J -- OVERHAUL BUOY BOOM USCGC SMILAX (WLIC 315)

SPECIFICATION FOLLOWS: SMILAX (WLIC-315) 100 FOOT INLAND CONSTRUCTION TENDER SPECIFICATIONS FOR DOCKSIDE REPAIRS 2005 Commander (v) Maintenance and Logistics Command, Atlantic 300 E. Main Street, Suite (600) Norfolk, VA 23510-9102 TABLE OF CONTENTS Work Item Title Page List of Sketches ii Revisions Record iii List of Applicable References iv List of Government-furnished Property v List of Critical Inspection Items vi Principal Characteristics 1 General Requirements 2 1 Overhaul Buoy Boom 4 List of Sketches Work Item Sketch Number Page This section is not applicable to this package. Revisions Record This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package. DATE REV.# CHANGES MADE AFFECTED PAGES NOTE: All work item numbers, page numbers, paragraph numbers, etc listed above for a given revision correspond to what they were in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated. List of Applicable References The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution. Electronic copies of the 2004 Edition of MLCA Standard Specifications are available on the Internet and may accessed at the following Internet Uniform Resource Locator (URL) address: http://www.uscg.mil/mlclant/vdiv/specs/default.htm. Guidance for obtaining copies of all other documents referenced herein is provided in Section L (Instructions, Conditions and Notices to Bidders) of the contract solicitation. Order of precedence. In the event of conflicts between text of this specification and the applicable references specified herein, order of precedence shall be in accordance with MLCA Standard Specification 0000_STD, paragraph 3.2 (Order of precedence), unless otherwise specified by the Contracting Officer (KO). The Contractor shall immediately notify the KO in writing of any perceived conflicts contained herein. Nothing in these documents, however, supersedes applicable laws and regulations, unless a specific exemption has been obtained. DOCUMENTS Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0000_STD, 2004 Edition, General Requirements Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes DRAWINGS Coast Guard Drawing 180 TE 1701-14, Derrick Swinging Gear Installation, Rev B, 27 SEP 1993 Coast Guard Drawing 180 TE-1702-1, Cargo Mast Details (Derrick), Rev D, 08 DEC 1997 Coast Guard Drawing 180 TE-1702-5, Cargo Boom Details, Rev C, 08 DEC 1997 PUBLICATIONS Coast Guard Commandant Instruction (COMDTINST) M10360.3B, Nov 2003, Coatings and Color Manual http://isddc.dot.gov/OLPFiles/USCG/010968.pdf List of Government-furnished Property The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings. WORK ITEM MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST($/Unit) *Government-loaned property, which shall be returned to the vessel upon completion of the availability. **New or refurbished equipment that the Government may provide for installation in place of existing equipment. ***Government-furnished property, which is to be supplied by either the vessel, Electronic Systems Support Unit (ESU) or local Electronic Support Detachment (ESD). List of Critical Inspection Items The following is a list of work items which contain Critical Inspection reports which the Contractor must complete within the first 25% of the availability contract period (see Std Spec 0000_STD, paragraph 3.6.2 (Inspection report particulars)): Work Item Title This section is not applicable to this package. Principal Characteristics USCGC SMILAX TENDER (WLIC-315) Length overall 100' 0" Length between Perpendiculars 96' 0" Breadth, Extreme 24' 0" Depth, Molded 5' 0" Frame Spacing 1' 6" Design Draft to Baseline 4' 0" Displacement at Mean Draft 170 long tons PROPULSION Type Diesel engines Number of Units 2 Total Shaft Horsepower 600 PROPELLERS Number 2 Number of Blades 5 Diameter 46 Pitch 44 fixed Shaft Revolutions per Minute 480 00000N_FLT (25 Aug 2004) General Requirements 1. SCOPE 1.1 Scope. This item describes the general requirements to be followed by the Contractor while conducting this availability. 2. APPLICABLE DOCUMENTS Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0000_STD, 2004 Edition, General Requirements 3. REQUIREMENTS 3.1 General. The Contractor shall conform to all requirements specified in Std Spec 0000_STD and in this item, as applicable, during the performance of this availability. NOTICE! The requirements of paragraph 3.1 (General) apply not only to all work under the scope of this contract, whether explicitly stated in work items or not, but also to all other work subsequently authorized by changes, modifications, or extensions to the contract. 3.2 Contractor-provided fire watch personnel. The Contractor shall provide fire watch personnel and equipment. 3.3 Crew composition. The Contractor shall be aware that the crew is comprised of both male and female personnel, for the purpose of providing portable toilets and shower & sink facilities, when applicable. 4. QUALITY ASSURANCE No additional requirements. 5. NOTES This section is not applicable to this specification. S57382W_315(10/4/04) WORK ITEM 1: Overhaul Buoy Boom 1. SCOPE 1.1 Scope. This work item describes the requirements for the Contractor to inspect, overhaul, and test the buoy boom. This work item serves as a Level II inspection. 2. APPLICABLE DOCUMENTS Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Commandant Instruction (COMDTINST) M10360.3B, Nov 2003, Coatings and Color Manual http://isddc.dot.gov/OLPFiles/USCG/010968.pdf Coast Guard Drawing 180 TE 1701-14, Derrick Swinging Gear Installation, Rev B, 27 SEP 1993 Coast Guard Drawing 180 TE-1702-1, Cargo Mast Details (Derrick), Rev D, 08 DEC 1997 Coast Guard Drawing 180 TE-1702-5, Cargo Boom Details, Rev C, 08 DEC 1997 3. REQUIREMENTS 3.1 General. The Contractor shall inspect, overhaul, and test the weight handling equipment, shown on Coast Guard Drawings 180 TE-1701-14, 180 TE-1702-1 and 180 TE-1702-5, as specified herein. 3.1.1 Disposal of oils, oily rags, and other hazardous materials. Dispose of any oil, hydraulic fluid, contaminated cleaning materials, or any other hazardous waste material, drained, lost, spilled, or otherwise removed during work on any system, in accordance with all applicable Federal, state, and local regulations. 3.1.2 Contractor's option for component renewal. The Contractor may, at no additional cost to the Government, opt to renew any component designated for overhaul; ensure all new components conform to the system manufacturer's specifications. 3.1.3 Mandatory renewals. The Contractor shall renew all disturbed software (seals gaskets and o-rings) and self-locking fasteners. 3.2 Visual inspection of system. Before disassembly, the Contractor shall visually inspect all visible surfaces of all components of the buoy boom system for excessive corrosion, damage, or wear. Identify any necessary repairs not already specified herein and include data specified in the alignment survey specified below. Submit a CFR for the completed inspections. 3.2.1 Existing alignment survey. Determine the existing gear backlash between the bull gear mounted on the deck and the pinion gear attached to the slew drive at 4 equally spaced points through the full slew rotation to the nearest 0.001 inch. Determine the existing radial and peripheral total indicator run-outs between the slew drive motor shaft and the slew drive gear box shafts. 3.3 Machinery overhauls. The Contractor shall disassemble and overhaul the following major machinery components: - Three (3) air winch assemblies, including all associated controls and actuators. Match-mark and maintain the existing alignment of the three winch assemblies at reinstallation. - One (1) air motor assembly (slew drive assembly) - One (1) planetary gear reducer assembly (slew drive assembly) 3.3.1 Overhaul requirements. Perform the following in conjunction with all other work specified. - Completely disassemble the specified components and assemblies. - Determine which parts are wearing parts. Inspect all exposed uncoated surfaces of non-wearing parts for wear, damage, or corrosion. Submit a CFR for the completed inspection. - Clean all accessible uncoated surfaces of the component or assembly. - If a Change Request has been authorized and released by the KO, renew each part determined to be a wearing part and perform all other work specified in the Change Request. - Lubricate all uncoated surfaces of the component or assembly. - Preserve all previously coated surfaces of each component as specified in paragraph 3.5 (Preservation). - Perform all other work specified or invoked by the task description that can only be performed prior to reassembling the component or assembly. - Reassemble the component or assembly and return it to normal operating condition within the system. 3.4 Boom and lifting appliance inspections. Unship and remove boom and king post mast from the vessel to a suitable repair facility. Disassemble all blocks, fairleads, sheaves, swivels, hooks, shackles, connecting links, and all associated pins from the mast and boom assembly. During the disassembly, tag and mark all removed components and parts to ensure exact reassembly. Visually inspect all components for corrosion, wear, deformation, surface cracks or other conditions that may lead to failure. Inspect all sheaves using a sheave gauge in four points around the wire run. 3.5 Preservation. The Contractor shall:. - Prepare and coat all previously coated surfaces of the boat boom system (all spar surfaces) in accordance with Std Spec 0000_STD. - Use the coating system specified for - Machinery, Deck, Option I in Appendix A (Cutter and Boat Exterior Paint Systems) of COMDTINST M10360.3 - Use spar (10371) as the finish coat color. - Select material brands as specified in Appendix C (Authorized Coatings For Use On Cutters and Boats) of COMDTINST M10360.3. 3.5.1 Nondestructive examination (NDE). The Contractor shall perform NDE on the following specified areas in conjunction with all other work specified - All weld joints on the boom. - Weld joints that attach the kingpost to the base of the turret. 3.5.1.1 Inspections. When the area specified for examination is coated or uncoated, has not been affected by a weld repair, and is being examined only as part of a periodic inspection, an examination using an alternating current field measurement technique may be performed in accordance with ASTM E 2261 or other emerging technique approved by the COR in lieu of the methods specified in paragraph 3.5.1.2 (Coated surfaces) below. Submit a CFR for the completed inspection. Areas that fail examinations by alternating current field measurement techniques shall have their coatings removed, as applicable, and shall be reexamined in accordance with paragraph 3.5.1.2 (Coated surfaces), below. 3.5.1.2 Coated surfaces. Remove the coating from the specified area while maintaining the existing surface profile, and perform an examination in accordance with the requirements specified in paragraph 3.5.1.3 (Uncoated surfaces) below. Recoat in accordance with paragraph 3.5 (Preservation) above. 3.5.1.3 Uncoated surfaces. Examine uncoated surface areas in accordance the requirements specified for nondestructive inspection of components, in Std Spec 0740_STD, Appendix C. Submit a CFR for the completed inspection. 3.5 Wire rope renewal. The Contractor shall: - Un-reeve and dispose of all wire rope from the main hoist, whip hoist, and topping lifts, including the boom stays. - Renew the wire rope assemblies as specified below. - Pressure lubricate the rope with grease provided by the cutter. - Submit to the COR written documentation certifying that each new wire rope assembly has been pull tested to the tensions specified below. - Install the new wire rope assemblies on the drums and boom. 3.5.1 Main hoist, whip hoist, and topping winch wire rope assemblies. Furnish and install three (3) new wire rope assemblies using of 1/2-inch diameter, 6x19 IWRC, LRL, XIPS wire rope. Use fiege type end fittings identical to the existing fittings. The main hoist wire rope length shall be 180 feet. The whip hoist wire rope length shall be 110 feet. The topping hoist wire rope length shall be 160 feet. The wire rope assembly pull test tension shall be 10,400 (+520 -0) pounds. Install the new wire rope assemblies onto the winch drums under tension, in a manner that will prevent the rope from kinking. 3.5.2 Boom stay wire rope. Furnish and install two (2) new wire rope assemblies using 1-inch diameter, 6x19 stainless steel, RRL, IWRC, domestic wire rope. Use poured spelter end fittings identical to the existing fittings. Template the length of the new wire rope assemblies from the length of the old wire rope assemblies (approximately 65 feet per assembly). The wire rope assembly pull test tension shall be 25,920 (+1296 -0) pounds. 3.6 Installation. The Contractor shall reassemble and reinstall all removed and disassembled components, and follow the requirements specified below. 3.6.1 Foundation fasteners. Renew all foundation fastener assemblies (winches, slew motor, etc.) using cadmium plated Grade 8 fasteners. 3.6.2 Flex hose assemblies. Reuse existing flex hose assemblies. 3.6.3 Alignment. Perform the following alignment checks and submit a CFR for the fabrication of liners to obtain the specified tolerances. 3.6.3.1 Slew bull gear to slew gearbox pinion alignment. Align the pinion gear on the slew drive gear box to the bull gear mounted on the deck to obtain a gear tooth backlash range of 0.040-0.060 inches through the full range of motion. 3.6.3.2 Air motor to slew gearbox alignment. Align the slew drive air motor to the slew drive gearbox to within 0.005 inches total indicator run-out radial and peripheral per inch of shaft radius. 3.7 Grooming. Prepare the buoy boom system for operational and weight testing. While cycling all actuators grease all lubrication points found in the system. 3.8 Weight test requirements/preparation. Before weight testing, the Contractor shall accomplish the following preparations: 3.8.1 Plan. Submit a written plan to accomplish the weight test 48 hours beforehand which shall describe (1) the test weights to be used, (2) ship's loading condition, (3) the anticipated tide, current, and weather conditions, and (4) proposed safety precautions and procedures to be taken in the event of a casualty. 3.8.2 Briefing. Conduct a briefing for cognizant shipboard personnel at least 24 hours beforehand. 3.8.3 Pretest inspection. Visually inspect the boom, rigging, and test equipment. 3.8.4 Vessel displacement condition. Test while the ship is waterborne in full liquid load condition. If any equivalent weights are to be added to compensate for liquid load, they shall be placed to achieve the same metacentric height (GM) that would result from a full load condition. 3.8.5 Rigging. Rig all topping lifts, vangs and whips single part. Rig the main and relief purchase with the maximum number of parts authorized. 3.9 Weight test safety precautions. The Contractor shall observe the following safety precautions when conducting weight handling equipment tests: 3.9.1 Sudden load application. Avoid conditions that would cause sudden application of test loads because test loads specified are designed to provide for the effects of wave action, acceleration, and inspection under operational conditions. 3.9.2 Rotation. Do not rotate the boom with test loads at boom topping angles greater than 60 degrees. Rotate the boom during the 1.25 working load test of the main purchase rig. 3.9.3 Load arrangement. Place dunnage under test loads and keep test loads as close to the deck as possible to preclude excessive damage in the event equipment fails and the load drops unexpectedly. 3.9.4 List. Reduce the test load accordingly if any of the tests will result in (a) deck edge immersion or (b) a list of over 15 degrees. The test loads specified are intended to be within the limits that can be handled safely considering the unit's stability characteristics. 3.9.5 Preventers. Rig preventer lines or cables athwartships from the test load to prevent the load from moving off center in the event of a casualty. At a minimum, the breaking strength of the preventers must be greater than or equal to the test load. 3.10 No-load test. The Contractor shall perform an operational no-load test of the weight handling equipment to ensure proper operation. The ship's personnel will operate all ship's equipment. 3.11 Weight test procedures. The Contractor shall accomplish the following test procedures: 3.11.1 Test loads criteria. The test loads shall be 125 percent of the maximum working loads the boom is required to handle during normal operation. 3.12.2 Test procedure criteria. The test procedure shall include: 3.12.2.1 Rotation of the test load throughout the range that it is required to perform in operation. The king post rotating machinery must be able to start, stop, and hold the king post at any angle within the operational rotating range. Maximum stress occurs when the boom is 45 degrees off the centerline. 3.12.2.2 Lifting, lowering, stopping, and holding a test overload by every winch to ascertain the brakes' ability to hold the load under accelerations experienced in operation. 3.13 Label. After successfully conducting the load test, the Contractor shall fabricate and install an anodized-hydrated aluminum label plates on the boom to indicate the following: 3.13.1 The working load limit and test weights for each hoisting equipment tested. 3.13.2 The name of the facility where the test was accomplished. 3.13.3 The date of the load test was accomplished. 4. QUALITY ASSURANCE No additional requirements. 5. NOTES 5.1 Working Load Limit. The working load limits for the boom assembly are: - Main hoist 10,000 lbs. - Whip hoist 2,000 lbs. 5.2 The ship's force will operate the equipment during operational and weight tests.