidance provided in NAVMED P-5010-6, Water Supply Afloat, Section 6-22.

After successful chlorination the tank shall be drained and refilled with potable water. Water samples shall be laboratory tested for free available chlorine and bacteriological contamination. Furnish three (3) copies of the lab results and certification that the water meets the requirements of the USPHS for potable water to the MSCREP.

4) Potable Water Tank Painting – Maintenance Recoat

Apply two (2) spot coats of the MSC approved paint system as detailed in the base work item, to all prepared bare metal surfaces on the interior of the tank. The dry film thickness for each coat of paint shall be as noted in the base work item. Within the area of prepared surfaces, apply a stripe coat to all limber holes, snipes, corners, weldments, pitted areas, threaded surfaces or other areas that are not conducive to proper paint coverage.

In the event that the paint is applied by spray, immediately prior to the start of spray application, the spray pump(s), lines and gun(s) shall be flushed-out with new thinner of the type recommended by the paint manufacturer. This flushing shall be witnessed by the manufacturer’s tech rep and the MSCREP.

Note: Application by brush or roller normally results in dry film thicknesses less than that achieved by spray application. It is the responsibility of the contractor to achieve the total dry film build called out in the base specification, whether by altering the application method or through application of additional coats. It is incumbent upon the contractor to allow sufficient time in their production schedule to allow for the possibility of having to apply additional coats of paint and time for proper curing of those coats, without impacting the end date to place the tank in service.

Each coat of paint in the system shall be allowed to cure a minimum of 48 hours, under the dehumidification conditions set forth in in the Universal Requirements above, prior to the start of the successive coat.

After access plates have been reinstalled and touch-up coats and final application of the coating, the tank shall be allowed to cure, with DH operating in accordance with the requirements of paragraph 7, for a minimum of seven (7) days before introducing water to the tank.

The tank and associated disturbed piping and equipage shall be super chlorinated in accordance with the guidance provided in NAVMED P-5010-6, Water Supply Afloat, Section 6-22

. After successful chlorination the tank shall be drained and refilled with potable water. Water samples shall be laboratory tested for free available chlorine and bacteriological contamination. Furnish three (3) copies of the lab results and certification that the water meets the requirements of the USPHS for potable water to the MSCREP.

5) Chain Locker Preservation

Chain locker preservation shall follow the requirements as set forth above for preservation of Tanks, Voids and Cofferdams. In addition to those requirements, contractor shall be responsible to clear the chain locker eductor system, and demonstrate its proper operation to the satisfaction of the MSCREP and the ABS Surveyor.

ITEM 102 - 1