PF 204 SOWv2.docx

STATEMENT OF WORK

DRYDOCKING AND REPAIR

PF 204 PATROL BOAT

ALUMINUM HULL

STATEMENT OF WORK

The subject vessel is owned by the United States of America acting through the Maritime Administration, Department of Transportation (herein after called MARAD).

1. SERVICES:

1.1. Contractor is to provide all labor and material required to perform a dry docking of PF-204 Patrol Boat according to the Statement of Work. Barring any weather related or unforeseeable delays, MARAD intends for the patrol boat to be delivered and tendered to the contractor facility within three working days of notice to proceed. MARAD will deliver the PF-204 to the contractor’s facility which shall be located in the Hampton Roads area, such area to include the James River, all branches of the Elizabeth River, York River, Mobjack Bay and tributaries. The dry-docking POP will be 45 days upon completion of delivery and tender. MARAD will assume custody and take re-delivery of the craft at the same contractor’s facility after all work is performed and accepted. MARAD intends to have a representative on site during most production days while the craft is at the contractor’s facility. The contractor will provide the following services to support this project:

1.2. The contractor shall provide line handlers to moor the vessel (including a gangway) upon arrival, to cast off the vessel during the final departure, and during all shifts within the Contractor’s facility.

1.3. Contractor shall provide services of a crane, crane operator, and rigger to assist in the performance of all work items required by this contract (if required).

1.4. In addition, contractor shall provide fire protection to the vessel upon arrival at Contractor’s facility. Fire Protection shall comply with the National Fire Protection Association, “Standard for Fire Protection of Vessels during Construction, Repair, and Lay-up”, NFPA 312.

1.5. Contractor shall also provide sufficient compressed air during the entire period of performance of the contract. The compressed air shall be free of moisture and oil; furnish all labor, material, and equipment to set-up temporary lighting in all spaces and tanks where work is to be carried out. Contractor shall furnish labor and material to connect and supply power in quantity sufficient to light the vessel and operate any equipment needed to accomplish the specification while vessel is berthed at the Contractor’s facility.

1.6. The contractor shall provide all labor, material, and equipment necessary to make all removals and restorations; remove and replace interference’s; rig and unrig; make all disassembles and subsequent reassembly to accomplish the work specified herein. All work shall be in compliance with the latest Regulatory Body requirements. The term, “Regulatory Bodies” includes the United States Coast Guard, American Boat and Yacht Council, United States Public Health Service, the Department of Labor Occupational Safety and Health Administration, and the Institute of Electrical and Electronic Engineers.

1.7. If, in the performance of any work required in these specifications, it becomes necessary to remove or disturb any structural part of the vessel, the contractor shall, upon completion of that work, reinstall or renew, if necessary, any affected structural part and restore to original conditions of durability, appearance, and seaworthiness. All temporary removals in the way of the work are to be replaced in good order.

1.8. All removed equipment or parts remain the property of the government and is to be left aboard the vessel. The contractor shall re-deliver the vessel in the same clean and orderly condition as when received.

1.9. All work specified shall be accomplished and completed in conformity with the highest standards of shipbuilding practices. All items contained in these specifications must be proved to the satisfaction of the Contracting Officer’s Representative (COR).

1.10. The term “or equal” means that components, equipment, or material shall be equivalent in terms of performance, services required, compatibility with interrelated systems and arrangements and supportability over the service life of the components or equipment. In the case of component or equipment substitution for those components or equipment noted on the Contract Guidance Drawings or Specification, the Contractor shall submit a written request delineating the design and the performance data on both the specified and substituted piece of equipment for COR approval and if approved, the Contractor shall take full contractual and technical responsibility for ensuring installation of components or equipment’s or both and compatibility with interrelated systems.

1.11. The terms “Replace” or “Renew” mean to remove the existing unit, equipment, or systems, including all interferences and to install a new unit, equipment or system which is either identical to or equal to that which was removed; the installation shall include at a minimum all hook-up, supports, and adapters which are required to affect a fully operational installation complete in all respects.

1.12. Any repairs or other work resulting from recommendations or other discoveries after the vessel is docked are to be brought to the attention of the COR immediately by use of a contractor generated inspection report. Any such additional work will be subject to a delivery order. Additional work to be accomplished ONLY WHEN AUTHORIZED IN WRITING.

1.13. The contractor shall gas-free or inert all spaces affected by the work described in this specification and is responsible for determining all spaces requiring gas freeing. All safety precautions contained in the United States Department of Labor Safety and Health Regulations for Ship Repairing, Title 29 CFR Part 1915 must be strictly observed. A copy of the gas-free certificate is to be presented to the COR before beginning work on the repairs. Initial Certificates are to be issued by a Certified Marine Chemist, as will recertification if conditions change which will affect the Certificate. Gas-Free Certificates shall be updated daily by competent persons.

1.14. All welding shall meet ABS and USCG requirements and conform to American Welding Society (AWS) standards. All welds shall be cleaned prior to painting. All surfaces which have been cut, drilled, welded, or otherwise modified shall be cleaned, free of grease, slag and foreign matter; and painted in accordance with the coating sections of these Specifications. Prior to any surface preparations the contractor will conduct a joint inspection of the welding repairs with the COR.

1.15. Contractor shall provide an office space near the dry dock or marine railway for use by the Owner’s representative or representatives during the course of this contract with a desk and chair. Contractor shall supply internet in the office.

1.16. Except when specified in writing from the Owner’s Representative, the Contractor shall not use any of the vessel’s spare parts, equipage, material, or equipment in the performance of specifications, including mooring lines, etc. Any spare parts, equipage, material, etc. authorized for use by the Owners Representative to the contractor are to be replaced, at the Contractor’s expense, prior to the completion of the contract. The Contractor shall be responsible for all deficiencies and the prompt and proper restoration of same and all deficiencies arising from the Contractor’s use of the vessel equipage, machinery, etc.

1.17. Some of the vessel’s crew will be onboard the craft periodically and shall have free access to and from shore. The vessels crew will not be feeding and sleeping aboard, but the crew shall be free to do regular maintenance and repairs to all machinery and equipment. By no means will crew work be allowed to interfere with contract work.

1.18. All dirt and debris resulting from the work required by these Specifications shall be removed from the vessel and disposed of at contractor’s expense. All affected areas shall be left clean and in good order at the end of the dry-docking period.

2. DRYDOCKING

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2.1.

2.1.1. Provide the required drydocking facilities as outlined in "General Requirements" section of this specification and drydock the vessel.

2.1.2. The vessel shall be blocked sufficiently to prevent stress and strain on vessel's hull.

2.1.3. The line of flotation shall be established by the Contractor prior to drydocking vessel.

2.1.4. Shift the vessel on the blocks for 100 percent cleaning and painting.

2.2. Drydocking Report:

2.2.1. Contractor shall provide a drydocking report.

2.3. Undocking: Upon completion of all related repairs and satisfactory inspection by the Contractor and the GOV COR, refloat the vessel.

2.4. Contractor and GOV COR Checkpoints:

2.4.1. Inspect blocking of the vessel.

2.4.2. Inspect each compartment for leakage when vessel is shifted and when undocked.

2.4.3. Witness the undocking of the vessel.

3. PLATE RENEWAL AND STRUCTURAL REPAIRS

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3.1. Scope of Work:

3.1.1. Furnish and replace plating and required structural members in areas indicated by the COR.

3.1.2. The price for this item shall include the necessary labor to remove and reinstall, as original, all interferences in way of access to remove and replace defective and deteriorated plate, guards, and structural members.

3.1.3. Such interferences shall include liquid in tanks, ballast of all descriptions, structural members, piping and valves, insulation, machinery and components, stored items, and equipment, and drydock or marine railway blocks used to support the vessel while docked for underwater repairs.

3.1.4. Materials replacement shall include flat, rolled, bent, formed or other designed shapes applicable to the vessel.

3.1.5. Structural members replacement shall include longitudinal and transverse bulkheads, support stanchions, pillars, frames, stringers, stiffeners, I beams, H beams, channels, tees, zees, or other designed shapes applicable to the vessel.

3.1.6. All aluminum furnished for use in this item shall conform to material requirements of the applicable vessel drawings to the areas being repaired.

3.2. Requirements:

3.2.1. In the performance of any burning, heating, or welding required to accomplish the repairs specified in this item, it shall be the responsibility of the Contractor to provide a "gas free" or "safe for hot work" certificate to the COR, certifying that all tanks and other adjacent areas in the way of repairs and alterations are free of gas and other fire hazards.

3.2.2. In the performance of this item, the Contractor shall dispose of all waste products in accordance with Federal, state, and local regulations.

3.2.3. Cost of performing the above parts of this item shall be included in the price of this item.

3.3. Removals:

3.3.1. Remove interferences required to provide access to the areas of deteriorated plating identified for renewal.

3.3.2. Crop out and remove all defective plating and any structural members or interferences as indicated by the COR.

3.3.3. All material edges in the way of removals shall be faired and cleaned free to receive new materials.

3.4. Installation:

3.4.1. All new materials shall conform to original vessel design. Actual type and size material requirements shall be obtained from the vessel by the Contractor.

3.4.2. All new materials installed to the vessel shall be welded in place to conform with vessel's original construction.

3.5. Painting: All new materials and disturbed areas shall be primed and painted.

3.6. Repairs:

3.6.1. Areas and Locations:

3.6.1.1. Underwater plate and related structural members are defined as all original configuration of plating and fixed appendages from the vessel's deep load line down to and including the keel.

3.6.1.2. Above deep load line plate and related structural members are defined as all original configuration of plating, guards, and rub rails from the deep load line up to and including the main deck.

3.6.1.3. Estimated Quantity:

3.6.1.3.1. Underwater Plate: NONE

3.6.1.3.2. Above deep load line Plate: approximately 2 square feet, 20 pounds.

3.6.1.3.2.1. Remove both bolted on docking light covers on bow. Weld in new 3/16” plate aluminum.

3.6.1.3.2.2. Repair cracked area above cockpit port step/storage box.

3.6.1.3.2.3. Repair broken port cockpit storage box lid hinges.

4. ULTRASONIC TESTING

4.1. Scope of Work: Contractor shall perform ultrasonic testing in areas indicated by the COR.

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4.1.

4.2. Applicable Areas: All areas of the vessel's hull plating, shell plating, decks, bulkheads, tank tops, ballast tanks, all structural framing, and any other areas as indicated by the COR.

4.3. Preparation:

4.3.1. The Contractor shall include in the price of this item the removal and reinstallation of all interferences required for access to areas to be tested.

4.3.2. Prior to taking readings, all areas shall be ground smooth as required for attaining satisfactory testing conditions.

4.4. Tests:

4.4.1. Perform ultrasonic tests and record thicknesses in all applicable areas as required by the American Bureau of Shipping. A micrometer depth gauge shall be used in conjunction with ultrasonic tests to determine the depth of excessively deep pits.

4.4.2. Prepare a report chart showing the location of each test, existing thickness, vessel designed thickness and percentage of wastage. Additionally, prepare a sketch of the vessel's applicable areas showing average thickness readings of each plate.

4.4.3. When complete, furnish the COR a copy of the finished report showing test readings as specified, date readings were taken, vessel's name, place of test, testing agency and type of equipment used for test.

4.4.4. Estimated Quantity: 100 hundred (100) test readings.

5. ZINC REPLACEMENTS

5.1. Replace four transom zincs. GOV Furnished

5.2. Replace four shaft zincs. GOV Furnished

5.3. Replace 2 rudder zincs. GOV Furnisned

6. HULL CLEANING AND PAINTING

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6.1. Scope of Work: Adhere to listed requirements and abrasive blast, clean and paint the below designated surfaces using materials of the listed specifications. Line of flotation shall be established prior to the commencement of abrasive blasting and painting.

6.2. Requirements:

6.2.1. Prior to any abrasive blasting as specified in this item, all hull openings, hatches, vents, or other openings to the interior of the vessel shall be blanked off and sealed to prevent entry of abrasive blasting material.

6.2.2. Precautions shall be taken to prevent damage to electrical wiring, fixtures, data and name plates, glass of port lights and windows, instruments or any other components not intended to be blasted. Any components damaged on the vessel in the performance of this item shall be repaired or replaced at the expense of the Contractor.

6.2.3. No abrasive blasting shall be performed until the GOV COR has approved the installed methods of protection.

6.2.4. No work shall be performed on the interior of the vessel during abrasive blasting operations.

6.2.5. These precautions shall be adhered to during the entire time of abrasive blasting operations on the vessel and when the vessel is in the vicinity of blasting operations where the possibility exists of abrasive blasting material entering the vessel due to wind conditions or force of the blast.

6.2.6. NOTE: Requests to deviate from the specified paint system shall be submitted in writing to the Contracting Officer with all applicable documentation. Written authorization shall be received from the Contracting Officer prior to proceeding with any deviation.

6.2.7. In the performance of this item, the Contractor shall dispose of all waste products in accordance with Federal, state, and local regulations.

6.3. Removals:

6.3.1. Line of flotation shall be established prior to commencement of abrasive blasting and painting.

6.3.2. Make the required disconnections and removals prior to performance of this item. Reinstall any removals upon completion of blasting/painting.

6.3.3. Unbolt and remove exterior D rubber fendering from exterior of vessel.

6.4. Cleaning and Abrasive Blasting:

6.4.1. Prior to the commencement of abrasive blasting, the Contractor shall perform high pressure water cleaning at 5,000 – 10,000 psi (SSPC HP WC) of entire surface to be abrasive blasted.

6.4.2. Abrasive blast or wet abrasive blast listed areas to near white metal (SSPC TR2 or SSPC-SP10).

6.4.3. Abrasive blasted surfaces shall conform to the standards set forth in Seaguard 5000 HS Epoxy Application Bulletin.

6.5. Areas to be Abrasive Blasted:

6.5.1. Abrasive blast all exterior hull plate surfaces from the keel up to the main deck.

6.5.2. Abrasive blast main deck and cockpit. Blast away all adhesive attached nonskid.

6.6. Inspection: Prior to application of any paints, prepared surfaces will be inspected and approved by the GOV COR.

6.6.1. Prior to application of any paints, above deck structure; cabin, glass, mast, electronic equipment shall be covered, masked or protected by appropriate means to prevent overspray.

6.7. Paint Application:

6.7.1. Apply paint only to clean, dry surfaces prepared as specified, using the designated paint and coating thicknesses as specified.

6.7.2. Paint coatings shall be free of runs and sags with borderlines struck clean, clear, and precise.

6.7.3. The Contractor shall comply with the temperature, wind and humidity requirements stated in the referenced technical bulletin.

6.7.4. Drying time between paint coatings shall be as recommended by the paint manufacturer using the referenced technical bulletin as a guide.

6.7.5. The basic color requirements are:

6.7.5.1. Keel to waterline- DARK RED

6.7.5.2. Freeboard- BLACK

6.7.5.3. Main Deck- DECK GRAY

6.7.5.4. Names, Drafts, ETC. – BLACK or WHITE

6.8. Painting (LINE OF FLOTATION AND BELOW): Including freeboard up to main deck.

6.8.1. To all bared surfaces, apply one (1) coat of Sherwin Williams Seaguard, 5000 HS Epoxy Gray for a DFT of 5-7mils.

6.8.2. To all primer coated surfaces, apply a second (2) coat of Sherwin Williams Seaguard, 5000 HS Epoxy Gray for a DFT of 5-7mils.

6.8.3. Second coat must be tacky when applying next Antifouling coat, per application bulletin.

6.8.4. To all tacky gray surfaces, BELOW WATERLINE apply one (1) coat of Sherwin Williams SEAVOYAGE Copper Free Antifouling Paint Red to a DFT of 3.0-6.0 mils.

6.8.5. To all Red surfaces, apply a second coat of Sherwin Williams SEAVOYAGE Copper Free Antifouling Paint Red to a DFT of 3.0-6.0 mils.

6.9. Painting (LINE OF FLOTATION AND ABOVE TO INCLUDE FREEBOARD TO MAIN DECK AND MAIN DECK):

6.9.1. To all bared surfaces, apply one (1) coat of Sherwin Williams Seaguard, 5000 HS Epoxy Gray for a DFT of 5-7mils.

6.9.2. To all primed surfaces apply a second (2) coat of Sherwin Williams Seaguard, 5000 HS Epoxy Gray for a DFT of 5-7mils.

6.9.3. FREEBOARD TO MAIN DECK

6.9.3.1. Apply 2 coats of Sherwin Williams Seaguard 1000 BLACK marine enamel paint to a DFT 2.0-3.0 mils each coat.

6.10. Painting (MAIN DECK):

6.10.1. Apply 2 coats with a non-skid broadcast, DECK GRAY

6.10.2. Paint BLACK; bull nose, bow bit, all handrails, stern bit, ER vents, fuel tank vents, fuel fill pipes, and tow spool mounts.

6.11. Reinstallation: Reinstall all removals. Contractor shall replace all missing, defective, and incorrect securements.

6.12. Hull Markings: Strike in the vessel's draft markings and names as original with white or black GOV COR approved, as required, for a DFT of 2-3 mils.

6.13. Vessel Undocking:

6.13.1. A minimum drying period of 24 hours, preferably longer, is necessary between final coat of antifouling paint and undocking to ensure solvent release.

6.13.2. Undock the vessel within 30 days after application of final coat of anti-fouling paint.

7. FUEL TANK CLEANING/INSPECTION

7.1. Scope of Work

7.1.1. Inventory and remove all fuel from the vessel. Dispose of waste fuel oil in accordance with Federal, state, and local regulations. Disposal costs shall be included in the price of this item.

7.1.2. Open, clean free of fuel, sludge, and foreign matter, and inspect fuel tank interiors to include accessible piping.

7.1.3. Wipe down interior surfaces with lint free rags.

7.1.4. Ensure that each tank access cover sealing surface is free of rust, foreign matter, and distortion in order to provide a smooth flush fit.

7.1.5. Joint Contractor and GOV COR inspection of each tank will be conducted to ensure cleanliness and removal of plugs and blanks.

7.1.6. Furnish material; fabricate and install a new gasket for each access cover.

7.1.7. Furnish and replace all missing, defective and incorrect securements.

7.1.8. Upon completion of all repairs and final inspections by the Contractor and the GOV COR, ensure that all blanks and plugs are removed and tanks are clean. Contractor shall reinstall all covers and close each tank.

7.1.9. Air Tests: Perform a satisfactory two (2) PSI air test of each tank in the presence of the GOV COR. All tank closures shall be soap tested during air tests.

8. REMOVE, INSPECT, AND REINSTALL RUDDERS

8.1. Scope of work

8.1.1. Remove and unship the rudder assembly from the tiller.

8.1.2. Visually inspect all components, including but not limited to: rudder stock and blade surfaces, bearings, and bearing housings, rudder zincs, for signs of excessive wear and other mechanical defects such as nicks, cracks, and corrosion, as applicable.

8.1.3. Renew upper and lower bearings.

8.1.4. Upon completion of all inspections and any authorized repairs, the Contractor shall reassemble and reinstall the rudder assembly back to its original configuration. Renew all zincs with Government-furnished material.

9. REMOVE, INSPECT, AND REINSTALL PORT AND STARBOARD PROPELLERS

9.1. Scope of work

9.1.1. Loosen and remove the propeller nut and jam nut. Remove each propeller from the shaft taper.

9.1.2. Visually inspect each propeller for any damage, cracks, and other defects. Examine and record the suction and pressure face thickness, blade tip profiles, leading and trailing edges, contours, track, width, diameter, taper, pitch, weight, and keyway of the propeller. Submit a written CFR to the COTR within 24 hours after the inspections.

9.1.3. Reinstall propellers with new contractor provided nuts, jam nuts and stainless steel cotter keys.

10. REMOVE, INSPECT, AND REINSTALL BOTH PROPELLER SHAFTS

10.1. Scope of work

10.1.1. The Contractor shall mark and disconnect the shafts from the associated shaft couplings. Matchmark the removed couplings to ensure the same couplings are reassembled on the shafts removed from. Matchmark the coupling bolts from their respective holes. Disassemble and remove the stuffing box cooling hoses, hose clamps and attached components. Remove the shafts from the vessel.

10.1.2. Ensure each shaft is properly supported at all bearing journals while being transported or stored.

10.1.3. Inspection. The Contractor shall clean the propeller shafts and all disassembled components to remove any marine growth, dirt, and grease. Set up the shafts in a lathe, providing supports at each bearing surface. Conduct the following inspections:

10.1.3.1. Complete a visual inspection for mechanical defects.

10.1.3.2. Visually inspect and measure all keyways, keys and shear pins for excessive wear.

10.1.3.3. Check the shafts on rollers for straightness. Conduct a dial indicator run-out survey at every 20 inches of the shaft. Plot the run-out readings on an appropriate scale to detect any shaft bending.

10.1.3.4. Submit a CFR of all findings from the above inspections and any recommended repairs to the Contracting Officer's Representative (COR) within 24 hours of completing each inspection and test.

10.1.4. Clean and visually inspect the stern tube interior surfaces for defects.

10.1.5. Prior to reinstalling the Drive-saver onto the reduction gear output flange, perform a face-to-face alignment of the output flange to the propeller shaft coupling to ensure proper alignment of the associated shaft.

10.1.6. After completion of all authorized repairs, the Contractor shall reinstall the propeller shafts, and all disassembled components to their original configuration.

11. AIR TEST INACCESSIBLE VOIDS

11.1. Scope of work

11.1.1. The Contractor shall air test the skeg and shaft struts at a pressure of 2 psig for 10 minutes with no allowable leakage.

12. RENEW SEA VALVES and HOSES

12.1. Renew two main engine 2.5” butterfly valves on sea chest.

12.2. Renew one generator 3” butterfly valve on sea chest.

12.3. Renew both main engine seawater intake hoses from sea chest to strainers.

12.4. Remove sea chest grate.

12.4.1. Remove all growth and debris

12.4.2. Clean screens

13. MISCELLANIOUS ITEMS AND REPAIRS

13.1. Replace Government Furnished shaft drive savers.

13.2. Replace Government Furnished dripless shaft seals.

13.3. Replace two broken rub rail studs on port bow.

13.4. Replace three small hatch gaskets; bow peak, engine room access, lazarette, and 2 main engine hatch gaskets.

13.5. Replace 3 broken engine mount bolts.

13.6. Apply PROPSPEED to propellers, shafts, and rudders.

14. OPTIONAL ADDITIONAL LABOR HOURS

14.1. Labor Hours: The Contractor shall provide a fully burdened labor rate for an estimated amount of labor hours for additional work required by a line item(s) and/or new work discovered during the performance of the contract.

14.2. Subject to the availability of funds

15. OPTIONAL ADDITIONAL MATERIALS

15.1. Materials: The Contractor shall provide materials and repairs for additional work by a line item(s) and/or new work discovered during the performance of the contract.

15.2. Subject to the availability of funds.