(5) HALIBUT (WPB 87) DS FQ4 SCP 21R0.pdf

USCGC HALIBUT (WPB 87340)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2021

Developed By: Stephen C Pitre2

(Rev 0, 11 February 2021)

USCGC HALIBUT (WPB-87) DOCKSIDE AVAILABILITY FY2021

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property ................................................................................. vi Consolidated List of Critical Inspection Items ........................................................................................... vii Principal Characteristics ............................................................................................................................ viii General Requirements WORK ITEM 1: U/W Body, Diver Clean and Inspect WORK ITEM 2: Main Diesel Engine Assemblies, Perform W-5 Maintenance And Update Control

System Configuration WORK ITEM 3: Grey Water Holding Tank(s), Clean and Inspect WORK ITEM 4: Sewage Holding Tank(s), Clean and Inspect WORK ITEM 5: Grey Water Piping, Clean And Flush WORK ITEM 6: Sewage Piping, Clean And Flush WORK ITEM 7: Sewage Air Compressor, Remove WORK ITEM 8: Forepeak Compartment, Preserve - Partial WORK ITEM 9: Quick-Acting Watertight Closure(s), Repair WORK ITEM 10: Bracket, Sound Powered Phone, Renew WORK ITEM 11: Stern Door Cross Connect Valves Modify iii (Rev-0)

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# WORK

ITEM#

CHANGES MADE

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

iv (Rev-0)

CONSOLIDATED LIST OF 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 the time of specification writing and during contract execution.

All Coast guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – from links located on the SFLC website. Commercial sites provide access to their respective documents.

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 085-013, Rev B, Docking Plan

Coast Guard Drawing 87 WPB 111-001, Rev H, Shell Expansion

Coast Guard Drawing 87 WPB 131-001, Rev J, Deck Construction Plan

Coast Guard Drawing 87 WPB 151-001, Rev L, Superstructure Details

Coast Guard Drawing 87 WPB 161-001, Rev C, Skeg Construction

Coast Guard Drawing 87 WPB 167-002, Rev C, CG Schedule of Doors, Manholes, Windows & Hatches

Coast Guard Drawing 87 WPB 167-004, Rev H, W.T. Doors and Hatches

Coast Guard Drawing 87 WPB 243-003, Rev -, Propulsion Shaft Details

Coast Guard Drawing 87 WPB 435-001, Rev - , Sound Powered Telephone System

Coast Guard Drawing 87 WPB 526-001, Rev J, Scuppers & Deck Drains Piping

Coast Guard Drawing 87 WPB 556-005, Rev -, Hyd Steering Sys mods for Emer Door Operation

Coast Guard Drawing 87 WPB 562-001, Rev A, Rudder Details

Coast Guard Drawing 87 WPB 593-001, Rev L, Sewage Piping

Coast Guard Drawing 87 WPB 593-005, Rev -, Air Compressor, Removal

Coast Guard Drawing 87 WPB 601-001, Rev R, Outboard Profile & General Arrangements

Coast Guard Drawing 87 WPB 635-001, Rev C, Linings and Insulation Plan & Details

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Jun 2006, Coatings and Colors Manual

Coast Guard Technical Publication (TP) 4573, Coolant Heating System, 17 March 2003

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2020, Auxiliary Machine Systems

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures v (Rev-0)

OTHER REFERENCES

ASTM International (ASTM) D1330, 2010, Standard Specification for Rubber Sheet Gaskets

ASTM International (ASTM) D1330, 2015, Standard Specification for Rubber Sheet Gaskets

Code of Federal Regulations (CFR) Title 29, Part 1910, Subpart T, 2011, Commercial Diving Operations

Installation of MTU Electronic Systems E 530 606/06E

MTU 8V 396 TE.4 Maintenance Manual M020046/21E

MTU 8V 396 TE94 Description and Operation Manual M011511/00E

MTU 8V 396 TE94 Parts Catalog M033971/00DE, Order #771903

MTU 8V396 TE.4 Tolerances & Wear Limits List M070026/00E

MTU Customer Connecting System CCS for ECS 396, E 531 415/00EMTU Electrical Start Device SUE- ES for ECS 396, E 531 482/00E

MTU Customer Connecting System CCS for ECS 396, E 531 416/00E

MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED

MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED

MTU Engine Management System Typ ECS 396/S Version E & F with ETB 4E/ETB 4F Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E

MTU Exhaust Turbocharger ZR140 M040052/10E

MTU Fluids and Lubricants Specification A001061/35E

MTU Junction Box CCS-ECS 396E Illustrated Parts Catalog E 535 151/01ED

MTU Local Operating Panel for ECS E 531 301/01E

MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED

MTU Monitoring & Control Unit Documentation E 535 164/00ED

MTU Service Information 396-99/0562B Electric Governor Actuator with Oil Drain

MTU Solenoid Actuator, Description, Assembly Instructions M040082/10E

MTU Tool List M004021/20DE vi (Rev-0)

CONSOLIDATED 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)

2 Y Cylinder Head NSN: 2815-12-345-1076 16 3274.71 2 Y “A⠀ Bank

Turbocharger

NSN: 2950-12-347-2009 2 12,642.58

2 Y “B⠀ Bank Turbocharger

NSN: 2950-12-347-2010 2 11,050.16

2 Y Sea Water Pump NSN: 2930-12-344-4810 2 15,086.29 2 Y Jacket Water Pump NSN: 2930-12-344-4606 2 3799.67 2 Y Starter NSN: 2920-12-156-2556 2 3255.35 2 Y **Charge Air Cooler NSN: 2930-12-354-2436 2 32,974.85 2 Y **Injector with retainer NSN: 2910-12-341-9988 16 706.45 2 N **Cylinder Liner NSN: 2815-12-315-7282 16 1103.14 2 N **Piston NSN: 2815-12-362-8999 16 3816.34 2 N/A Engine Acceptance

Test Record N/A 0 N/A

*Government-loaned property, which must 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 or the C4IT ServiceCenter vii (Rev-0)

CONSOLIDATED 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 SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)):

Work Item

Title

8 Forepeak Compartment, Preserve - Partial viii (Rev-0)

PRINCIPAL CHARACTERISTICS

87' WPB

PHYSICAL

Length overall 87' Length between perpendiculars 81' 7" Depth 10' 11" Maximum beam 19.4' Draft, mean to design waterline 5' 9" Height of highest projection 50.2' Full load displacement 93.5 long tons Minimum operating displacement 83.9 long tons Displacement, light ship 77.9 long tons Framing Longitudinal Bulkheads Four watertight bulkheads located below the Main Deck Anchor 40 lb Fortress with 480 ft. 3 strand 5/8" dia. Line stayset

HULL

Hull/main weatherdeck material ABS Grade AH 36 Superstructure 5086 Aluminum

MACHINERY

Main propulsion Two MTU 8V396TE94, sequential turbo-charged diesels Reduction gears Two ZF Type BW 255 Propulsion shaft Two AQUAMET 22, 101.6mm Shaft diameter 4" Shaft seal Two John Crane mechanical seals Shaft bearing, intermediate Thordon Elastomeric Bearing Shaft bearing, aft Thordon Elastomeric Bearing Number of propellers 2 Number of blades 5 Diameter of propeller 1040mm Pitch 1230 mm fixed Shaft RPM 828 Rudders Two 316L Stainless Steel Ship's service generators Two Man Model D08241F01 diesel with Stanford 60KW Generator

TANK CAPACITIES

3-9-1-f (fuel oil) 1402 gal 3-9-2-f (fuel oil) 1402 gal 3-12-2-f (waste oil) 86 gal 3-12-1-f (oily water) 86 gal 3-7-0-q (sewage collection) 352 gal 3-7-1-q (grey water) 52 gal 3-12-1-w (fresh water) 200 gal 3-12-2-w (fresh water) 200 gal

1 (Rev-0)

00000_0220_FLT

REC_00000_FLT_Commercial Project @ CG Facility (1212)

General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed by commercial contractors at a Coast Guard facility for Coast Guard vessels.

1.2 Term interchangeability. The terms 'Contractor', 'CG Yard', 'NAVSTA EVERETT', 'shipyard', 'Base', and 'Coast Guard Industrial' are used interchangeably in this specification. Where the primary service provider is Coast Guard personnel, references to contractor and other noted descriptors within this specification or within drawings, publications, SFLC Standard Specifications or other commercial and military references are deemed the same as prime service provider.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General. The Contractor must conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

2 (Rev-0)

3.2 Contractor-provided fire watch personnel. The Contractor must provide fire watch personnel and equipment.

3.3 Preservation requirements. The Contractor must accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec 6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

3.3.2 Coating colors and system color schemes. Ensure that all colors and color coat/paint schemes are in accordance with COMDTINST M10360.3, Chapter 6 (Cutter and Boat Colors Exterior and Interior).

NOTE

Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes (provided in Chapter 6 of COMDTINST M10360.3) are strictly prohibited.

3.4 Welding and brazing requirements. The Contractor must perform all welding and allied processes, and NDE in accordance with SFLC Std Spec 0740.

3.5 Environmental protection requirements. The Contractor must adhere to the following environmental protection requirements in accordance with the SFLC Stand Spec 0000:

3.5.1 USCG facilities. The Contractor must provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, during the performance of this availability. Contractor must plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor must comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item must not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.1.1 USCG Generator status. The activity Generator Status for the Coast Guard Facility is _________.

3.5.1.2 Plans and permits. The CG Facility has unit specific permits including the following:

Spill Prevention Control and Countermeasures (SPCC) Plan: Unit has a SPCC Plan which requires certain unit-specific procedures be followed for the storage, inspection, and transfer of petroleum products in containers 55 gallons or greater.

National Pollutant Discharge Elimination System (NPDES) Storm Water (SW) Permit: Unit has an NPDES SW permit which requires unit-specific procedures be followed for the storage and inspection of equipment and materials which may contribute contaminants to storm water discharges.

Air Emission Permit: Unit has an Air Emission Permit which requires unit-specific procedures be followed for the emissions of VOCs and hazardous air pollutants.

3.5.2 Test and procedures. The Contractor must be required to promptly conduct tests and procedures for the purpose of assessing whether operations are in compliance with applicable Environmental Laws. Analytical work must be done by qualified laboratories; and where required by law, the laboratories must be certified.

3.5.3 Regulatory notifications. The Contractor must be responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, 3 (Rev-0) and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The Contractor must submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications must be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

3.5.4 Environmental manager. The Contractor must appoint in writing an Environmental Manager for the project, and must be responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager must ensure compliance with Hazardous Waste Program requirements, including hazardous waste handling, storage, manifesting, and disposal; implement the Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas;

ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the Environmental Records binder and required documentation, including environmental permits compliance and close-out.

3.5.5 HW disposal. Contractor must comply with SFLC Std Spec 0000 Appendix B, Requirements For Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.5.6 Additional Requirements. The Contractor must be aware of the following:

3.5.6.1 No Contractor or Subcontractor must have the authority to sign a Hazardous Waste Manifest using the Coast Guard facility’s EPA Generator ID Number or remove contract generated hazardous waste from the Coast Guard facility without COR or KO-approval.

3.5.6.2 Local environmental regulations at the Government facilities may be more stringent. As with all environmental regulations, the Contractor must prepare for and comply with local and state regulations.

3.5.6.3 Coast Guard facilities do not maintain Facilities Response Plans (FRPs) per 33 CFR 154. Contractor must furnish the FRP when required for over-the-water liquids transfers to and from vessels, and is required for oil/fuel transfers to/from vessels for 250 barrels (10,500 gallons) or more.

3.6 Local Policy. None.

3.7 SFLC Standard Specification approved changes. The Contractor must be aware that the following are approved changes to published SFLC 2020 Edition Standard Specifications and supersede published content:

None.

4 (Rev-0)

4. NOTES

4.1 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 6310 to be completed and submitted during preservation of “critical-coated surfaces”, are provided at the end of this document.

5 (Rev-0)

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

VESSEL NAME HULL # WORK ITEM

WORK ITEM TITLE

LOCATION OF WORK (INCL. FRAME #’S) AREA (SQFT)

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

Ensure all coatings are in compliance with SFLC Std Spec 6310, Appendix C.

CHECKPOINT 2 - PAINT STORAGE

Ensure all coatings are kept at a temperature of 65 to 85°F at all times, unless otherwise specified by the coating mfg.

CHECKPOINT 3 - AMBIENT CONDITIONS

Ensure surface and surrounding temperatures are each between 50 and 90°F for water-containing coatings, and 35 and 95°F for other coatings, unless otherwise specified by the coating manufacturer(s).

Ensure maximum relative humidity (RH) is as follows, from surface preparations through final curing of topcoat: 50% for tanks, voids, and vent plenum; and 85% for all other areas, unless otherwise specified by manufacturer(s).

Ensure surface temperature is at least 5°F above the dew point, unless otherwise specified by the coating mfg.

CHECKPOINT 4 - PRE-SURFACE PREPARATION

Remove surface contaminants (soluble salts, loose rust, mud, and marine growth) with low pressure fresh water wash down (maximum 5,000 psi). If oil and grease are present, perform solvent cleaning, as per SSPC SP-1.

Verify equipment setup, blast media, and surface preparation methods match designated test coupon.

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure cleanliness of prepared surface is as per specification (i.e.: SSPC SP-11, SP-10, SP WJ-2…).

Verify surface anchor profile using ASTM D4417-Methods B or C against SFLC Std Spec 6310. Conduct profile readings at a minimum of 5 locations for the first 1000-sqft area, and 2 locations for each succeeding 1000-sqft area.

Measure soluble salt conductivity in accordance with SSPC-Guide 15. Conduct 5 measurements per each 1000-sqft area (max. threshold: 70 microsiemens/cm for non-submerged surfaces, 30 microsiemens/cm for submerged surfaces).

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Verify proper mixing and stand-in (induction) times.

Ensure no paint is applied when the temperature is expected to drop to freezing before the paint has dried.

Ensure surfaces are completely dry, unless otherwise allowed by the coating manufacturer(s).

Verify wet film thickness (WFT) at random, to prevent under or over application. Verify final DFT.

Brush out all runs, sags, drips, and puddles.

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

After primer coat (mist coat after inorganic zinc), brush-apply un-thinned coat of same primer paint over edges, weld seams, cut-outs, and areas of complex geometries @ 3-4 mils wet film thickness (WFT).

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

Verify proper mixing and stand-in (induction) times, as applicable.

Verify wet film thickness at random, to prevent under or over application.

Brush out all runs, sags, drips, and puddles.

CHECKPOINT 9 – FINAL INSPECTION

Verify final system dry film thickness. Conduct 5 sets of 3 readings for each of the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area.

Ensure that system cure is in accordance with manufacturer's recommendation for intended service.

Ensure potable water tank exhaust ventilation is maintained continuously from and during coating application through final system cure, to exhaust all solvent to the atmosphere and to prevent solvent entrapment.

For immersion coatings (including tank U/W body), record date and time of the following events:

Final coat application: _____/_____; Return to service or removal from environment controls: _____/_____

CHECKPOINT 10 – RECORD KEEPING

Complete, sign, and submit all provided QA Inspection Forms.

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE / TIME

6 (Rev-0)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

VESSEL NAME HULL #

WORK ITEM

Use one sheet for each activity. Record conditions every four hours from before surface preparation to application of final coating system coat.

DATE

TIME

ACTIVITY (SURFACE

PREPARATION, PRIMER COAT,

BARRIER COAT, TOP COAT,

ETC…)

LOCATION (FRAME &

DECK, RELATION TO

EQUIPMENT, ETC.)

TEMPERATURE % REL.

HUMID-

ITY

DEW

PT.

SURFACE AMBIENT ΔT

| DP -

SURFACE |

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE / TIME

7 (Rev-0)

QA-3A - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-C)

VESSEL NAME HULL # WORK ITEM

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area) Brush-blasting (non-metallic substrate)

ABRASIVE MANUFACTURER: ABRASIVE SIEVE SIZE:

PLACE SURFACE PROFILE REPLICA TAPES IN THE SPACES PROVIDED BELOW, TO SERVE AS

PERMANENT QA RECORD. MAINTAIN A SEPARATE LOG FOR EACH LOCATION. WHEN AN AREA IS

DIVIDED INTO SEPARATE SECTIONS, MAINTAIN A SEPARATE LOG FOR EACH SECTION.

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

MEAN MIL READING (IAW ASTM D4417-METHOD C) FOR ABOVE 15 READINGS:

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE /

TIME

8 (Rev-0)

QA-3B - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-B)

VESSEL NAME HULL # WORK ITEM

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area) Brush-blasting (non-metallic substrate)

ABRASIVE MANUFACTURER: ABRASIVE SIEVE SIZE:

RECORD MEASUREMENTS TAKEN IN THE SPACES PROVIDED BELOW, TO SERVE AS PERMANENT QA

RECORD. MAINTAIN SEPARATE LOG FOR EACH LOCATION. WHEN AN AREA IS DIVIDED INTO

SEPARATE SECTIONS, MAINTAIN A SEPARATE LOG FOR EACH SECTION.

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Mean Reading (mils)

Mean Reading (mils) IAW ASTM DD4417).

9 (Rev-0)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

VESSEL NAME HULL # WORK ITEM

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15.

DATE TEST LOCATIONS CONDUCTIVITY (MICROSIEMENS/CM)

10 (Rev-0)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

VESSEL NAME HULL #

WORK ITEM

COATING MFG PRODUCT NAME

BATC

H #

INDUCTI

ON TIME

COATING SYSTEM

SEQUENCE

(PRIMER/TOUCHUP/3RD

COAT, ETC.)

DRY FILM THICKNESS (DFT) MEASUREMENTS IAW SSPC-PA 2.

SPOT 1 2 3 4 5

AVERAGE

VALUE

*BASE METAL READING

(BMR) Required, If Magnetic Pull-Off (Type I/Banana) Gauge Is Used.

LOCATION (FRAME REFERENCE):

SPOT 1 2 3 4 5 OVERALL AVG. DFT ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE ADJUSTMENTS AFTER ADJUSTMENTS

AVG.

1 AVG. BMR DEVIATION

1 AVG. BMR DEVIATION

APPLICATION METHOD (AIRLESS,

CONVENTIONAL SPRAY, ROLLED)

AVERAGE DFT

11 (Rev-0)

11001_FJL_0220_87WPB

WORK ITEM 1: U/W Body, Diver Clean and Inspect

1. Scope

1.1 Intent. This work item describes the requirements for the Contractor to inspect and clean the vessel’s underwater (U/W) body prior to sea trials, while the vessel is moored pier side. Affected surfaces or components include, but are not limited to the following:

Hull plating.

Shafts.

Transducers

Propellers.

Rudders.

Sea chests and gratings.

Miscellaneous appendages (examples: bilge keels, rope guards, and fairwaters).

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 085-013, Rev B, Docking Plan

Coast Guard Drawing 87 WPB 111-001, Rev H, Shell Expansion

Coast Guard Drawing 87 WPB 161-001, Rev C, Skeg Construction

Coast Guard Drawing 87 WPB 243-003, Rev -, Propulsion Shaft Details

Coast Guard Drawing 87 WPB 562-001, Rev A, Rudder Details

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1910, Subpart T, 2011, Commercial Diving Operations

12 (Rev-0)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not Applicable.

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection.

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.1.5 Dive notification. The Contractor must provide the Coast Guard Inspector 24 hours advance notice of when the diver inspection will occur. Before diving procedures are commenced, meet with the COR and the Coast Guard Inspector, to discuss diving safety requirements and the securing of cutter machinery, as applicable.

NOTE

Coast Guard preference is to schedule diving operations as near as possible to the end of the availability in order to minimize development of new growth prior to sea trials.

3.2 Pre-diving requirements.

3.2.1 The Contractor must, in accordance with 29 CFR 1910.401-440, provide a certified diver and a tender team, as well as necessary support personnel and equipment, to accomplish the tasks specified herein.

WARNING

Mixed gas diving and live boating are not permitted.

3.2.2 The Contractor must ensure that the diving team must obtain clearance from the Officer-of-the-Deck (OOD) before beginning diving operations. Ensure the Coast Guard Inspector has capability for maintaining continuous two-way communication with diving personnel at all times, during the performance of the this work item.

3.3 Inspection requirements. Using the drawings listed in Section 2 as guidance, the Contractor must perform the following inspections and fill out forms provided in Section 4. Submit CFR with results of inspections.

3.3.1 Conduct a pre-clean biofouling inspection. Fill out Form 4-1, including fouler rating for each component (see Table 1 for fouler rating descriptions).

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NOTE:

When completing the fouler rating, ensure that all (100%) of the area of the component/surface being inspected has a fouler rating. For example, if only 50% of the rudder has growth at a FR-20 rating, then there should be another rating on the rudder that is FR-0 rating over 50% of the area. All ratings should equal 100% of the area/component being inspected.

TABLE 1 - FOULING RATINGS (FR) IN ORDER OF INCREASING SEVERITY

TYPE FOULING

RATING

(FR)

DESCRIPTION

Soft 0 A clean, foul-free surface; red and/or black AF paint or a bare metal surface.

Soft 10 Light shades of red and green (incipient slime). Bare metal and painted surfaces are visible beneath the fouling.

Soft 20 Slime as dark green patches with yellow or brown colored areas (advanced slime).

Bare metal and painted surfaces may be obscured by the fouling.

Soft 30 Grass as filaments up to 3 inches (76 mm) in length; projections up to ¼ inch (6.4

mm) in height; a flat network of filaments, green, yellow, or brown in color; or soft, non-calcareous fouling such as sea cucumbers, sea grapes, or sea squirts projecting up to ¼ inch (6.4 mm) in height. The fouling cannot be easily wiped off by hand.

Hard 40 Calcareous fouling in the form of tubeworms less than ¼ inch in diameter or height.

Hard 50 Calcareous fouling in the form of barnacles less than ¼ inch in diameter or height.

Hard 60 Combination of tubeworms and barnacles, less than ¼ inch (6.4 mm) in diameter or height.

Hard 70 Combination of tubeworms and barnacles, greater than ¼ inch in diameter or height.

Hard 80 Tubeworms closely packed together and growing upright away from surface.

Barnacles growing one on top of another, ¼ inch or less in height. Calcareous shells appear clean or white in color.

Hard 90 Dense growth of tubeworms with barnacles, ¼ inch or greater in height; calcareous shells brown in color (oysters and mussels); or with slime or grass overlay.

Composite 100 All forms of fouling present, soft and hard, particularly soft sedentary animals without calcareous covering (tunicates) growing over various forms of hard growth.

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TABLE 2 - PAINT DETERIORATION RATINGS (PDR)

FORANTIFOULING/ANTICORROSION (AF/AC) PAINT SYSTEM

PAINT

DETERIORATION

RATING (PDR)

DESCRIPTION

10 AF paint intact, red in color or with mottled pattern of light green and red.

20 AF paint missing from edges, corners, seams welds, river or boll head to expose AC paint.

30 AF paint missing from slightly curved or flat areas to expose AC paint.

40 AF paint missing from intact blisters to expose AC paint.

50 AF blisters ruptured to expose intact AC paint.

60 AF/AC paint missing or peeling to expose steel substrate, no corrosion present.

70 AF/AC paint removed from edges, corners, seams, welds, river or bolt heads to expose steel substrate with corrosion present.

80 Ruptured AF/AC blisters on slightly curved or flat surfaces with corrosion stains present.

90 Area corrosion of steel substrate with no AF/AC paint cover due to peeling or abrasion damage.

100 Area corrosion showing visible surface evidence of pitting, scaling, and roughening or steel substrate.

3.3.2 Conduct diver hull inspection. Fill out Form 4-2. Complete any additional inspection forms as required to document underwater component damage (Forms 4-2, 4-3, and 4-4). See Table 2 for description of Paint Deterioration Ratings (PDR’s).

3.4 Cleaning requirements. The Contractor must employ suitable means to clean the U/W body surfaces free of all marine growth, debris, and all other surface contaminants as detected during biofouling inspection. The Contractor must ensure the following:

3.4.1 Ensure all transducer surfaces are cleaned with only hand held brushes, without the use of power attachments.

3.4.2 Ensure that existing u/w body coating system or non-coated surfaces do not incur any damage during cleaning process.

3.5 Additional documentation requirements. The Contractor must submit video highlights of underwater body surfaces (e.g. bow thruster, propellers, rudders, transducers, heavily fouled hull areas, etc.) before and after cleaning. Place linear measuring devices, as applicable, in the field of view when videotaping hull damages, to provide scale for these damages.

4. NOTES

4.1 Unit responsibilities. The ship's force will tag-out and secure the following:

All propulsion machinery and shafting and all steering machinery whenever the diver is in the

15 (Rev-0) water.

All underwater body transducers, including the sonar equipment, for the duration of the underwater hull cleaning operation.

All active cathodic protection equipment for the duration of the hull cleaning operation.

Each sea suction while the diver is inspecting the sea suction's sea chest strainer.

4.2 Inspection forms. (See following pages)

16 (Rev-0)

FORM 4-1. PRE-CLEAN BIOFOULING INSPECTION DATA

VESSEL NAME: HULL TYPE / NUMBER LOCATION (CITY) DATE (mm/dd/yy)

PRODUCT LINE: INSPECTING ACTIVITY VISIBILITY (ft)

LOCATION OF LAST DRYDOCKING UNDOCKING DATE

LOCATION OF LAST PAINTING DATE

PAINT

TYPE: ANTIFOULING: ANTICORROSION:

DATE OF THE LAST WATERBORNE FULL HULL CLEANING DATE OF THE LAST WATERBORNE INTERIM CLEANING

UNDERWATER PHOTOGRAPHS TAKEN □ YES □ NO VIDEO TAKEN □ YES □ NO

COMPONENTS

( CHECK IF: )

N/A NOT INSPECTED

( PERCENTAGES MUST ADD UP TO 100 )

FOULING RATING FOULING RATING FOULING RATING

PROPELLER Centerline FR- % FR- % FR- %

Port Outboard FR- % FR- % FR- %

Port Inboard FR- % FR- % FR- %

Starboard Inboard FR- % FR- % FR- %

Starboard Outboard FR- % FR- % FR- %

SHAFT Centerline FR- % FR- % FR- %

Port Outboard FR- % FR- % FR- %

Port Inboard FR- % FR- % FR- %

Starboard Inboard FR- % FR- % FR- %

Starboard Outboard FR- % FR- % FR- %

RUDDER Centerline FR- % FR- % FR- %

Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

SONAR DOME Port Side FR- % FR- % FR- %

Starboard Side FR- % FR- % FR- %

SEA CHEST Typical FR- % FR- % FR- %

BOW Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

SIDES Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

BOTTOM Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

STERN Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

TRANSOM Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

Signature (Ship’s Engineer):_______________________________________________________ Signature (Diving Supervisor):______________________________________________________

17 (Rev-0)

FORM 4-2. DIVER HULL INSPECTION DATA

VESSEL NAME: HULL TYPE / NUMBER LOCATION (CITY) DATE (mm/dd/yy)

PRODUCT LINE: INSPECTING ACTIVITY VISIBILITY (ft)

LOCATION OF LAST DRYDOCKING UNDOCKING DATE

LOCATION OF LAST PAINTING DATE

PAINT

TYPE: ANTIFOULING: ANTICORROSION:

DATE OF THE LAST WATERBORNE FULL HULL CLEANING DATE OF THE LAST WATERBORNE INTERIM CLEANING

UNDERWATER PHOTOGRAPHS TAKEN □ YES □ NO UNDERWATER COLOR VIDEO TAKEN □ YES □ NO

UNDERWATER WORK ACCOMPLISHED THIS DATE

□ FULL CLEAN □POLISH □MULTI-BRUSH □INSPECT □PAINT

□INTERIM □HYDRO □HAND-HELD □REPAIR □OTHER__________________________________

1. HULL COATING SYSTEM (PDR___________)

a. ANTIFOULING PAINT

PERCENTAGE REMAINING________________ PERCENT REJUVENATION________________

IS THE A/F □ HARD □ SOFT

PERCENTAGE __________ PEELING __________ LOCALIZED or __________ GENERAL __________ BLISTERING __________ LOCALIZED or __________ GENERAL __________ ABRASION __________ LOCALIZED or __________ GENERAL

CONDITION SUMMARY [ IF PAINT DAMAGE IS LOCALIZED, GIVE LOCATION(s) ]

b) ANTICORROSION PAINT

PERCENTAGE REMAINING _______________

PERCENTAGE __________ PEELING __________ LOCALIZED or __________ GENERAL __________ BLISTERING __________ LOCALIZED or __________ GENERAL __________ ABRASION __________ LOCALIZED or __________ GENERAL

CONDITION SUMMARY [ IF PAINT DAMAGE IS LOCALIZED, GIVE LOCATION(s) ]

c) DOCKING BLOCK AREAS (PDR _________)

AVERAGE PERCENTAGE OF BLOCK AREAS PAINTED ____________________ %

BARE METAL PITTING ____________________ % __________________ IN. DIAMETER ____________________ IN. DEEP

CONDITION SUMMARY [ IF PAINT DAMAGE IS LOCALIZED, GIVE LOCATION(s) ]

18 (Rev-0)

FORM 4-2. DIVER HULL INSPECTION DATA (CONTINUED)

2. CATHODIC PROTECTION SYSTEM

a. SACRIFICIAL ANODES (ZINCS)

AVERAGE PERCENTAGES OF ANODES REMANING ____________________ %

ANODES ARE: □ UNIFORMLY WASTED □ WASTAGE GREATEST IN FOLLOWING AREAS:

ANODES ARE : □ WELDED □ BOLTED □ BOTH

NUMBER AND LOCATION OF ANY ANODES MISSING OR INACTIVE:

MISSING___________________________________________________

INACTIVE__________________________________________________

b. IMPRESSED CURRENT □ NOT APPLICABLE

□ DAMAGE NOTED ON ATTACHED DRAWING (Port/Stbd) (FRAME ____________________ )

□ WIRES LOOSE, BROKEN, OR MISSING (Port/Stbd) (FRAME ____________________ )

□ CAPASTIC SHIELD DAMAGE (Port/Stbd) (FRAME ____________________ )

□ INSULATORS LOOSE OR DAMAGED (Port/Stbd) (FRAME ____________________ )

□ OTHER (Port/Stbd) (FRAME ____________________ )

3. GENERAL HULL DAMAGE (HULL PLATING, BILGE KEELS, etc.):

4. HULL PENETRATIONS (PDR _________)

_______________ % CLOGGED WITH MARINE GROWTH (POST CLEAN)

_______________ % BARE METAL (AREA SURROUNDING PENETRATION)

_______________ % BARE METAL PITTING

AVERAGE PIT SIZE: _______________ in. DIAMETER, _______________ in. DEPTH

CONDITION SUMMARY: ___________________________________________________

19 (Rev-0)

FORM 4-2. DIVER HULL INSPECTION DATA (CONTINUED)

5. SONAR DOME □ NOT APPLICABLE

□ NO VISIBLE DAMAGE □ DAMAGE NOTED ON ATTACHED DRAWING □ CUTS □ LAYER SEPARATION □ WIRE PILES EXPOSED

6. PROPULSION SHAFTING

VISIBLE BARE METAL □ YES □ NO RUST BLEEDING □ YES □ NO PITTING □ YES □ NO

CONDITION SUMMARY (TYPE OF DAMAGE, LOCATION AND SIZE):

7. STRUTS AND BEARING HOUSING

PERCENT BARE METAL: STARBOARD PORT

MAIN _________________________ % ___________________ %

INTERMEDIATE _________________________ % ___________________ %

PDR _________________________ ___________________

CONDITION OF STRUT LEADING AND TRAILING EDGES: ______________________________________

CONDITION OF ROPE GUARDS: __________________________________________________

CONDITION OF FAIRWATERS: ___________________________________________________

8. RUDDERS

□ NO DAMAGE □ DAMAGE SHOWN ON ATTACHED DRAWINGS

STARBOARD PORT

PERCENT BARE METAL % %

PDR

ACCESS PLATES INTACT? □ YES □ NO □ YES □ NO

WAS RUDDER SOUNDED? □ YES □ NO □ YES □ NO

ANY SIGNS OF

FLOODING? □ YES □ NO □ YES □ NO

ANY SIGNS OF

DROPPING? □ YES □ NO □ YES □ NO

CONDITION SUMMARY:

9. PROPELLERS

□ NO DAMAGE □ DAMAGE SHOWN ON ATTACHED DRAWINGS

PROP #1: NICKS __________ CURLS __________ CRACKS – LARGEST CRACK LENGTH __________ in.

PROP #2: NICKS __________ CURLS __________ CRACKS – LARGEST CRACK LENGTH __________ in.

PROPELLERS NUMBERED STARBOARD TO PORT.

20 (Rev-0)

Diving Supervisor: ___________________________________________ Ship’s Engineer: _________________________________

21 (Rev-0)

FORM 4-3. PROPELLER VISUAL INSPECTION FORM

Pressure Face Suction Face

Contractor inspector (written/signature): /

USCG (written/signature): /

22 (Rev-0)

FORM 4-4. PORT AND STARBOARD RUDDER INSPECTION DATA

23 (Rev-0)

23002_FJL_0220_87WPB

WORK ITEM 2: Main Diesel Engine Assemblies, Perform W-5 Maintenance And Update Control System Configuration

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a W-5 overhaul of the port and starboard main diesel engines (MDEs) and to update the control system configuration.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y Cylinder Head NSN: 2815-12-345-1076 16 3274.71 Y “A” Bank Turbocharger NSN: 2950-12-347-2009 2 12,642.58 Y “B” Bank Turbocharger NSN: 2950-12-347-2010 2 11,050.16 Y Sea Water Pump NSN: 2930-12-344-4810 2 15,086.29 Y Jacket Water Pump NSN: 2930-12-344-4606 2 3799.67 Y Starter NSN: 2920-12-156-2556 2 3255.35 Y **Charge Air Cooler NSN: 2930-12-354-2436 2 32,974.85 Y **Injector with retainer NSN: 2910-12-341-9988 16 706.45 N **Cylinder Liner NSN: 2815-12-315-7282 16 1103.14 N **Piston NSN: 2815-12-362-8999 16 3816.34

N/A Engine Acceptance Test Record

N/A 0 N/A

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 4573, Coolant Heating System, 17 March 2003

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements

MTU 8V 396 TE.4 Maintenance Manual M020046/21E

24 (Rev-0)

MTU 8V 396 TE94 Description and Operation Manual M011511/00E

MTU 8V 396 TE94 Parts Catalog M033971/00DE, Order #771903

MTU 8V396 TE.4 Tolerances & Wear Limits List M070026/00E

MTU Tool List M004021/20DE

MTU Exhaust Turbocharger ZR140 M040052/10E

MTU Solenoid Actuator, Description, Assembly Instructions M040082/10E

MTU Service Information 396-99/0562B Electric Governor Actuator with Oil Drain

MTU Fluids and Lubricants Specification A001061/35E

MTU Engine Management System Typ ECS 396/S Version E & F with ETB 4E/ETB 4F Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E

MTU Customer Connecting System CCS for ECS 396, E 531 416/00E

MTU Customer Connecting System CCS for ECS 396, E 531 415/00EMTU Electrical Start Device SUE-ES for ECS 396, E 531 482/00E

MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED

MTU Junction Box CCS-ECS 396E Illustrated Parts Catalog E 535 151/01ED

MTU Local Operating Panel for ECS E 531 301/01E

MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED

MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED

MTU Monitoring & Control Unit Documentation E 535 164/00ED

Installation of MTU Electronic Systems E 530 606/06E

ANSI/NCSL Z540 3 2006.08.03, Requirements for the Calibration of Measuring and Test Equipment

ANSI/ASQC Q90003-1994, dated 18 July 94, Inspection System

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor must provide the services of a Qualified Technical Representative who is familiar with overhauling and commissioning MTU marine engines, to accomplish the following on site:

Advise on manufacturer's proprietary system information.

Assist with installation and repair method(s)

Ensure compliance with manufacturer's procedures and standards during system disassembly, inspection, and reassembly as applicable.

3.1.2.1 Ensure the Tech Rep has experience with the system/equipment stated above and demonstrated on their résumé.

3.1.2.2 Submit the name and résumé of the Tech Rep to the COR at the Arrival Conference.

25 (Rev-0)

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection.

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following:

Piping

Valves

Electrical Wiring

Insulation

3.1.5 Labor. Provide all necessary labor to perform disassembly, reassembly, and any other required repairs associated with this contract.

3.1.6 Training. Allow Coast Guard personnel to observe all diagnostic and repair tasks; advise ship’s force on proper operation and maintenance of the equipment in the normal course of performing disassembly, reassembly, and repairs. Coast Guard personnel may be allowed to perform minor tasks, at the discretion of the Contractor, if those tasks will assist in training and in no way compromise schedule.

Coast Guard personnel will NOT be utilized to complete contract obligations; the Contractor must supply adequate labor to complete the contract within the performance period without Coast Guard supplied labor.

3.1.7 Reports. All reports must be forwarded to the Contracting Officer, Port Engineer (COR), MTU Equipment Specialist in AMS1 and copied to 87 PDM Section Chief.

3.2 Maintenance, overhaul and repair work. The Contractor must perform the following on each:

3.2.1 Engine condition pre-check. Perform engine condition check prior to W-5 Maintenance in accordance with M020046/21E Section 2.1. This check must require the cutter to get underway in order to run the engines at the maximum possible power.

3.2.2 W5 Maintenance. Perform an in-place MTU 8V396TE94 Maintenance Operation W-5 in accordance with the references listed beneath Section 2 above. Submit Condition Found Reports (CFRs) for all inspections.

NOTE

Engine lube oil and coolant/inhibitors will be supplied and disposed of by the government.

3.2.3 Non-Government-furnished part and component renewal. Renew all gaskets, seals, and o-rings disturbed during the performance of disassembly and reassembly. Renew all other components required by the MTU 8V396TE94 Maintenance Operation W5. Furnish all required components not identified as Government-furnished Property (GFP). The contractor must use only MTU certified components; the use of aftermarket non-certified components is not permitted.

3.2.4 Government-furnished part and component renewal. Renew the following components using Government-furnished property.

“A” Bank Turbocharger

“B” Bank Turbocharger

26 (Rev-0)

Cylinder Heads

Jacket Water Pump

Sea Water Pump

Starter Motor

3.2.5 Clean and inspect components. Remove, clean, inspect, and reinstall the following components.

Submit CFR for all inspections.

Sequential Turbo Charging Actuator

Sequential Turbo Charger Mechanism

Lube Oil Cooler

Plate Cooler

Charge Air Manifold

Fuel Injectors

Charge Air Cooler (must be cleaned ultrasonically)

Exhaust sleeves

3.2.5.1 Inspect the cylinder liners in place, without removal. Record dimensions on the “Data Sheet Cylinder Liner (installed)”. Submit CFR if cylinder liners are found out of tolerance. Renew components using Government-furnished property if a Change Request is released by the Contracting Officer.

3.2.5.2 If during the course of conducting the W5 maintenance the contractor discovers any damaged parts or parts worn beyond specification, the contractor must submit a Condition Found Report (CFR) to the Contracting Officer, COR, & MTU Equipment Specialist in AMS1 for review and approval. The CFR must include any applicable MTU Data Sheets that documents the damage or out of tolerance condition and the price of any parts that cannot be furnished by the Government as well as the estimated labor cost to correct the discrepancy.

3.2.6. Configuration update. The Contractor must validate and update, as needed, the system parameters to match the current 87' WPB configuration.

3.3 Quality assurance. The Contractor must maintain an inspection system which must ensure each item offered to the Government for acceptance conforms to contract requirements. The system must be documented and in compliance with ANSI/ASQS Q90003.

3.3.1 Records. The Contractor must maintain records of all inspections and tests. The records must indicate the nature and number of observations made, type of deficiencies found and the corrective action taken. Records must be furnished upon arrival of the Coast Guard Representative.

3.3.2 Contractors calibration system. The Contractor, as well as any Subcontractors, must be required to maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540-3. The system must include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to ensure adherence to calibration schedules. Calibration standards must be traceable to the National Institute of Standards and Technology (NIST). Documentation in support of this requirement must be readily available for Government review.

27 (Rev-0)

3.3.3 Responsibility For inspection. The Contractor must be responsible for all inspections/test requirements specified herein. The Contractor must provide space, personnel, and test equipment to conduct all inspection requirements. Testing and inspection must be at the Cutter’s location or other facilities acceptable to the Government. The Government reserves the right to verify or have performed any of the inspection/tests set forth in this specification where such inspections are deemed necessary to ensure that supplies or services conform to the prescribed requirements.

3.3.4 Reports. The Contractor must complete & submit the following data sheets & reports: Cylinder Liner (installed), Valve & Injection Timing, Piston Crown Clearance Adjustment (if any pistons & liners are replaced), and Sea Trial Test results. All reports must be forwarded to the Contracting Officer, Port Engineer (COR), MTU Equipment Specialist in AMS1, and copied to 87 PDM Section Chief.

3.4 Dock and sea trials. Under the supervision of the COR, the Contractor must commission the engine and conduct dock and sea trials utilizing the Diagnostic System (DIASYS) and the original Engine Acceptance Test Record Data to ensure proper operation of the marine propulsion diesel engines in accordance with MTU 8V396 TE.4 Workshop Manual M020046/21E Section 2 & SFLC Std Spec 0000.

The contractor must demonstrate for the CG Inspector or COR that all engine parameters are within the correct range and the engine is operating properly. Submit CFR detailing all sea trial test results.

4. NOTES

4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and…