SOW_FA_FY17_DOCKSIDE_FAIRWEATHER_REV_2_(1).pdf

FY17 REPAIR SPECIFICATIONS FOR NOAA SHIP FAIRWEATHER

IMO Number: 6710920

ABS Class Number: 6800389

Delivery Date: 1968

Designer: Maritime Administration

Construction: Welded Steel/Ice Strengthened

Builder: AEROJET – General Shipyards, Jacksonville, Florida

Overall Length: 231 feet (70.4M)

Beam: 42 feet (12.8M)

Displacement: 1800 Tons

Draft: 14.3 feet (4.36M)

WORK ITEM LIST

ITEM 101 GENERAL REQUIREMENTS

ITEM 102 CATHODIC PROTECTION SYS INSPECT & TEST

ITEM 103 ENGINE ROOM VENT LOUVERS

ITEM 104 GAYLORD HOOD & VENT CLEAN ZONE 3

ITEM 105 NEW MAIN ENGINE GOVERNORS

ITEM 106 NEW PROPULSION CONTROLS

ITEM 107 MACS UPGRADES

ITEM 108 FLUSH PORT REDUCTION GEAR

ITEM 109 CLEAN MAIN ENGINE SUMPS

ITEM 110 HN-9000 DAVIT MODIFICATION

ITEM 111 GREY WATER & SEWAGE TANK CLEAN

ITEM 112 GALLEY HOOD WASHDOWN DRAIN

ITEM 113 REPLACE INTERIOR & EXTERIOR HOSES

ITEM 114 BOW THRUSTER VENT B-14-1

ITEM 115 PROVIDE TEMPORARY BOILER

ITEM 116 INSTALL BROMINE FEEDER

ITEM 117 NEW BOAT DECK DRAIN

ITEM 118 AFT CORNER WHEELHOUSE REPAIR

ITEM 119 WASTE OIL MANIFOLD & PIPING

ITEM 201 ADDITIONAL WORK

ITEM 202 BILGE PUMPING

REPAIR SPECIFICATIONS FOR NOAA SHIP FAIRWEATHER

101-1

ITEM 101 GENERAL REQUIREMENTS

1. INTENT.

1.1 This specification contains the general requirements for work by the dry dock and repair Contractor for the NOAA Ship FAIRWEATHER. These general requirements apply to all work items contained in this contract including care of the ship, sea trials, and services provided to the ship during the contract.

2. REFERENCES.

2.1 NOAA Standard Specification S4800-2, Piping Systems

2.2 American Bureau of Shipping "Rules for Building and Classing Steel Vessels"

2.3 U. S. Coast Guard "Subchapter F - Marine Engineering", 46 CFR 50 through 46 CFR 64.

2.4 U. S. Coast Guard "Subchapter J - Electrical Engineering", 46 CFR 110 through 46 CFR

113.

2.5 IEEE Std 45-2002, "IEEE Recommended Practice for Electric Installations on

Shipboard"

3. DEFINITIONS. Wherever used in this specification and in all other work items in this contract, the following definitions of terms apply:

3.1 Inspect. Visually evaluate the specified surface, item, part, or component for evidence of contamination, damage excessive wear, scoring, and any other condition which could interfere with the proper operation or functioning of the surface, item, part or component.

3.2 Install. Place the specified item in position for service and make all connections needed to insure proper use, service, appearance, and operation. Except as may otherwise be specified, this shall include the following:

3.2.1. Provide new or modify existing foundations. Securely mount equipment and components using new fasteners. Align connected equipment and components to meet manufacturer’s specifications.

3.2.2. Make all electrical connections. Provide new electric cable runs between controllers and motors of new equipment. Existing cables may be reused in other applications, except where the existing cables are too short to make connections. Renew cables which are

101-2 too short and less than 20 feet long. Junction boxes may be used to increase the cable run length where the existing cable runs are longer than 20 feet.

3.2.3. Modify new piping to suit the new equipment, including the rerouting of existing piping and adding of new piping as needed to properly connect equipment and components. Piping modifications greater than five feet from the equipment are not required.

New piping is required only to the extent necessary to accommodate modifications of existing piping.

3.3 Piping. A system of pipe, tube, elbows, tees, valves, couplings, and other pipe fittings. Unless otherwise specified in the detailed item description, all piping systems and components shall comply with material and installation requirements of reference 2.1.

3.4 Rebuild. Disassemble, clean, inspect, repair (including renewal of all parts needed), reassemble, test, and calibrate the specified part, component, system, or machine to restore it to a condition of reliability equivalent to a new part, component, system, or machine.

Components and parts shall meet the manufacturer's applicable rebuild specifications.

3.5 Reinstall. Return the same item which was previously removed to its previous configuration and location.

3.6 Renew. Provide and install a new item as replacement for an existing item previously removed or to be removed. The new item must be the same as or comparable in material, performance and configuration to the item removed.

3.7 Replace. Same as "renew", defined above.

4. REQUIREMENTS.

4.1 Condition Reports.

4.1.1. A Condition Report shall be prepared and submitted by the Contractor to the Contracting Officer's Technical Representative (COTR) on all of the following occasions:

4.1.1.1. Whenever specifically required by other documents.

4.1.1.2. Whenever the Contractor determines or notes that additional work or material or other deviation is necessary in order to produce a reliable or complete repair.

4.1.1.3. Whenever defect or deficiencies are noted in Government-furnished Property.

101-3

4.1.1.4. Whenever measurements, tests or inspections are required by other specifications or procurement documents, the results and findings shall be documented on a Condition Report.

4.1.2. Condition Reports shall contain, as a minimum, the following:

4.1.2.1. Name of the ship.

4.1.2.2. Contract number and related work item number.

4.1.2.3. Detail description of conditions observed, including a record of all measurements taken and other supporting data.

4.1.2.4. Recommendations of additional work and materials deemed to be needed, if any including the contractors proposed cost for time and material incidental to the recommendation.

4.1.2.5. Estimate of the impact on the completion of the contract, if any.

4.1.3. Submit Condition Reports to the COTR within twenty-four hours after completing the measurements, inspections, or tests, or after the need for additional work or material is noted.

4.1.4. For work involving disassembling and inspection of equipment, machinery or systems and for work involving opening and inspection of tanks, the work must be completed and a Condition Report must be submitted during the first 25-percent of the work performance period.

4.2 Progress Meetings.

4.2.1. Weekly progress meetings shall be held at a time and place mutually agreeable to the COTR and the Contractor. As a minimum, the meetings shall be attended by the COTR and a Contractor's management official having authority to make binding commitments. Other interested parties may attend the meetings as appropriate.

4.2.2. Prior to the end of the work day preceding the progress meeting, the Contractor shall submit to the COTR a preliminary progress report containing the following information:

4.2.2.1. Percentage completion of each contract item, including all additional work items authorized by the Contracting Officer.

101-4

4.2.2.2. Notation of any problems which could impact timely completion, including material delivery delays.

4.3 Personnel Information. Provide to the COTR a list of the Contractor's supervisors, including shop supervisors, and a list of telephone numbers where the supervisors can be reached during non-working hours in event of an emergency.

4.4 Protective Coverings.

4.4.1. Prior to starting work on interior spaces, protect the decks and deck coverings of spaces in which contract work is to be performed and spaces through which workers will traverse by covering the decks and deck coverings with a temporarily fitted heavy vinyl, plywood or particle board. Securely tape all edges and joints of the protective covering.

Maintain the protective covering in place during the entire contract period, renewing sections which are damaged during the contract period. For those decks over which equipment, valves, piping, or other materials must be handled, the temporary protective covering shall be plywood or particle board and shall be of sufficient thickness to protect the deck from damage in the event the equipment or materials are dropped.

4.4.2. Protect all compartments, machinery, equipment, deck coverings, furnishings, vent terminals, insulation, glass, cables, piping systems, coatings, structures, and other ship components from damage and from entry of dust, dirt, grit, sand, and other foreign particles.

4.4.3. Whenever abrasive blasting or other operations which create atmospheric contamination are performed on or near the ship, or which could otherwise allow airborne contaminates to collect on or in the ship, the Contractor shall plug, wrap, blank, cover, or mask all openings to prevent entry of the contaminates into the ship. Install industrial foam filter material on the intake and exhaust end of ventilation systems which will be in use.

Renew the filter materials when air flow becomes restricted. Whenever abrasive blasting is performed inside the ship, blast materials shall be confined to the compartment being blasted.

4.4.4. All damage and contamination resulting from failure to provide adequate protection shall be repaired and cleaned to re-establish the condition which existed at the start of the work.

4.4.5. After completion of all other work, remove and dispose of all protective coverings.

4.5 Restricted Access. Access by workers to the ship's compartments shall be restricted to those in which work is being performed or through which passage is necessary to reach the work site. All other compartments shall be considered off-limits to workers.

101-5

4.6 Daily Clean-up.

4.6.1. Clean-up and remove from the ship all dirt, debris, scrap, and other materials incident to Contractor's work at the end of each work day. The work site shall be left "broom-clean".

4.6.2. Whenever abrasive blasting or other operations on or near the ship causes collection of blasting residue or other foreign particles to collect on exterior decks of the ship, the Contractor shall vacuum or sweep the decks to remove the residue and particles prior to the end of the day on which the contamination occurred. Do not wash the residue or particles through the ship's deck drains.

4.7 Disruption of Ship's Systems.

4.7.1. Except as necessary to perform work, none of the ship's fire main, electrical, steam, heating, potable water, drainage, or other systems which are vital to crew safety or comfort shall be shut off or disrupted. The COTR must advanced notice of a disruption at least 4 hours in advance.

4.7.2. Disruptions shall be limited to 4-hour intervals. If the required work will need a longer interval, temporary bypass hoses, blank flanges, or piping shall be installed to keep the system in operation.

4.7.3. For purposes of this specification, a "disruption" occurs whenever a large section of a system will be unusable. If the only section of the system affected is that on which work is being performed and the remainder of the system can be operated, a "disruption" has not occurred and the requirements of this paragraph do not apply.

4.8 Work Hours. At the beginning of the repair period, the Contractor shall advise the COTR in writing of the planned regular work day schedule. In the event the Contractor desires to work at times other than those previously scheduled, notify the COTR at least 4 hours prior to the end of the scheduled work day preceding the unscheduled work time. If previously unscheduled work is to be performed on a weekend or federal holiday, the COTR must be notified prior to 9:00am on the last regular work day before the unscheduled work.

4.9 Local Policies and Directives. While Contractor personnel, including those of subcontractors, are on the ship or on other government facilities, they shall comply with all policies and directives issued by the Master, Commanding Officer, or Director of the ship or facility.

4.10 Safety Requirements.

4.10.1. Gas Free Certification.

101-6

4.10.1.1. The Contractor shall be responsible for certifying that a safe atmosphere exists in and about a compartment prior to the commencement of any work.

Whenever compartments must be gas free to meet state and federal regulations, the Contractor shall pump down, open, remove sludge, clean, wipe, ventilate and take all other action required to make the compartments safe for the work to be performed. When requested by the Contractor, and to the extent empty tank space is available, NOAA will shift fuel as required to facilitate gas free requirements. If off-loading of fuel oil is necessary because of insufficient empty tank space, the Contractor shall off-load the fuel.

4.10.1.2. Copies of gas free certificates, issued by a Marine Chemist certified by the National Fire Protection Association, shall be posted on the ship in two locations designated by the COTR. Follow-up inspections by the Contractor's Competent Person shall also be documented at the same two locations.

4.10.1.3. The Contractor shall be responsible for identifying the compartments which require gas free certification. Specific requirements for gas free certification are not normally included in the detail specifications of any work item.

4.10.2. Fire Watch Standers.

4.10.2.1. Hot work is permitted only when fire watch standers are provided by the Contractor. A fire watch stander is required whenever welding, flame cutting or other hot work is performed where combustible materials are present within 35 feet; or where wall or deck openings within a 35-feet radius expose combustible materials in adjacent areas; or when combustible materials are adjacent to the opposite side of metal partitions exposed to hot work, and could be ignited by conduction or radiation. In the latter case, a fire watch stander is required on both sides of the partition.

4.10.2.2. Each fire watch stander shall be outfitted by the Contractor with a fire extinguisher of a suitable size and type.

4.10.2.3. Prior to leaving the work site, the fire watch stander shall verify with the worker performing the hot work that no further hot work will be performed.

4.10.2.4. Insulation, sheathing, or other materials which limit access to either side of a partition or structure on which hot work is being performed shall be considered to be an interference, and shall be removed and restored by the Contractor.

4.10.3. Written Hot Work Notice. Prior to starting hot work on any job or separate area of the ship, provide a written notice to the OOD. The notice shall the location of the work, the time hot work will commence and the current gas free status of the area if needed.

101-7

4.10.4. Asbestos-Containing Materials (ACM). Existing panels, insulation, gaskets, and other materials on the vessel may contain asbestos. Asbestos shall be removed by a certified removal contractor. All asbestos projects shall comply with all federal, state, and local regulations governing the removal of asbestos.

4.10.5. Miscellaneous Requirements.

4.10.5.1. Oxygen, acetylene, and gas supply manifold systems shall be located off the ship and have a shutoff valve to the gas supply located on the dock. The shutoff shall be in addition to the master shutoff valve at the inlet to each portable outlet header.

4.10.5.2. Material brought onto the ship shall be stored until used in areas which do not interfere with access to fire-fighting equipment or personnel access. Crating and packing shall be removed prior to bringing the equipment or material aboard the ship, unless needed to protect the equipment or material from damage during handling. In that case, the crating and packing shall be removed from the equipment or material, and shall be removed from the ship, immediately after being brought aboard.

4.10.5.3. Rigging of hoses, welding leads, and temporary lights shall be kept clear of the decks on temporary "trees" or brackets and be arranged so as to minimize tripping and other safety hazards. Passageways shall be kept as clear of obstructions as possible.

4.11 Interferences and Restorations.

4.11.1. Remove all interferences and obstructions necessary to complete the required work. This shall include the disassembly and removal of machinery, piping, ducts, cable, wiring, insulation, structures, and anything else which interferes with the proper accomplishment of work. Except as otherwise specified, this does not include relocations made necessary by new installations which physically prevent an interference from being returned to its existing location.

4.11.2. Whenever an interference to be removed involves a structural strength member, temporary supports shall be provided to compensate for the strength loss.

Whenever watertight integrity is violated by a removed interference, provide a temporary means of maintaining watertight integrity, except when work is actually being performed or the space is otherwise manned.

4.11.3. Restore all interferences to their existing configuration and condition.

Install new gaskets and fasteners. In place of material which is rendered unsuitable for reinstallation during removal or storage, provide and install new materials which are equal in

101-8 composition, strength, design, type, and size as existed prior to removal. All insulation removed or damaged shall be renewed with new insulation.

4.11.4. Material containing asbestos which is removed as an interference shall not be reinstalled. Instead, renew the asbestos-containing material with a new non-asbestos material which provides the same function and general appearance as that removed.

4.11.5. Align and conduct strength, tightness, and operational tests to ensure that the reinstalled interferences safely perform their normal functions.

4.11.6. The Contractor shall be responsible for identifying all interferences involved in accomplishing required work. Interferences are not normally identified in the detail specifications of the work item.

4.12 Shipboard Storage. No space or compartment on the ship shall be used for storage by the Contractor of materials or tools. The materials allowed at the work site shall be limited to those which will be installed, consumed, or otherwise used during the work shift in progress. When needed or required, provide a temporary dockside storage area to store materials and tools.

4.13 Watertight Integrity. Maintain or restore the watertight integrity of the ship's watertight bulkheads, decks, and hull by installing stuffing tubes, welded bulkhead and deck penetrations, multi-cable transits, couplings, and kickpipes as appropriate. All materials and installation details shall be same as the nearest similar existing penetrations.

4.14 Removals.

4.14.1. Whenever removal of equipment or machinery is specified, but reinstallation is not specified, the Contractor shall remove all related electric cables, brackets, foundations, and piping. Removal of cables shall be to the nearest circuit breaker or terminal not needed for operation of other equipment or machinery. Removal of piping shall include all related piping not used by other systems or equipment. Install pipe caps as needed to maintain remaining piping tight.

4.14.2. Whenever removal of piping or cables involve penetration through bulkheads, decks, hull plating or other watertight boundaries, crop out the penetration and install an insert plate of same thickness as the adjacent plating. Insert plates shall be a minimum of 6-inch diameters.

4.15 Structural Access Openings.

4.15.1. The Contractor may, with prior approval, cut access openings in ship's structure if required to perform work. Such openings shall be limited to those which are

101-9 essential for access to otherwise inaccessible areas or which greatly improve accessibility for removals or installations.

4.15.2. Prior to making any access opening in ship's structure, submit to the COTR a sketch of the proposed opening, showing the location and dimensions of the proposed access cut, adjacent framing members, nearby penetrations, and scantlings of the structure.

Generous radii shall be provided at all corners. Also include a description of the eventual restoration configuration, with material and welding details, and a narrative justification for cutting the opening. Submittal of the sketch does not insure that the COTR will authorize the cut as proposed. The Contractor shall proceed with the access cut only after return by the COTR of a signed copy of the sketch.

4.16 Brackets and Supports. All pipe, cables, ducts, furniture, equipment, machinery installed by the Contractor shall be bracketed, supported, and secured so as to carry the weight, prevent vibration, and withstand inertia forces resulting from rolling and pitching of the ship.

4.17 Gaskets, Packing, and Seals. Whenever the Contractor performs work which disturbs existing gaskets, packing, or seals, new gaskets, packing, and seals of same material as existing shall be installed unless otherwise specified, except use 3/16-inch thick cork rubber impregnated gasket material conforming to SAE-AMS-6183 for all fuel oil tank manhole covers and fuel oil service piping.

4.18 Welding and Allied Processes.

4.18.1. All welding, brazing, and allied processes shall be in accordance with the requirements and recommendations of references 2.2 and 2.3.

4.18.2. While the ship is water-borne, welding shall be permitted only when welding leads are properly grounded. Welding machines and other welding power sources shall have both cables connected only to the ship where welding is done. The return ground cable shall never be grounded to anything but the ship it is servicing. All welding cables shall be fully insulated and not be permitted to drop overboard into the water. The total cross-sectional areas of the return ground cable shall be at least one million circular mils per 1,000 amperes per 100 feet, but not less than 85,000 circular mils. The ground cable shall be securely fastened to grounding plates or to an integral part of the ship, with contact areas thoroughly cleaned to bare metal.

4.18.3. When welding on equipment, machinery, pressure vessels, or piping, the return ground cable to the welding machine shall be connected in the immediate vicinity (as close as practical) of the work to ensure that current does not flow through bearings, pipe hangers or other areas where arcing or high resistance paths exist.

101-10

4.19 Painting.

4.19.1. Prior to applying any paint or coatings, the Contractor shall verify that all surfaces have been properly prepared and that weather conditions are suitable for painting.

4.19.2. Paint shall be applied only when the following conditions exist and can be maintained until the paint has cured:

4.19.2.1. Apply paint only to dry surfaces and when there is no chance of precipitation until after the paint has cured. The temperature of the surface to be painted shall be at least 5 degrees Fahrenheit above the dew point. The dew point can be presumed to be satisfactory if a thin, clearly defined film of water applied to the cleaned surface with a damp cloth evaporates within 15 minutes. Otherwise, the dew point shall be measured prior to painting by taking the dry-bulb temperature of the surface and the wet-bulb temperature at the jobsite.

4.19.2.2. The air temperature and surface temperature must both be a minimum of 45 degrees Fahrenheit at all times, unless a lower temperature is specifically authorized by the paint manufacturer's printed instructions.

4.19.2.3. Painting is permitted only when the humidity is less than 80 percent unless otherwise specified in the paint manufacturer’s written instructions. In the event the Contractor desires or must proceed with painting when the existing weather conditions do not meet the above specified conditions, the Contractor shall erect a cover over the surfaces to be painted and shall heat the surfaces and the surrounding air to establish the required conditions. The conditions shall be maintained until the paint has fully cured in accordance with the paint manufacturers’ application instructions.

4.19.3. Restore all existing coating systems which are damaged during performance of work. The new coating system shall be same as existing.

4.19.4. Surface preparation and paint application shall be in accordance with applicable NOAA specifications. In event no applicable NOAA specification exists, comply with the paint manufacturers' printed recommendations and instructions for all aspects of surface preparation, and handling, mixing, and application of paint materials.

4.19.5. Paint schedule: Paint systems used on the ship shall consist of a primer coat followed by a minimum of two top coats unless otherwise specified either in the detailed specification or by the manufacturer of the paint. It is the responsibility of the Contractor to ensure that paint used is compatible with existing paint on the ship. As a general guide, the paint used on the vessel is manufactured by INTERNATIONAL. Interior paint on the ship is latex exterior paint is epoxy. Painted surfaces below the walking flat in the engine room and inside

101-11 tanks shall be epoxy. Bare steel shall be coated with a zinc rich primer before rust bloom is allowed to form. Top coats shall be applied according to the manufacturer’s procedures.

4.20 Electrical. All requirements and recommendations of references 2.4 and 2.5 shall be followed in the selection and installation of electrical cables, equipment, and machinery.

4.21 Sea Trials.

4.21.1. Approximately 2 days before the ship is scheduled to leave the contractor's facility, conduct a one day sea trial. The date for sea trials must be approved by the COTR.

4.21.2. The contractor shall submit to the COTR a schedule for testing all equipment the contractor has worked on two days before sea trials. The contractor must submit a list of the personnel who will ride the ship during sea trials prior to departure. The list must include Name, SSN, Citizenship, Address and person to be notified in case of emergency.

4.21.3. The contractor shall provide at least one supervisor for sea trials to coordinate testing, adjustment and repair of discrepancies.

4.21.4. All equipment will be operated by ship's force personnel.

4.21.5. An attempt will be made to do all testing during normal working hours however, it may be necessary to depart early and return late.

4.21.6. No contractor work will be allowed during trials except as approved by the COTR.

4.21.7. Sea trial discrepancies must be corrected before the ship leaves the contractor's facility.

4.22 Tests and Inspections.

4.22.1. At least four hours, but not more than 24 hours, in advance of conducting each required test and inspection, notify the COTR in order to allow the COTR the opportunity to witness, or to arrange for another NOAA representative to witness, the tests and inspections. If the COTR or other NOAA representative is not present at the scheduled time of the test or inspection, and if the required 4-hour advance notification was furnished to the COTR, the Contractor may proceed with the test or inspection.

101-12

4.22.2. All tests and inspections shall be witnessed by the Contractor's supervisor responsible for the work. A Condition Report (See 4.1 ) shall be prepared to document the results of all tests and inspections.

4.22.3. To the extent possible, all tests and inspections shall be scheduled during the normal weekday work shift. Tests and inspections may be scheduled for other times only when necessary to avoid a delay in the contract completion. When necessary to schedule a test or inspection after the normal day shift or on a weekend, the COTR shall be notified of the test or inspection at least four hours before the end of the last preceding regular work shift.

4.22.4. Perform an operational test of all newly installed, overhauled, and repaired equipment to demonstrate proper operation. Shipboard equipment will be operated by the ship's crew.

4.22.5. Whenever a "hose test" is specified, conduct the test by directing a 50-psig stream of water from a 1-1/2 inch fire hose through an all purpose nozzle at a distance of not more than 10 feet from the surface being tested. Direct the stream of water in a manner most likely to disclose a leak and inspect the opposite side of the surface for leaks.

4.23 Fuel Oil and Lube Oil Offloading.

4.23.1. Whenever the Contractor is required to or elects to offload fuel oil or lube oil from the ship, the oil shall be pumped to and stored in clean moisture-free storage tanks. Meter the oils with a calibrated meter during offloading and during return. Take test samples during offloading and during return, and have the test samples analyzed by a lab for water and impurities to verify that the oils were not contaminated while in the Contractor's possession. Provide copies of lab reports to the COTR.

4.23.2. After all work which necessitated the oil's removal has been completed, return the oil to the ship. In lieu of storing the oil, the Contractor may accept title and responsibility for disposal of the oil and provide an equal amount of new clean oil, same as that removed. Test samples are required, even if this option is exercised by the Contractor.

4.24 Disposal of Fluids. Whenever work requires that equipment, machinery, piping, or tanks be drained of fluids, the Contractor shall be responsible for draining and proper disposal of the fluid. If the Contractor drains the fluid into the ship's bilges, the Contractor shall pump all fluid from the applicable bilges into dockside tanks and properly dispose of the fluid, including the fluid that existed prior to and the fluid that accummulates between the time the equipment, machinery, piping or tanks were drained and the time the bilges have been pumped dry by the Contractor.

4.25 Disassembly and Inspections. Whenever equipment, machinery, systems, or other system components are required to be disassembled, opened or overhauled, the

101-13 contractor shall complete all disassembling and inspections during the first 25-percent of the work performance period. All tanks required to be opened shall also be opened and gas-freed during the first 25-percent of the work performance period. No time extension of the work performance period will be granted for delays caused by the contractor's failure to comply with this 25-percent time requirement.

5. NOTES.

5.1 The requirements and provisions of this specification are additions to or amplification of the requirements and provisions set forth in other specifications, solicitation, or procurement documents. In the event a conflict should occur, the requirements of the other documents take precedence over those contained herein.

Page 102 - 1

ITEM 102 CATHODIC PROTECTION SYS INSPECT & TEST

1.0 INTENT.

1.1 Retain the services of a qualified Corrosion Technician to complete the inspection of the NOAA Fairweather Impressed Current Cathodic Protection System (ICCPS) in accordance with industry standards. Deliver a condition found report (CFR) detailing the results of the inspection.

2.0 REFERENCES

2.1 CAPAC CONTROLLER SPEC SHEET AND O&M MANUAL, MODEL 50145-033

2.2 CATHODIC PROTECTION SYSTEM DRYDOCK INSPECTION 2014

2.3 CATHODIC PROTECTION SYSTEM POST DRYDOCK WATERBORNE INSPECTION

2.4 ITEM 104 CAPACCONTROLLERPS SPECSHTO&M_MANUAL 50145-033

2.5 ITEM 101 GENERAL REQUIREMENTS

3.0 GOVERNMENT FURNISHED MATERIAL.

3.1 None

4.0 REQUIREMENTS.

4.1 With the ship in sea water, complete the inspection of the Fairweather Impressed Current Cathodic Protection System (ICCPS). The ICCP inspection shall be conducted by a qualified Corrosion Technician. Controller operational functions, testing and adjustments shall be made during a sea trial offshore of Newport, Oregon in sea water, not in the bay.

The most recent ICCP reports are provided in References 2.1 and 2.2.

4.2 Services of a Cathodic Protection System Engineer familiar with the Fairweather ICCPS can be obtained from:

Norton Corrosion Limited 8820 222nd Street SE Woodinville, WA 98072 Phone: 425-486-1616 Fax: 425-485-1754 E-Mail: sales@nortoncorrosion.com mailto:sales@nortoncorrosion.com

Page 102 - 2

5.0 TEST, INSPECTIONS, REPORTS.

5.1 Deliver a condition found report (CFR) detailing the results of the inspection and work performed on the system.

Power Supply 50145-033

SECTION 4

CONTROLLER POWER SUPPLY

MODEL 50145 – 033

CAUTION

Note that more than one model of power supply may be supplied for this ship or structure. Various power supplies may be similar in appearance but different in construction, amperage rating and operation. Ensure that you are using proper instructions for the power supply installed.

4.1 SYSTEM DESCRIPTION

The purpose of the controller-power supply is to continuously monitor the level of cathodic protection on a submerged metal surface and to adjust the amount of current supplied to the anodes to maintain this protection at a preset optimum level.

An AUTOMATIC CONTROL SETTING adjustment is located on the control panel inside the enclosure, which permits the controller to be set at the optimum level for the metal structure being protected (See Table 4.2).

Two meters are provided on the unit. The ammeter indicates the total anode current and the voltmeter is used to indicate the level of cathodic protection.

4.1.1 SPECIFICATIONS

Input Power: 120V AC, ± 10%, 1 ∅, 60 Hz ± 5% Model Input Max. KVA Input Max. Rated Min.

No. Power Input Circuit Output Output Breaker V A

50145-033 220 VAC 3.6 30A 12V 150A 0

1∅, 60 Hz 3 Output’s

Table 4.1

Sensitivity: A difference of 50 millivolts (0.05 V) BETWEEN THE AUTOMATIC CONTROL SETTING and the reference electrode voltage will cause the anode output to change from 0% to 100% of rated values.

Dimensions: Volume - all units 2.75 cu ft

Net Weight: 180 lb - Model 50145-033

Control Circuit: Analog control circuit driving a switching Power Supply. The control signal changes the switching output by pulse width modulation (PWM) from 0% to 100% output.

Construction: Welded Steel drip-proof enclosure finished in gray enamel.

Components mounted on back panel. For ease of servicing, the enclosure can be lifted off the back panel by removing four screws and disconnecting the meter/alarm harness.

4.2 SYSTEM OPERATION

4.2.1 INITIAL OPERATIONS

The operating controls referred to are shown on the power supply installation drawing located at the end of this section.

The voltmeter M2 reads from 0 to 1.0 volt full scale and normally indicates no readings. When button SW1 is pushed, M2 will indicate the voltage of the control reference cell connected to terminal No 5 of controller. When button SW2 is pushed, M2 will indicate the voltage of the auxiliary reference cell connected to terminal No 7 of the controller. With a silver-silver chloride reference electrode, the readings shown in Table 4.2 on the following page, should be obtained when either SW1 or SW2 is pressed.

The ammeter M1 indicates the total current delivered to the anodes and reads 0 to 10 amperes full scale.

Unprotected Protected Recommended Metal Surface Controller Off Controller On Set Point Voltage

Steel 0.5 to 0.6 V 0.80 to 0.95 V .85 Brass and Bronze 0.1 to 0.3 V 0.55 to 0.75 V .70 Aluminum 0.75 to 0.8 V 0.9 to 1.05 V .95

SS 304 0.53 V 0.75 - .085 V .77

Optimum Reference Cell Potentials Table 4.2

The following procedure is used to place the equipment in operation once the anodes and reference electrodes are in the water. See the power supply installation drawing at the end of this section.

A. With the cover open, rotate the Automatic Control Settings and Manual

Control Settings full counter-clockwise and place the Automatic-Manual Switches SW3 towards MANUAL.

B. Turn the AC INPUT breaker (CB) On. The voltmeter M2 should read 0.3 ± 0.1V, and the ammeter M1 should read less than 6 amperes.

C. Slowly rotate the Manual Control Settings clockwise until ammeter M1 reads the rated current of the unit. The equipment will deliver maximum rated current in salt water and less in brackish or fresh water.

D. Rotate the Manual Controls full counter-clockwise and place the Auto-Manual switches SW3 in Automatic.

E. Recheck the reference electrodes by pressing SW1 and SW2, Control and

Auxiliary Reference Cell check buttons as described above.

F. Adjust the Automatic Control Settings R19 so that the voltmeter M2 reads

0.85 for a steel structure, 0.7 for a cooper alloy structure and 0.95 for an aluminum structure. Where a combination of metals are used, set the controller for the most anodic metals, e.g., for a steel hull with bronze propeller, set the equipment for 0.85.

All potentiometers should be tightened with the same wrench after adjustments are made. The equipment will deliver maximum rated current (See Table 4.1) in salt water, (less in brackish or fresh water) until the Control Reference Cell reading is at the same value as the Automatic Control Setting.

Once the desired voltage (polarization) is achieved the current will vary in accordance with the corrosive conditions as explained in Section 1 and 2.

4.2.2 NORMAL OPERATION

The controller should always be in AUTOMATIC with the toggle switch (SW3) thrown to the left. Periodic operation checks are made on the controller to determine how well the system is operating. Usually a log sheet similar to the one shown in Figure 4.4 is kept for this purpose.

The AUTOMATIC CONTROL SETTING is recorded in the third column of the log sheet and is adjusted by turning potentiometer. This setting can be read from the meter (M2) at any time. Adjusting the AUTOMATIC CONTROL SETTING will change the meter reading from 0.4 to 1.3 volts, but it must be set for the type metal to be protected as described in 4.2.1. This AUTOMATIC CONTROL SETTING is held fixed by a regulating circuit in the controller and once it has been set to give the required reading, no adjustments should be necessary.

The fourth column of the log (Figure 4.4) is used to record the Control Reference Cell voltage. The CONTROL REFERENCE CELL CHECK button (SW1) is depressed and the meter reading is recorded. When polarization is achieved, this reading should be very close to the reading obtained before the button was depressed, as shown in column three of Figure 4.4.

The AUXILIARY REFERENCE CELL CHECK button (SW2) is depressed and the meter reading recorded in the fifth Column. If no auxiliary reference cell is furnished, this reading will be zero.

The auxiliary reference cell is located in a different area of the installation and does not operate the controller. It is provided only to make it possible to measure the effect of the CAPAC system at a second location and to serve as an installed spare.

The fourth controller reading is taken by recording the total anode current as read on meter (M1) in column 6. The log, Figure 4.4, will show how the anode current varies in order to keep the CONTROL REFERENCE CELL voltage (column 4) and AUTOMATIC SETTING (column 3) at the same value. It is normal for the anode current to change and in general, the current will increase from month to month as the paint on the installation loosens or wears away and more protective current is required. It is also subject to change with temperature, salinity, total dissolved solids, water velocity, etc.

4.2.3 MANUAL OPERATION

The circuit of the controller is designed to “fail safe”. This means that it reduces the anode current to a low value if the reference cell input is either open or short-circuited. Any difficulty in the system can be observed from the log sheet, Figure 4.4. The controller should be put in the MANUAL mode for any one of the following reasons:

A. When constant current output is desired to facilitate testing of anodes

(the current in the AUTOMATIC mode is usually not constant).

B. When the controller does not operate properly in AUTOMATIC.

1) When the Control Reference Cell check reads below 0.1V.

2) When the Control Reference Cell check reads more than 0.1 volts above the Automatic Setting and the Ammeter reads more than 6 amperes.

3) When the Control Reference Cell Check reads less than the Automatic Setting by 0.1 volts or more and the Ammeter reads less than 6 amperes.

If any of the above conditions are encountered, the system should be put in MANUAL until it is repaired. Repair and maintenance procedures are covered in Section 4.3. When the controller is in MANUAL, the automatic control portion of the circuit is disconnected and the output from the controller can be adjusted and held at a fixed value by adjusting the MANUAL CONTROL SETTING. The meter (M2) will still read the AUTOMATIC CONTROL SETTING but this should be disregarded.

There are two methods of determining the best MANUAL CONTROL SETTING. If past log records of correct automatic operation are available, then all that is necessary is to throw the AUTOMATIC-MANUAL toggle switch (SW3) to MANUAL and rotate the MANUAL CONTROL SETTING until the ammeter (M1) reads the same as it did when the controller was operating correctly.

The second method of determining the proper MANUAL CONTROL SETTING is to rotate until a reading of 0.85 is obtained on the CONTROL REFERENCE CELL CHECK. This is accomplished as follows:

A. Throw the toggle switch (SW3) to MANUAL.

B. Adjust the MANUAL CONTROL SETTING until the meter (M1) reads one half the maximum rated current. (See Table 4.1).

C. After 30 minutes, press the CONTROL REFERENCE CELL CHECK button (SW1). The meter should read 0.85 for steel, 0.95 for aluminum, or 0.70 for bronze.

1. If the meter reading is less than required, more anode current is necessary. Release the CONTROL CELL CHECK button and repeat Step B, but increase the meter reading (M1) by 10%.

A. After an additional 30 minutes, repeat Step C. Continue to increase or decrease the current output with the MANUAL CONTROL SETTING until reference cells check reading near the required value is obtained.

CAUTION: Under no conditions should aluminum be protected at reference electrode potentials above 1.10 volts.

B. In the event the Control Electrode is defective, the Auxiliary Electrode may be used (if installed) or a portable electrode meter can be employed.

4.2.4 CURRENT LIMITING

A current limiting feature has been furnished which limits the output current of the controller regardless of whether the controller is in AUTOMATIC or MANUAL operation. Turning the current limit potentiometer in a clockwise direction increases the controller’s maximum output current while turning the adjustment screw in a counter-clockwise direction decreases the maximum output current. The rheostat is factory adjusted so that the output current does not exceed the maximum rated current shown in Table 4.1.

In the event that one or more anodes have failed, the Current Limit is used to prevent the remaining anodes from drawing excessive current. For example, a controller-power supply 50145-024 normally powers four anode circuits with a 100 ampere output (25 amp per anode). If one anode should fail, the current limiting would be reduced by rotating potentiometer (CCW) to limit the current to 75 amperes. On a ship hull, this adjustment must be made when the ship is in salt water.

4.2.5 ALARM CIRCUIT

Over/under protection alarm circuit is intended to provide a quick overview of the performance of an automatic impressed current protection system or subsystem.

A set of indicating lights are provided to show whether the ICCP system is performing satisfactorily.

4.2.6 ALARM CIRCUIT OPERATION

On the front of the power supply below the M1 meter three (3) indicating lights are located (LT1, LT2, LT3). During normal operation the green indicator lamp (LT2) will be lit. This indicator light will be ON as long as:

A. AC input power in ON and rectified DC control voltage is ON.

B. Protection level, as indicated by the control reference electrode, is within normal limits of protection.

During an under/protection condition, i.e., when control reference electrode potential is below set limit, the green indicator light (LT2) will deactivate and a red indicator light (LT3) will energize. At the same time relay (RY) will de-energize closing contacts across terminals 4 and 9.

This condition of under/protection can only be normal if ICCP system is just activated and hull/structure has not received optimum potential level.

Polarization time will depend on many factors and may take minutes or hours.

In all other under/protection conditions the operator must analyze log sheet readings in order to determine the reason for the condition.

During an over/protection condition the polarization potential, as measured across the control reference electrode, will be above preset limit.

This condition will activate red indicator light (LT1). Green indicator light will de-energize dry contacts (RY) across terminals 4 and 9.

Over/protection may be caused by two factors:

C. If the controlled leakage current from power supplies exceeds the amount necessary for optimum protection resulting in over/protection, solution is to turn OFF some anodes or power supplies if hull/structure is protected by more than one.

D. Or equipment malfunction, which must be carefully investigated and if corrections cannot be performed within hours, particular power supply must be secured.

Both over and under alarm lights are factory set for optimum corrosion protection condition but may be reset in the field, if necessary.

4.3 MAINTENANCE AND SERVICE

4.3.1 CONTROLLER MAINTENANCE

Since the controller has no moving parts to be lubricated or adjusted, the only maintenance recommended is the daily operating readings recorded on the Capac Log as described in Paragraph 4.2. If the readings on the Log Sheet indicate the controller is not performing properly, refer to Service Paragraph 4.3.2.

Visually inspect the electrical connections to the controller and particularly the point where the wires from Terminals No. 6 and (-) are connected to the hull for loose or corroded connections.

4.3.2 CONTROLLER SERVICING

4.3.2.1 THEORY OF OPERATION

Before reading this section, it is important to review Section II in order to understand how the controller-power supply fits into the overall system and the function it performs. In the following description, refer to the schematic, Figure 4.3.

The controller-power supply consists of two electrical sections:

A. The controller section P/N 50508-22, which measures and compares the Reference Electrode Voltage with the Automatic Control Setting Voltage.

The controller output is automatically adjusted to keep the Reference Electrode Voltage at the same value as the Automatic Control Setting. It accomplishes this by impressing its output voltage on the saturable reactor control winding. It consists of IC amplifiers IC1 through IC7 powered by a separate unfiltered 12 volt DC supply, T2 and DR2. It also provides an alarm function for under and over protection conditions. This alarm circuit activates the appropriate indicator lamps and provides Form C dry contacts for an external alarm.

B. The power supply section which consists of a saturable reactor, SR in series with the stepdown transformer primary T1. A full wave center-tapped rectifier circuit (DR1) is in the secondary of the transformer.

4.4 STORAGE

4.4.1 STORAGE METHOD

Item classification (ANSI 45.22): Level C storage facility required. Level B preferred.

It is suggested to retain original packaging until installation of power supply. If original packaging is destroyed, wrap power supply enclosure in a waterproof barrier material.

TABLE 4.3

REPLACEMENT PARTS LIST

ITEM

NO.

SCHEMATIC

DESIGNATION

DESCRIPTION

APPLICABLE

MODEL

PART NO.

1 M1 Ammeter – 100 amp 50145 50379-1

2 M2 Voltmeter 50145 36512-1 (50380)

3 CB Circuit Breaker – 30 amp

50145 50517-2

4 SR Saturable Reactor 50145 50249-2

5 T1 Transformer 50145 50248-3

6 T2 Power Supply Transformer

50145

7 DR1 Rectifier Cell 50145 37954-1

8 DR2 Power Supply Rectifier Assembly

50145 50550

9 F1 Fuse 10 amp 50145 33890-3

10 F2 to F7 Fuse 35 amp 50 amp 100 amp

Depends on configuration

50518-14 50518-7 51742-1

11 --- Terminal Block 50145 34706-24

12 --- Controller Assembly 50145 50508-22

13 SH1 Shunt 100 amp 50145 36739-100

Figure 4.1

Figure 4.2

Figure 4.3

Figure 4.4

SECTION 4

CONTROLLER POWER SUPPLY

MODEL 50145 – 033

CAUTION

Note that more than one model of power supply may be supplied for this ship or structure. Various power supplies may be similar in appearance but different in construction, amperage rating and operation. Ensure that you are using proper instructions for the power supply installed.

4.1 SYSTEM DESCRIPTION

The purpose of the controller-power supply is to continuously monitor the level of cathodic protection on a submerged metal surface and to adjust the amount of current supplied to the anodes to maintain this protection at a preset optimum level.

An AUTOMATIC CONTROL SETTING adjustment is located on the control panel inside the enclosure, which permits the controller to be set at the optimum level for the metal structure being protected (See Table 4.2).

Two meters are provided on the unit. The ammeter indicates the total anode current and the voltmeter is used to indicate the level of cathodic protection.

4.1.1 SPECIFICATIONS

Input Power: 120V AC, ± 10%, 1 ∅, 60 Hz ± 5% Model Input Max. KVA Input Max. Rated Min.

No. Power Input Circuit Output Output Breaker V A

50145-033 220 VAC 3.6 30A 12V 150A 0

1∅, 60 Hz 3 Output’s

Table 4.1

Sensitivity: A difference of 50 millivolts (0.05 V) BETWEEN THE AUTOMATIC CONTROL SETTING and the reference electrode voltage will cause the anode output to change from 0% to 100% of rated values.

Dimensions: Volume - all units 2.75 cu ft

Net Weight: 180 lb - Model 50145-033

Control Circuit: Analog control circuit driving a switching Power Supply. The control signal changes the switching output by pulse width modulation (PWM) from 0% to 100% output.

Construction: Welded Steel drip-proof enclosure finished in gray enamel.

Components mounted on back panel. For ease of servicing, the enclosure can be lifted off the back panel by removing four screws and disconnecting the meter/alarm harness.

4.2 SYSTEM OPERATION

4.2.1 INITIAL OPERATIONS

The operating controls referred to are shown on the power supply installation drawing located at the end of this section.

The voltmeter M2 reads from 0 to 1.0 volt full scale and normally indicates no readings. When button SW1 is pushed, M2 will indicate the voltage of the control reference cell connected to terminal No 5 of controller.