SPECIFICATION_PKG._REV-0,_7_AUGUST_2018_CG_STA_BRUNSWICK_(45741).pdf

USCG 45741 (RB-M 45)

SPECIFICATION FOR DRYDOCK REPAIRS

FY2019

Developed By: Armando Perez

(Rev-0, 7 August 2018)

USCG 45741 (RB-M-45) DRYDOCK AVAILABILITY FY2019

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 .............................................................................................. x Principal Characteristics ............................................................................................................................... xi General Requirements WORK ITEM 1: Ultrasonic Testing (UT) (100) Shots, Perform WORK ITEM 2: Hull Plating (U/W Body), Inspect WORK ITEM 3: Main Diesel Engine(s) To Auragen Generator(s) And Jet Drive(s), Align WORK ITEM 4: Water Jet-Inspect, Perform Service WORK ITEM 5: Jet Drive Anodes, Renew WORK ITEM 6: Water Jet Drive, Preserve WORK ITEM 7: U/W Body, Preserve (100%) WORK ITEM 8: Drydock WORK ITEM 9: Temporary Services, Provide WORK ITEM 10: Sea Trial Performance, Support, Provide 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 45 RB-M 084-002, Rev -, Docking Plan

Coast Guard Drawing 45 RB-M 084-002, Rev –, Docking Plan

Coast Guard Drawing 45 RB-M 110-001, Rev -, Hull Structure

Coast Guard Drawing 45 RB-M 170-002, Rev -, Folding Mast

Coast Guard Drawing 45 RBM 201-001, Rev B, Main Engine Arrangement

Coast Guard Drawing 45 RBM 247-002, Rev -, Water Jet Propulsor Arrangement

Coast Guard Drawing 45 RB-M 247-002, Rev -, Water Jet Propulsor Arrangement

Coast Guard Drawing 45 RBM 311-004, Rev -, APU Generator Drive System

Coast Guard Drawing 45 RB-M 631-001, Rev -, Painting Layout

Coast Guard Drawing 45 RB-M 633-002, Rev -, Cathodic Protection Sacrificial Anode

COAST GUARD PUBLICATIONS

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

Manual

Coast Guard Technical Publication (TP) 5737, SWBS 247, Jun 2014, Water Jet – Model FF375S

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General

Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and

Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 8634 (SFLC Std Spec 8634), 2014, Drydocking

Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), 2014, Temporary

Services

OTHER REFERENCES

45 RB-M Water Jet Disassembly / Assembly Procedures

ASTM International (ASTM) D4138, Rev A, 2007 (R 2017), Standard Practices for Measurement of Dry

Film Thickness of Protective Coating Systems by Destructive, Cross-Sectioning Means

Rolls-Royce Kamewa Water Jet Assembly Drawing 376 000 49 v (Rev-0)

The Society for Protective Coatings (SSPC) Surface Preparation Specification No. 1 (SSPC-SP 1), 2015, Solvent Cleaning

The Society for Protective Coatings (SSPC), 2015 (E 2017), Paint Application Specification No. 2 (PA-

2), Procedure for Determining Conformance to Dry Coating Thickness Requirements 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)

3 Y * MDE/ TO GENERATOR

ALIGNMENT TOOL

PN: MMRBM0030 1 ea. 0

3 Y * MDE/ TO JET DRIVE

ALIGNMENT TOOL

PN: MMRBM0451 1 ea. 0

3 Y * ENGINE LIFTING BAR PN: MMRBM0956 1 ea. 0

4 N Stainless Steel Ball Joint NSN: 3040016152117 or

PN: 59915K483

10 ea. 12.26

4 N Stainless Steel Threaded

Rod

NSN: 5306016152224 or

PN: 93250A140

1 ea. 10.67

4 N Bearing Bushing NSN: 3120014555212 or

PN: 10106911

4 ea. 9.80

4 N Bearing Bushing NSN: 3120580006242 or

PN: 36M05101

4 ea. 49.00

4 N **Socket Head Screw NSN: 5305016171580 or

PN: 91210050

16 ea. 2.71

4 N **Bolt Kit NSN: 2815016171688 or

PN: 93112085A

2 ea. 15.64

4 N **Key NSN: 5315016166360 or

PN: 10100824

3 ea. 28.14

4 N Seal NSN: 5330580006238 or

PN: 10118902

2 ea. 4.35

4 N Bushing NSN: 3120580006239 or

PN: 10105511

2 ea. 48.19

4 N Bearing Bushing NSN: 3120014555272 or

PN: 10105111

4 ea. 35.33

4 N **Bolt Kit NSN: 2815016171974 or

PN: 93112080F

2 ea. 6.13

4 N **Bolt Kit NSN: 5340016167191 or

PN: 93112065K

12 ea. 13.07

4 N Bearing Unit NSN: 3110016166342 or

PN: 37506201

2 ea. 614.35

4 N Bushing NSN: 3120580006240 or

PN: 10106011

4 ea. 47.21

4 N **Set Screw NSN: 5305016020672 or

PN: 91608012

6 ea. 0.58

4 N **Bolt Kit NSN: 5305016173161 or

PN: 93112090K

10 ea. 12.56

4 N O-ring NSN: 5331580006241 or

PN: 10202606

6 ea. 14.56 vii (Rev-0)

4 N **Mechanical Sealing NSN: 4320580006403 or

PN: 10203870

2 ea. 1052.97

4 N Bolt Kit NSN: 5306016164058 or

PN: 93310030E

6 ea. 1.92

4 N O-ring NSN: 5331016020679 or

PN: 10202631

2 ea. 4.39

4 N O-ring NSN: 5331016020680 or

PN: 10202625

4 ea. 15.15

4 N Sealing NSN: 5365016233174 or

PN: 41018801

2 ea. 8.87

4 N O-ring NSN: 5331016200368 or

PN: 10202611

2 ea. 5.21

4 N Seal Lip NSN: 4730016204613 or

PN: 10202590

4 ea. 39.47

4 N Sealing NSN: 5330016163186 or

PN: 45002010

2 ea. 535.93

4 N **Lock Nut NSN: 5310016162982 or

PN: 10202908

2 ea. 16.63

4 N Lock Washer NSN: 5310016232756 or

PN: 10203008

2 ea. 2.34

4 N **Ring Nut NSN: 5310016164016 or

PN: 10202912

2 ea. 32.60

4 N Seal NSN: 5330016243735 or

PN: 10202540R

6 ea. 19.68

4 N **Screw NSN: 5305016162955 or

PN: 93305025

8 ea. 0.28

4 N **Washer NSN: 5310016162966 or

PN: 912505

8 ea. 0.06

4 N Gasket NSN: 5330016232867 or

PN: 37527805

2 ea. 63.43

4 N Bushing NSN: 5365016202680 or

PN: 10108416

8 ea. 15.91

4 N **Bolt Kit NSN: 5305016242899 or

PN: 93110060A

4 ea. 12.91

4 N **Bolt Kit NSN: 5305016242922 or

PN: 99110040G

14 ea. 6.60

4 N Bushing NSN: 3120014555268 or

PN: 10106902

8 ea. 7.90

4 N Gasket NSN: 5330016163014 or

PN: 10108901

2 ea. 5.65

4 N **Bolt Kit NSN: 5305016231019 or

PN: 93110090A

4 ea. 5.05

4 N Lock Washer NSN: 5310016232699 or

PN: 10203012

2 ea. 5.62

4 N O-ring NSN: 5331016242120 or

PN: 10202603

2 ea. 3.89

4 N **Screw, Countersunk NSN: 5305016309734 or

PN: 99106016

8 ea. 5.65

4 N Seal/Gasket NSN: 1040016337691 or

PN: 45011611

2 ea. 57.64 viii (Rev-0)

4 N Woodruff Key NSN: 5315016172999 or

PN: 10100823

2 ea. 19.09

4 N Washer, Sealing NSN: 5310016452084 or

PN: 8755000050

24 ea. 0.06

4 N Screw, Connection NSN: 5305016476396 or

PN: 91212045L

8 ea. 6.45

5 N Anode, Inspection Hatch

(Port & Stbd)

NSN: 5342580003759 or

PN: 10108231

2 ea. 46.63

5 N Transom Anode NSN: 5342016020658 or

PN: 10108230

4 ea. 52.76

5 N Tunnel Anode NSN: 5342016020668 or

PN: 10108220

4 ea. 26.88

5 N Impeller

Housing/Bucket/Interceptor

Anode

NSN: 5342226078672 or

PN: 10107701

10 ea. 24.94

5 N Guide Vane Chamber

Anode

NSN: 5342016020669 or

PN: 37517411

2 ea. 44.43

5 N Anode, Anode Hatch NSN: 5342251465439 or

PN: 10108210

2 ea. 28.20

5 N Screw Connection NSN: 5305016022100 or

PN: 93310025H

4 ea. 2.52

5 N Screw Connection NSN: 5305016275854 or

PN: 93308025H

14 ea. 1.30

5 N Screw Connection NSN:5305016022105 or

PN: 91206020E

8 ea. 0.49

5 N Screw Connection NSN: 5340016243271 or

PN: 93308025E

8 ea. 1.00

5 N O-ring NSN: 5331016020670 or

PN: 10202639

2 ea. 6.60

5 N Screw Connection NSN: 5305016240905 or

PN: 93310016E

8 ea. 1.58

5 N Screw Connection NSN: 5306016309800 or

PN: 93312030E

2 ea. 2.42

5 N Screw Connection NSN: 5305016204602 or

PN: 91212025E

8 ea. 1.93

5 N O-ring NSN: 5331226078691 or

PN: 10202626

2 ea. 9.26

5 N Tube Extension NSN: 4730016210708 or

PN: 37610802

2 ea. 148.88

5 N Tube Clamp NSN: 4730016200951 or

PN: 10217881

2 ea. 20.05

5 N Screw Connection NSN: 5305016022101 or

PN: 93310030H

2 ea. 2.08

5 N Connecting Cable NSN: 6145016203663 or

PN: 10234301

4 ea. 21.23

5 N Screw Connection NSN: 5305016176732 or

PN: 93306016E

8 ea. 0.44

5 N Anode, Corrosion NSN: 5340015899440 or

PN: 51125

2 ea. 32.56

5 N Anode, Corrosion NSN: 5340015899425 or 2 ea. 12.34 ix (Rev-0)

PN: 89287

*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 or the C4IT ServiceCenter x (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

1 Ultrasonic Testing (UT) (100) Shots, Perform

3 Main Diesel Engine(s) To Auragen Generator(s) And Jet Drive(s), Align

4 Water Jet-Inspect, Perform Service

6 Water Jet Drive, Preserve

7 U/W Body, Preserve (100%) xi (Rev-0)

PRINCIPAL CHARACTERISTICS

45' RB-M

PHYSICAL

Length overall 44 feet, 10.5 inches

Unfixed height 20 feet 9 inches

Beam, maximum 14 feet, 7.75 inches

Full load draft 3 feet, 4 inches

Full load displacement 36,500 pounds

Max sustained speed 42.5 knots

Range 250 nautical miles at 30 knots

Mission limits 8 foot seas / 30 knot winds

Survivability limits 12 foot seas / 50 knot winds

HULL

Hull manufacturer Marinette Marine Corp.

5086 (GRADE) Aluminum

Hin- 2009

MACHINERY

Type 6, cylinder diesel engine

Number of units 2, MTU's 60 series 825 hp

Propulsion type 2, Rolls-royce water-jet

TANKS

1 (Rev-0)

00000_0917_FLT

REC_00000_FLT_Boats @ Commercial Facility (0914)

General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting boat repairs performed at a commercial contractor’s 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), 2014, General

Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and

Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General. The Contractor shall 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 shall provide fire watch personnel and equipment.

3.3 Preservation requirements. The Contractor shall 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 shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740.

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

3.5.1 Contractor operated (non USCG) facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix A, Requirements for Environmental Protection at

Contractor Operated (Non USCG) Facilities, as applicable, during the performance of this availability. Contractor shall 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 shall 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 shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

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

3.5.3 Regulatory notifications. The Contractor shall 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, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The

Contractor shall 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 shall 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 shall appoint in writing an Environmental Manager for the project, and shall be responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager shall 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, 3 (Rev-0) 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 shall comply with SFLC Std Spec 0000 Appendix A, Requirements For

Environmental Protection At Contractor Operated (Non USCG) Facilities for HW disposal.

3.6 Local Policy.

3.6.1 Coast Guard turn-over preparation. The Contractor shall be aware that, upon arrival, after haul out, and prior to departing the Contractor’s facility, the Coast Guard crew shall be allowed to accomplish various tasks in preparation for the turn-over of the boat to the Contractor. The following conditions apply to this paragraph:

3.6.1.1 The Coast Guard requires a maximum of three days at the beginning of the contract, and three days at the end to accomplish various tasks.

3.6.1.2 The Contractor may commence/continue work during these time frames.

<<APM Note: Paragraph 3.6.1.3 pertains to 47’ MLB only. For all other SBPL assets delete this paragraph.>>

3.6.1.3 Coast Guard personnel will disconnect the Detroit Diesel Electronic Control (DDEC) System and any other electronic equipment, as required to avoid damage to systems arising from hotwork on the vessel during the availability.

3.6.1.4 Coast Guard personnel will remove the transducers after initial haul-out and reinstall prior to re-floating the vessel.

3.6.1.5 The Unit will contact the servicing ESD or ESU to setup removal/installation of the transducer if Unit personnel are unable to accomplish this task.

3.7 SFLC standard specification approved changes. The Contractor shall be aware that the following are approved changes to published SFLC 2014 Edition Standard Specifications and supersede published content:

3.7.1 SFLC Standard Specification 6310, Requirements for Preservation of Ship Structures.

3.7.1.1 SFLC Std Spec 6310, page C-2, Section C1.5.1. Change from "lead-containing paint as 0.06%" to "lead-containing paint as 0.009%".

3.7.1.2 SFLC Std Spec 6310, page 4, Section 2 References, Group- Other References. Add “The Society for

Protective Coatings (SSPC) Paint Application Guide No. 11, 2008, Protecting Edges, Crevices, and Irregular Steel

Surfaces by Stripe Coating”

3.7.1.3 SFLC Std Spec 6310, page Appendix C-6, add "Hempel Hempadur Multi-Strength GF 35870" with FED-

STD-595 color "Black/Red" under ANTI-ABRASION COATING, ICE BREAKING CAPABLE VESSELS, <235’.

4 (Rev-0)

3.7.1.4 Standard Spec 6310, page Appendix A-7, Under "UNDERWATER (U/W) BODY/BOOT-TOP", Add line

Column 1: Option for U/W Body and Boot-Top, Steel Hulls, <154', in Salt Water. Column 2: Blank. Column 3:

SSPC-SP 10/NACE NO. 2 using grit conforming to MIL-A-22262 / (1.5-3.5) - or - SSPC-SP WJ-2(M)/NACE

WJ-2(M). Columns 4 and 5: Same as "U/W Body and Boot-Top, Aluminum Hull, High Speed (>30 knots)".

3.7.1.5 SFLC Std Spec 6310, page Appendix C-8, Under "Epoxy/Primer/Mid-Coat", add line Column 2:

International Intergard 264. Column 3: Various. Under "Polysiloxane", add line Column 2: International Interfine

979. Column 3: Various.

3.7.2 SFLC Standard Specification 0000 General Requirements.

3.7.2.1 SFLC Std Spec 0000, paragraph 1.3 ‘Acronyms and term definitions’, page 5, “PCL (Paint Containing

Lead)” definition replaced by, “Any paint or coating containing lead in excess of 0.009 percent by weight (1.0 mg/cm2 or 90 ppm). Lead Based Paint (LBP) is an interchangeable term with PCL.”

3.7.2.2 Change Std Spec 0000 paragraph 3.2.4.2.3(QP 1 inspector or tech rep duties) bullet, “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph

3.1.19 of SFLC Std Spec 6310 (Critical drying time requirements)).” to “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph 3.1.17 of SFLC

Std Spec 6310 (Critical drying time requirements)).”

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 mfgr.

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 mfgr.

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)

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 |

7 (Rev-0)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

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:

8 (Rev-0)

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

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)

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)

COATING MFG PRODUCT NAME

BATCH

INDUCTION

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)

10000_AKP_0418_45RBM

WORK ITEM 1: Ultrasonic Testing (UT) (100) Shots, Perform

1. Scope

1.1 Intent. This work item describes the requirements for the Contractor to take 100 UT shots.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph(s):

3.3 Reporting

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures - general. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces in the vicinity of the work area against contamination during the performance of work. Upon

12 (Rev-0) completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std

Spec 0000, paragraph 3.3.5 (Interferences).

3.2 UT measurement. The Contractor shall perform a total of 100 UT measurements in accordance with SFLC Std Spec 0000 and SFLC Std Spec 0740.

3.2.1 Standard measurements. The Contractor shall take 70 standard thickness measurements for the designated locations numbered 1 thru 70 between the boot top and keel, (Refer to Figure 1 and Figure 2).

3.2.1.1 The Contractor shall record each measured metal thickness in the Standard Underwater

(U/W) Body Test Results Report, (Refer to Table 1 and Table 2).

3.2.1.2 The Contractor shall calculate each percent loss.

3.2.1.3 The Contractor shall record each percent loss in the Standard U/W Body Test Results

Report.

3.2.2 Additional measurements. The Contractor shall take 30 additional thickness measurements at locations designated by the Coast Guard inspector and numbered 1A through 30A between the boot top and keel, (Refer to Figure 1 and Figure 2).

3.2.2.1 The Contractor shall record each measured metal thickness in the Additional U/W Body

Test Results Report, (Refer to Table 3).

3.2.2.2 The Contractor shall calculate each percent loss.

3.2.2.3 The Contractor shall record each percent loss in the Additional U/W Body Test Results

Report.

3.2.3 Minimum thickness. The Contractor shall record the minimum thickness found for each designated hull section. (A, B, and C) in the Underwater Hull Body Minimum Thickness Test

Results Report, (Refer to Table 4).

3.3 Reporting. The Contractor shall submit a CIR to include a marked up drawing of Figure 1 and 2 and the completed tables.

4. NOTES

4.1 Coast Guard Personnel. The Coast Guard inspector will witness all readings.

13 (Rev-0)

FIGURE 1. BOTTOM SHELL PLATING EXPANDED

14 (Rev-0)

FIGURE 2. STERN SECTION SHELL PLATING

TABLE 1 - STANDARD U/W BODY TEST RESULTS REPORT

DATE: ____________________________

*CALCULATING PERCENT LOSS = 100- (UT READING / DESIGN THICKNESS X

100)

15 (Rev-0)

TABLE 2 - STANDARD U/W BODY TEST RESULTS REPORT (STERN)

DATE: ____________________________

16 (Rev-0)

*CALCULATING PERCENT LOSS = 100- (UT READING / DESIGN THICKNESS X

100)

LOCATION

AREA

DESIGN

THICKNESS

MINIMUM

ALLOWABLE

THICKNESS

UT

READINGS

*PERCENT

LOSS

STERN SECTION “C”

61 .250 .187

62 .250 .187

63 .250 .187

STERN SECTION “B”

64 .250 .187

65 .250 .187

66 .250 .187

67 .250 .187

STERN SECTION “A”

68 .250 .187

69 .250 .187

70 .250 .187

17 (Rev-0)

TABLE 3 - ADDITIONAL U/W BODY TEST RESULTS REPORT

DATE: ____________________________

*CALCULATING PERCENT LOSS = 100- (UT READING / DESIGN THICKNESS X

100)

LOCATION

AREA

DESIGN

THICKNESS

MINIMUM

ALLOWED

THICKNESS

UT READING *PERCENT LOSS

PORT SIDE AREAS “A, B, C”

1A .250 .187

2A .250 .187

3A .250 .187

4A .250 .187

5A .250 .187

6A .250 .187

7A .250 .187

8A .250 .187

9A .250 .187

10A .250 .187

11A .250 .187

12A .250 .187

STARBOARD SIDE AREAS “A, B, C”

13A .250 .187

14A .250 .187

15A .250 .187

16A .250 .187

17A .250 .187

19A .250 .187

20A .250 .187

21A .250 .187

22A .250 .187

23A .250 .187

24A .250 .187

STERN AREAS “A, B, C”

25A .250 .187

26A .250 .187

27A .250 .187

28A .250 .187

29A .250 .187

30A .250 .187

18 (Rev-0)

TABLE 4 - UNDERWATER HULL BODY MINIMUM THICKNESS TEST RESULTS

REPORT

DATE: ______________________

LOCATIONS MIN. THICKNESS FOUND DESIGN

THICKNESS

MINIMUM

ALLOWED

THICKNESS

AT 25%

LOSS

MINIMUM

ALLOWED

THICKNESS

AT 50%

LOSS

(A) (B) (C)

Port Hull: Boot Top to Keel

.250 .187 .125

STBD Hull: Boot

Top to Keel

Stern Hull: Boot Top to Keel

Comments:

19 (Rev-0)

11000_AKP_0218_45RBM

WORK ITEM 2: Hull Plating (U/W Body), Inspect

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect/survey the vessel’s Under Water (U/W) hull plating, including U/W appendages and coating system.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 45 RB-M 084-002, Rev -, Docking Plan

Coast Guard Drawing 45 RB-M 110-001, Rev -, Hull Structure

Coast Guard Drawing 45 RB-M 631-001, Rev -, Painting Layout

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

OTHER REFERENCES

ASTM International (ASTM) D4138, Rev A, 2007 (R 2017), Standard Practices for

Measurement of Dry Film Thickness of Protective Coating Systems by Destructive, Cross-Sectioning Means

The Society for Protective Coatings (SSPC), 2015 (E 2017), Paint Application

Specification No. 2 (PA-2), Procedure for Determining Conformance to Dry Coating

Thickness Requirements

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

20 (Rev-0)

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std

Spec 0000, paragraph 3.3.5 (Interferences).

3.2 Inspection. The Contractor shall accompany the Underwater Hull Inspection Board

(UWHIB) in the performance of the below inspection tasks, as applicable, using the drawings listed in Section 2 (References) as guidance. The Contractor shall provide the following, to facilitate the UWHIB in assessing the condition of the designated U/W hull components and systems:

A hull repair supervisor and a marker.

Temporary staging and other necessary equipment, as applicable, for ensuring safe access to all areas of the U/W hull.

NOTES

1. The COR will convene the UWHIB as soon as possible after the vessel has been dry-docked and before any work (except U/W hull cleaning/wash down) is performed on the U/W hull and appendages.

2. Some of the components and/or systems addressed in this work item may not be applicable to all vessel classes.

3.2.1 Hull plating.

3.2.1.1 The Contractor shall inspect the condition of the hull plating (including thruster tunnel plating, as applicable), for the presence of marine growth, deformation, and any evidence of major corrosion or electrolytic action.

3.2.1.2 The Contractor shall inspect the hull and keel areas, report on the condition of butt-welded seams, doubler plates, lap seams, and for any signs of damaged plating or unusual waviness in the plating.

3.2.2 Sea chests and all other cooling system intake components. The Contractor shall inspect all sea chests, tunnels, hull openings, and grates for general appearance, loose, damaged, or missing grates, loose or missing fasteners, condition of sea strainers and lockwire on bolts, marine growth on grating slots, and any obstructions in the openings that might prevent proper suction and discharge of water.

3.2.3 Water jet drive. The Contractor shall inspect the water jet drive assembly for signs of corrosion, pitting, erosion, fouling, cracks, dings, and nicks. Inspect all linkages for any missing fasteners, physical damage, pitting, or other conditions effecting usage.

21 (Rev-0)

3.2.4 Transducers. The Contractor shall check general condition of the transducers for cuts, cracks, corrosion, and surface defects around the openings. Check transducer securing nuts for tightness, and inspect cables for chafing and other damage.

3.2.6 Zinc anodes.

3.2.6.1 The Contractor shall remove all marine growth and oxide coating from all hull, rudder, shaft strut, welds, water jet drives, and sea chest anodes, as applicable, using a light-wire brush.

3.1.6.2 The Contractor shall visually inspect all zinc anodes; check the soundness of mounting strap and stud welds, missing fasteners, and percentage of remaining material.

3.2.7 Coating system inspections. The Contractor shall accomplish the below inspections, in conjunction with the underwater hull inspection conducted by the Underwater Hull Inspection

Board (UWHIB). Document the condition found as “Partial - Condition A”, “Partial - Condition

B”, “Partial Condition C”, or “100%”, as applicable (see 4.1 (Definitions)). Submit a CFR.

NOTE

The following inspections are for determining the existing condition of the coating system for the underwater body surfaces, which are deemed “Critical-coated” surfaces; they must be carried out by a

SSPC-QP-1 certified contractor/sub-Contractor or a NACE Inspector

– see SFLC Std Spec 0000, paragraph 3.2.4.2 (In-process QC measures for “critical-coated surfaces”).

3.2.7.1 The Contractor shall perform a visual inspection of the existing U/W body coating system.

3.2.7.2 The Contractor shall take total dry film thickness (DFT) measurements of the U/W body coating system, in accordance with SSPC-PA 2. Ensure that film thickness measurement is taken with a suitable eddy current gauge, for non-ferrous metal substrate.

4. NOTES

4.1 Definitions.

4.1.1 “Partial – Condition A”: The condition that exists where the substrate is exposed in up to

33% of the entire U/W body.

4.1.2 “Partial - Condition B”: The condition that exists where the anticorrosive (AC) undercoating system has incurred damage, but, the u/w body hull substrate is not exposed in any location.

4.1.3 “Partial - Condition C”: The condition that exists where damage is confined to the antifoulant (AF) topcoat; the epoxy undercoating system is not exposed in any location.

4.1.4 “100%”: The condition that exists where more than 33% of the U/W body hull substrate is exposed.

22 (Rev-0)

4.2 UWHIB convention. The COR will convene the UWHIB as soon as possible after the vessel has been dry-docked and before any work (except U/W hull cleaning/wash down) is performed on the U/W hull and appendages.

23 (Rev-0)

24000_AKP_0318_45RBM

WORK ITEM 3: Main Diesel Engine(s) To Auragen Generator(s) And Jet Drive(s), Align

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to align the (Port and/or

Starboard) Main Diesel Engine(s) (MDE) to the Auragen Generator(s) and the MDE(s) to the Jet

Drive(s).

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y * MDE/ TO

GENERATOR

ALIGNMENT TOOL

PN: MMRBM0030 1 ea. 0

Y * MDE/ TO JET DRIVE

ALIGNMENT TOOL

PN: MMRBM0451 1 ea. 0

Y * ENGINE LIFTING BAR PN: MMRBM0956 1 ea. 0

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 45 RBM 201-001, Rev B, Main Engine Arrangement

Coast Guard Drawing 45 RBM 247-002, Rev -, Water Jet Propulsor Arrangement

Coast Guard Drawing 45 RBM 311-004, Rev -, APU Generator Drive System

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

24 (Rev-0)

3.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph(s):

3.2.1 MDE/ Auragen Generator Preliminary Alignment Check

3.2.2 MDE to Jet Drive Preliminary Alignment Check

3.2.3 Engine Mounts

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std

Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the below-listed:

Primary Fuel Filter Assembly

Marine Interface Module

NOTE

Coast Guard personnel will operate all vessel machinery and equipment.

3.1.5 Operational test - initial. Prior to commencement of work, the Contractor shall witness

Coast Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR.

CAUTION

The Coast Guard crew will complete Red Danger Tags IAW

COMDTINST 9077.1 (series) and attach them to the following:

Circuit Breaker CB2, ENGINE PRIMARY, Power Panel 24 VDC

ENGINE BUS 24P2, “OFF”.

Circuit Breaker CB1, ENGINE SECONDARY, Power Panel 24 VDC

VITAL BUS 24P1, “OFF”.

Affected MDE Propulsion Raw Water Suction Valve, Lazarette, “CLOSED”.

Affected MDE Propulsion Raw Water De-Icing Valve, Lazarette, “CLOSED”.

Affected MDE Fuel Shutoff Valve, Engine Room, “CLOSED”.

Affected MDE Secondary Fuel Filter Shutoff Valve, Engine Room, "CLOSED".

25 (Rev-0)

3.2 Preliminary alignment checks. The Contractor shall conduct preliminary alignment checks on the Main Diesel Engine(s) (MDE) to the Auragen Generator(s) and the MDE(s) to Jet Drive(s) in accordance with SFLC Std Spec 0000, Coast Guard Drawings 45 RBM 201-001, 45 RBM 247-

002 and 45 RBM 311-004.

3.2.1 MDE to generator preliminary alignment check. The Contractor shall conduct a preliminary alignment check. Submit A CIR.

3.2.1.1 Remove the generator drive shaft.

3.2.1.2 Remove the three roll pins from the Overhung Load Adapter (OHLA) shaft flange, (Refer to Figure 1).

3.2.1.3 Install the MDE to generator alignment tool, (Refer to Figure 2).

Align the generator alignment tool flange (Item 1) to the OHLA shaft (Item 2) and install.

Slide the alignment sleeve (Item 4) onto the generator alignment pin.

Align the MDE alignment tool flange (Item 5) to the MDE adapter (Item 6).

3.2.1.4 Check the MDE to generator alignment, (Refer to Figure 3).

CAUTION

Do not force the alignment sleeve when checking MDE-to-Generator alignment. Forcing the alignment sleeve will cause the alignment sleeve to bind, damaging the surfaces of the alignment sleeve and the alignment sleeve pins.

Slide the alignment sleeve (Item 1) towards the MDE adapter (Item 2).

Verify the alignment sleeve slides to the MDE alignment pin mark (Item 3) using finger force.

Slide the alignment sleeve towards the OHLA shaft (Item 4).

NOTE

Alignment is satisfactory if the alignment sleeve slides to each alignment pin mark using finger force.

Alignment is unsatisfactory if the alignment sleeve does not slide to each alignment pin mark using finger force.

Verify the alignment sleeve slides to the generator alignment pin mark (Item 5) using finger force.

3.2.1.5 If alignment is unsatisfactory measure the offset distance between the two alignment pins, (Refer to Figure 4).

3.2.2 MDE to jet drive preliminary alignment check. The Contractor shall conduct a preliminary alignment check. Submit A CIR.

3.2.2.1 Remove the cardan shaft.

26 (Rev-0)

3.2.2.2 Install the MDE to jet drive alignment tool, (Refer to Figure 5).

Align the MDE alignment tool flange (Item 1) to the reduction gear output flange

(Item 2) and install.

Slide the alignment sleeve (Item 4) onto the MDE alignment pin (Item 5).

Align the jet drive alignment tool flange (Item 6) to the jet drive input flange (Item

7).

3.2.2.3 Check the MDE to jet drive alignment, (Refer to Figure 6).

CAUTION

Do not force the alignment sleeve when checking MDE–to-Jet drive alignment. Forcing the alignment sleeve will cause the alignment sleeve to bind, damaging the surfaces of the alignment sleeve and the alignment sleeve pins.

Slide the alignment sleeve (Item 1) towards the MDE adapter (Item 2).

Verify the alignment sleeve slides to the MDE alignment pin mark (Item 3) using finger force.

Slide the alignment sleeve towards the jet drive shaft (Item 4).

NOTE

Alignment is satisfactory if the alignment sleeve slides to each alignment pin mark using finger force.

Alignment is unsatisfactory if the alignment sleeve does not slide to each alignment pin mark using finger force.

Verify the alignment sleeve slides to the jet drive alignment pin mark (Item 5) using finger force.

3.2.2.4 If alignment is unsatisfactory measure the offset distance between the two alignment pins, (Refer to Figure 4).

3.2.2.5 Measure the distance between the reduction gear output flange (Item 1) and the jet drive input flange (Item 2), (Refer to Figure 7). Distance is satisfactory if it is 16 inches +/- 3/32 inch.

3.2.3 Engine mounts inspect. The Contractor shall inspect the MDE(s) mounts. Submit A CIR.

3.3 Alignment. The Contractor shall align the MDE, (Refer to Figure 8).

Use the offset measured from the MDE-Generator alignment check to determine direction of adjustment.

Remove the nuts (Item 1) that secure the MDE (Item 2) to the aft MDE mounts (Item

3).

Loosen the lower jam nut (Item 4) on the MDE mounts.

Clean the threads of the nuts and the MDE mount using alcohol to remove any residual sealant or anti-seize.

Lever the MDE in the direction needed to correct misalignment, ensuring to prevent damaging any hoses or accessories.

27 (Rev-0)

It may be necessary to install the Engine Lift Tool, P/N: MMRBM0956, to adjust the

MDE alignment.

Measure distance between reduction gear output flange and jet-drive input flange.

Distance is satisfactory if it is 16 inches +/- 3/32 inch.

Check MDE-Generator Alignment.

If satisfactory, apply anti-seize compound, to the threads (Item 5) of the MDE

Mounts.

Install and tighten two forward mount top lock nuts without applying torque specification to secure position.

3.3.2 The Contractor shall recheck MDE-Jet Drive Alignment.

3.3.3 The Contractor shall if satisfactory, apply anti-seize compound, P/N: 37230, to the threads

(Item 5) of the MDE Mounts. (Item 2)

Install and tighten two aft mount top lock nuts without applying torque specification to secure position.

Repeat steps for MDE/Jet Drive Alignment until correct alignment is obtained.

Tighten the nuts to 430 ft-lbs to secure the MDE to the MDE Mount using a torque wrench, P/N: A-A-2411, Torque Multiplier, P/N: J6202A, and Socket, 1-7/16" Deep, 3/4" drive, P/N: 07523L, while holding the upper jam nut (Item 6) stationary with a

Wrench, Check Nut, 38mm, P/N: JKEM38.

Set the torque wrench to 131 ft-lbs to yield a torque multiplier output of 430 ft-lbs.

Apply sealing compound, P/N: 242, to the threads (7) of the MDE Mount.

Tighten the lower jam nut against the upper jam nut using Wrench, Check Nut, 38mm, P/N: JKEM38, while holding the upper jam nut stationary with a second

Wrench, Check Nut, 38mm, P/N: JKEM38.

Tap bottom wrench once firmly with hammer in the tightening direction to ensure secure fit.

3.3.4 The Contractor shall confirm the MDE to Jet Drive alignment is satisfactory and that the

MDE to Generator alignment is satisfactory. Submit a CFR.

3.4 Remove the MDE-Jet Drive alignment tool. The Contractor shall remove the alignment tool as follows:

Remove the four bolts (Item 8) that secure the jet-drive alignment tool flange (Item

6) to the jet-drive input flange (Item 7), (Refer to Figure 1).

Remove the jet-drive alignment tool flange from the jet-drive input flange.

Remove the alignment sleeve (Item 4) from the MDE alignment pin (Item 5).

Remove the four bolts (Item 3) that secure the MDE alignment tool flange (Item 1) to the reduction gear output flange (Item 2).

Remove the MDE alignment tool flange from the reduction gear output flange.

3.4.1 Install the cardan shaft.

28 (Rev-0)

3.4.1.1 Renew. The Contractor shall renew port and starboard cardan shaft lock washers forward and aft sides each, 22mm (12 total) and 16mm (16 total) Grade 8 hardened lock washers.

3.5 Remove the MDE-Generator alignment tool. The Contractor shall remove the alignment tool as follows:

Remove the three shoulder bolts (Item 7) that secure the MDE alignment tool flange

(Item 5) to the MDE adapter (Item 6).

Remove the MDE alignment tool flange from the MDE adapter.

Remove the alignment sleeve (Item 4) from the generator alignment tool (Item 1).

Remove the three bolts (Item 3) that secure the generator alignment tool flange to the

OHLA shaft (Item 2).

Remove the generator alignment tool flange from the OHLA shaft.

Renew all three roll pins (Item 1) to the OHLA shaft flange (Item 2), (Refer to Figure

1).

3.5.1 Install the generator drive…