BISCAYNE_BAY_(WTGB_140)_UPDS_FQ2_MWC_18R0_(3-19-18).doc

USCGC BISCAYNE BAY (WTGB 104)

SPECIFICATION FOR UNPLANNED DOCKSIDE REPAIRS

FY2018

Developed By: Michael W Check (Rev-0, 19 March 2018)

TABLE OF CONTENTS

iiiRevisions Record ivConsolidated List of References vConsolidated List of Government-furnished Property viConsolidated List of Critical Inspection Items viiPrincipal Characteristics - Tug, IceBreaking

1General Requirements

11WORK ITEM 1: #2 Main Diesel Engine Block and Components, Lifting Support

16WORK ITEM 2: #1 Main Diesel Engine Upper Crankline and #2 Main Diesel Engine Lower Crankline, Inspect and Machine (In-Place)

20WORK ITEM 3: #1 Main Diesel Engine (MDE) Hot Lube Oil Flush; Perform

28WORK ITEM 4: #2 Main Diesel Engine (MDE) Hot Lube Oil Flush; Perform

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.

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.

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 101-WTGB 101-001, Rev G, Booklet of General Notes

Coast Guard Drawing 101-WTGB 201-001, Rev H, Machinery Arrangement

Coast Guard Drawing 101-WTGB 262-001, Rev L, Lube Oil System Diagram

Coast Guard Drawing 101-WTGB 262-003, Rev B, Lube Oil System Mods Incidental to Spinner II Installation

COAST GUARD PUBLICATIONS

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

Coast Guard Technical Publication (TP) 3473, SWBS 233, Mar 2001, Main Diesel Engine – Model 38D8-1/8

Coast Guard Technical Publication (TP) 3989, SWBS 233, Mar 2006, Emissions Reduction Upgrade Kit – Service & Parts Manual (Model 38D8-1/8)

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

Fairbanks Morse Engine Condition Found Report No. 1 (CFR #001) “USCGC BISCAYNE BAY – Upper Crankline – Upper Crankline Dimension Discrepancy (#1 MDE)”, dated 3/8/18

Fairbanks Morse Engine Condition Found Report No. 2 (CFR #002) “USCGC BISCAYNE BAY – #2 MPDE #9 Lower Thrust Bearing”, dated 3/8/18

Fairbanks Morse Engine Condition Found Report No. 2 (CFR #002A) “USCGC BISCAYNE BAY – Lower Thrust Saddle Discrepancy (#2 MDE)”, dated 3/13/18

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.

This section is not applicable to this package.

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)):

This section is not applicable to this package.

Principal Characteristics - Tug, IceBreaking 140’ WTGB (TUG, Icebreaking)

Physical

Full load (winter) center of gravity

Min. operating condition center of gravity

Min. operating condition trimming moment

Machinery

Main Propulsion

Propeller

NOTE

Stability values above are for representative tug. Draft and longitudinal lever values provided above are for tugs in fresh water. Longitudinal lever values are provided to adjust tug's design drag of 1.0 feet by the stern.

00000_0917_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), 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.

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

3.2.1 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

· Provide fire watch personnel and fire extinguishers for the duration of the availability period, during and beyond noted Coast Guard fire watch support.

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 USCG facilities. The Contractor shall 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 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.

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

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 a 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 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, 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 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 shall be aware of the following:

3.5.6.1 No Contractor or Subcontractor shall 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 shall 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 shall 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 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’.

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.

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

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.

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.

| DP - Surface |

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

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

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

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:

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

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).

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY Measurements IAW SSPC-GUIDE 15.

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

Dry Film Thickness (DFT) Measurements IAW SSPC-PA 2.

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

Location (Frame Reference):

Avg.

Location (Frame Reference):

Avg.

Location (Frame Reference):

Avg.

23310_MWC_0318_104

WORK ITEM 1: #2 Main Diesel Engine Block and Components, Lifting Support

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to lift the #2 MDE block in support of lower crankline inspections, providing all labor and equipment to accomplish the following:

· Removal / reinstallation of the upper crankshaft.

· Removal / reinstallation of the blower.

· Removal / reinstallation of the vertical drive assembly.

· Lifting and supporting of the engine block.

· Removal / reinstallation of the lower crankshaft.

· Alignment of the engine to generator.

1.1.1 Fairbanks Morse Opposed Piston (OP) Engine – 38D878009DSM8 (#2 MDE)

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing 101-WTGB 101-001, Rev G, Booklet of General Notes

Coast Guard Drawing 101-WTGB 101-001, Rev G, Booklet of General Notes

Coast Guard Drawing 101-WTGB 201-001, Rev H, Machinery Arrangement

Coast Guard Publications

Coast Guard Technical Publication (TP) 3473, SWBS 233, Mar 2001, Main Diesel Engine – Model 38D8-1/8

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.

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

None.

3.1.2 Tech Rep (Engine). The Contractor shall provide the services of an Original Equipment Manufacturer (OEM) authorized/licensed Tech Rep for the Fairbanks Morse Engine (FME) Model 38D8-1/8 diesel engine to accomplish the following on site:

· Provide manufacturer's proprietary system/ equipment information, software, and tools.

· Assist with and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

· Provide pertinent technical information (e.g. component weights, engine lifting attachments, etc) in support of rigging operations.

· Provide engine-specific lifting tooling.

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above.

3.1.2.2 The Tech Rep shall be on-site for the duration of the work accomplished in this work item.

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. Additionally, furnish and install all special protective measures required (tarping, masking, plugging, etc) to ensure the internal engine surfaces are protected from debris during the rigging evolutions. Upon completion of work, remove all installed protective measures, inspect for the presence of contamination in the presence of the CG Inspector, 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.

NOTE

There exists approximately 36” of clearance between the top of the engine and the Engine Room overhead structure.

3.1.5 Rigging and crane support. The Contractor shall provide all labor and equipment in support of transporting and rigging engine components without causing any damage to equipment or ship structure. This shall also include all equipment required (i.e. pier-side crane) in support.

3.1.6 Additional / background information. Damage has been discovered on the lower crankline saddle of the #2 MDE. In order to inspect the lower crankline (a separate work item within this specification), the engine must be separated from the sub-base and generator, and lifted to allow removal of the lower crankshaft. The Coast Guard will be responsible for draining fluids from the MDE and removing parts as necessary except those noted in this work item. The Contractor shall be responsible for lifting and supporting the engine to allow crankline inspections and machining to be accomplished. The Contractor shall expect a break in his work to allow for repairs on the engine block and to allow the Coast Guard to reassemble the engine prior to final realignment.

3.2 Lifting points. Lifting points and padeyes will be needed to lift the engine components and to suspend the engine block and lower crankshaft while removing the vertical drive gear assembly. The Contractor shall accomplish the following in support:

3.2.1 Furnish, install, and test new lifting points and padeyes prior to lifting the engine components. All welding shall be in accordance with SFLC Std Spec 0740. Lifting points and padeyes shall only be installed after CG Inspector approval.

NOTE

All welding services in support of padeye installation shall be provided by the Contractor. The Contractor shall ensure all areas are certified “safe for hot work” in accordance with SFLC Std Spec 0000, Paragraph 3.3.1.2 (i.e. “Marine Chemist” and “Competent Person” support).

3.2.2 Prior to installation, the Contractor shall consult with the Tech Rep to ensure the padeyes are properly sized to support the weight of the component(s) to be lifted and supported.

3.2.3 Padeyes shall be sized in accordance with the diameter of the stock directly above the hole or eye of the padeye.

3.2.4 Inspection and test particulars. Accomplish the following inspections for all lifting points to be used (new and existing) and submit a CFR.

3.2.4.1 Visual. Perform a visual inspection of existing fitting structures and associated foundations for evidence of fractures, excessive wear, deformation, and corrosion.

3.2.4.2 NDE. Peform NDE of all fittings and welds in accordance with SFLC Std Spec 0740, Appendix C.

3.2.4.3 Pull-testing. Accomplish a pull test in accordance with SFLC Std Spec 5000, paragraph 3.2.7 (Pull-Test) to 150% of the rated working load.

NOTE

A dynamometer shall be installed in the test lead immediately adjacent to the padeye to record the actual test load being applied. Submit a copy of the dynamometer calibration certificate to the Coast Guard Inspector.

3.2.5 After inspection and testing, prime and paint all new padeyes with one coat of epoxy paint to match adjacent surroundings in accordance with SFLC Std Spec 6310. Affix a label plate, inscribed with the test load and date tested adjacent to each padeye.

3.2.6 All padeyes installed by the Contractor shall remain in place at the end of the contract unless removal is required to facilitate reinstallation of equipment.

3.3 Work to be accomplished. The Contractor shall accomplish the following, under the guidance of Tech Rep to accomplish the following.

NOTES

1. The Coast Guard will provide tools and labor in support of disassembling the #2 MDE to the “bare block” in support of lifting. The Contractor shall expect work stoppages throughout the rigging operations in support of engine disassembly and reassembly by the Tech Rep and/or Coast Guard personnel.

2. The Contractor shall ensure all components removed by the Contractor are adequately protected and placed in a position as to not interfere with inspection and machining of #2 MDE.

3.3.1 Disconnect all lube oil, seawater, and air piping from the diesel engine.

3.3.2 Remove the blower.

3.3.3 Remove the upper crankshaft.

3.3.4 Install the engine block lifting tools (furnished by the Tech Rep).

3.3.5 Disconnect the engine from the generator and the sub-base. Rig the engine and lift the engine as required to remove the lower crankshaft and vertical drive gear.

3.3.6 Rig and support the lower crankshaft.

3.3.7 Support the lower crankcase compartment to provide controlled lowering. Disconnect the lower crankcase compartment and lower the lower crankcase compartment as required to remove the flywheel and lower crankshaft.

3.3.8 Remove the lower crankshaft and vertical drive gear.

3.3.9 Position the lower crankshaft in an out of the way area of the Engine Room while optical measurements of the lower crankline are being conducted. Cover the crankshaft to prevent damage or contamination while measurements and engine repairs are being conducted.

3.3.10 Rig the vertical drive assembly from the ship. The vertical drive assembly will be sent out by the Coast Guard to Fairbanks Morse for inspection and recertification.

3.3.11 Support the engine block on Contractor-furnished stands to allow the Tech Reps and Coast Guard to inspect the lower crank line.

NOTE

Inspection of the lower crankline will be accomplished via a separate work item within this specification.

3.3.12 Upon completion of all lower crankline work, wipe out the lower crankcase compartment. Inspect the compartment with the Fairbanks-Morse Technical Representative and verify that all dirt and contaminants have been removed.

3.3.13 Reinstall the lower crankshaft.

3.3.14 Lower the engine to its original location.

3.3.15 Reinstall the vertical drive assembly.

3.3.16 Reinstall the upper crankshaft.

3.3.17 Reinstall the blower.

NOTE

Final reassembly of the MDE will be conducted by Tech Rep and/or Coast Guard personnel. No additional contractor services are required for engine reassembly.

4. NOTES

This section is not applicable to this work item.

23310_MWC_0318_104

WORK ITEM 2: #1 Main Diesel Engine Upper Crankline and #2 Main Diesel Engine Lower Crankline, Inspect and Machine (In-Place)

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to accomplish optical / laser-sight inspections and in-place machining of the following:

· #1 MDE upper crankline.

· #2 MDE lower crankline.

1.1.1 Fairbanks Morse Opposed Piston (OP) Engine – Model 38D8-1/8, S/N: 38D878012DSM8 (#1 MDE) and 38D878009DSM8 (#2 MDE)

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing 101-WTGB 101-001, Rev G, Booklet of General Notes

Coast Guard Drawing 101-WTGB 201-001, Rev H, Machinery Arrangement

Coast Guard Publications

Coast Guard Technical Publication (TP) 3473, SWBS 233, Mar 2001, Main Diesel Engine – Model 38D8-1/8

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

Other References

Fairbanks Morse Engine Condition Found Report No. 1 (CFR #001) “USCGC BISCAYNE BAY – Upper Crankline – Upper Crankline Dimension Discrepancy (#1 MDE)”, dated 3/8/18

Fairbanks Morse Engine Condition Found Report No. 2 (CFR #002) “USCGC BISCAYNE BAY – #2 MPDE #9 Lower Thrust Bearing”, dated 3/8/18

Fairbanks Morse Engine Condition Found Report No. 2 (CFR #002A) “USCGC BISCAYNE BAY – Lower Thrust Saddle Discrepancy (#2 MDE)”, dated 3/13/18

3. REQUIREMENTS

3.1 General.

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

· Paragraph 3.2.1.

3.1.2 Tech Reps.

3.1.2.1 Tech Rep (Engine). The Contractor shall provide the services of an Original Equipment Manufacturer (OEM) authorized/licensed Tech Rep for the Fairbanks Morse Engine (FME) Model 38D8-1/8 diesel engine to accomplish the following on site:

· Provide manufacturer's proprietary system/ equipment information, software, and tools.

· Assist with and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

· Provide welding services and/or guidance in support of all block weld repairs.

3.1.2.1.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above.

3.1.2.1.2 The Tech Rep shall be on-site for the duration of the work accomplished in this work item.

3.1.2.2 Tech Rep (Inspections and in-place machining). The Contractor shall provide the services of a qualified Tech Rep, who is familiar with optical/laser-sight inspections and in-place machining of marine engine cranklines, to do the following, on site:

· Conduct inspections of the #1 MDE (upper) and #2 MDE (lower) cranklines.

· Provide report detailing measurements and recommendations to return to OEM specifications.

· Conduct machining (in-place) to return to OEM specifications.

· Provide welding services and/or guidance in support of all block weld repairs.

3.1.2.2.1 Ensure the company has experience with crankline inspections and in-place machining on the Fairbanks Morse Engine (FME) Model 38D8-1/8 or similarly sized engines. The Contractor shall confirm with the FME Tech Rep that the in-place machining company is authorized by FME to perform inspections and machining of the FME 38D8-1/8 engine block.

3.1.2.2.2 Submit the name of the company to the Contracting Officer with proposal / bid.

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. Additionally, furnish and install all special protective measures required (tarping, masking, plugging, etc) to ensure the internal engine surfaces are protected from debris during the inspection and machining process.

3.1.3.1 Upon completion of work and prior to engine reassembly, remove all installed protective measures, inspect for the presence of contamination in the presence of the CG Inspector, 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.

3.2 Inspection. The Contractor shall assist the in-place machining Tech Rep to conduct an optical/laser-sight inspection of the following:

· #1 MDE upper crankline.

· #2 MDE lower crankline.

NOTES

1. For purposes of bidding, the Contractor shall provide the services of two (2) riggers and one (1) inside machinist in support of equipment set-up and additional services as required by the Tech Reps.

2. To ensure optimal use of Tech Rep support, the Contractor shall ensure in-place inspections and machining are properly coordinated with the engine component and block lifting accomplished via a separate work item in this specification.

3.2.1 Upon completion of all inspections, submit a report (CIR) to document the following:

· Existing line bore condition and measurements.

· Comparison of “as-found” condition with OEM specifications.

· Recommendations for in-place machining to return to OEM specifications.

3.3 Machining (in-place). If a Change Request has been authorized and released, the Contractor shall accomplish in-place machining of the cranklines to return to OEM specifications. Upon completion of all work, the Contractor shall conduct final optical/laser-sight inspections to confirm alignment. Submit a CFR, including a copy of all final crankline readings.

NOTE

It is anticipated that welding on the engine block will be required in support of returning the crankline to acceptable OEM specifications. Welding services shall be provided by the FME Tech Rep; however, the Contractor shall ensure all areas are certified “safe for hot work” in accordance with SFLC Std Spec 0000, Paragraph 3.3.1.2 (i.e. “Marine Chemist” and “Competent Person” support).

4. NOTES

4.1 Sources for optical/laser-sight inspections and in-place machining support. Although there may be several available sources from which the Contractor may procure support, the below listed are possible sources known to the Coast Guard with experience with the FME Model 38D8-1/8:

· In-Place Machining Company www.inplace.com

(414) 562-2000

· Team Industrial Services www.teamindustrialservices.com

(800) 662-8326

23300_MWC_0218_104

WORK ITEM 3: #1 Main Diesel Engine (MDE) Hot Lube Oil Flush; Perform

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to accomplish a staged hot flush of the #1 Main Diesel Engine (MDE) lube oil system.

1.1.1 Engine model. Fairbanks Morse Opposed Piston (OP) Engine – Model 38D8-1/8, S/N: 38D878012DSM8

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing 101-WTGB 101-001, Rev G, Booklet of General Notes

Coast Guard Drawing 101-WTGB 201-001, Rev H, Machinery Arrangement

Coast Guard Drawing 101-WTGB 262-001, Rev L, Lube Oil System Diagram

Coast Guard Drawing 101-WTGB 262-003, Rev B, Lube Oil System Mods Incidental to Spinner II Installation

Coast Guard Publications

Coast Guard Technical Publication (TP) 3473, SWBS 233, Mar 2001, Main Diesel Engine – Model 38D8-1/8

Coast Guard Technical Publication (TP) 3989, SWBS 233, Mar 2006, Emissions Reduction Upgrade Kit – Service & Parts Manual (Model 38D8-1/8) Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Other References

None

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

3.1.2.1 The Contractor shall provide the services of a qualified mechanic, who is familiar with lube oil hot flushing of the Fairbanks Morse Engine (FME) Model 38D8-1/8 diesel engine and related equipment (lube oil coolers, strainers, etc), to do the following, on site:

· Advise on manufacturer's proprietary information pertinent to the system.

· Assist with proper methods of connection(s) and lube oil system bypass methods required for proper diesel engine hot flush procedure in accordance with this specification.

3.1.2.2 Ensure the mechanic has a résumé of demonstrated experience with the system/equipment stated above.

3.1.2.3 Submit a copy of the mechanic’s résumé and a list of references (or the name of the company if sub-contracted) to the Contracting Officer with proposal / bid.

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 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:

· Deckplates.

· Piping.

· Hand Rails.

· Electrical wiring and cables/cableways.

· Miscellaneous machinery.

3.1.5 Flushing waste disposal. The Contractor shall dispose of all fluids, materials and other waste resulting from the hot flush in accordance with all applicable Federal, state and local regulations.

3.1.6 Additional / background information. The Contractor shall expect a break in his work to allow the Coast Guard to reassemble (overhaul) the engine prior to flushing. Additionally, the Contractor shall be aware of a possible break in work prior to the engine being available for engine run-in of Paragraph 3.6.

3.2 Work plan. The Contractor shall provide a work plan to the Contracting Officer (KO), at the time of solicitation submission, which lists all procedures, plans, and equipment the Contractor will utilize in support of flushing requirements. At a minimum, the plan shall include the following:

· Qualifications of Project Manager / Lead Mechanic overseeing flushing operations.

· List of all equipment used in support of flushing operations, including models and ratings.

· List of safety equipment, devices, and procedures.

· Quality assurance controls, including sample checklists, logs, checkpoints, etc.

· Step-by-step flushing procedure, including system diagrams and valve lineups.

· System restoration procedure.

3.3 Flushing requirements.

3.3.1 Flushing equipment. The Contractor shall provide all equipment required to support flushing operations, including (but not limited to), the following:

NOTE

The Contractor should be aware that neither the cutter, nor the cutter support base, is capable of providing the 440 VAC power necessary to operate any flushing support systems and that the Contractor must provide a suitable 450 VAC power source.

3.3.1.1 Flushing pump. A positive displacement pump capable of providing 260 GPM flow rate at 120 psig.

3.3.1.2 Flow meter. A flow meter capable of measuring flow of flushing fluid.

3.3.1.3 Portable Particle Counter. A particle counter capable of continuously measuring fluid contamination with output in NAS code.

3.3.1.4 Filtration system. A bag and cartridge filtration system that allows for continuous operation, rated at the flow rate of the pump (or greater), that is capable of supporting the following:

· “In-flush” bag change-outs.

· 25-micron commercial polyester, full-flow filter bags.

· 3-micron cartridge filters.

· Magnetic filters.

3.3.1.6 Heating system. A heating system capable of accurately maintaining flushing fluid at 160-190 oF.

3.3.1.7 Oil spill containment. A pier-side oil spill containment system with sufficient capacity to contain all components associated with the filtration, heating, and flushing pump systems.

3.3.1.8 Temporary valves, spools, blanks, and jumper lines. All valves, spools, blanks, flanges, and jumper lines required in support of flushing operations.

3.3.2 Filter bags. The Contractor shall accomplish the following for the flushing media filters/filtration system:

3.3.2.1 Filter the flushing fluid using commercial polyester full flow filter bags (sized to suit strainer basket) rated at 25 microns particle retention rating.

3.3.2.2 Renew filter bags as necessary during flushing operations to maintain a differential pressure increase of no more than 5 psig over the differential pressure of a clean filter bag.

3.3.3 Flushing media. The Contractor shall use commercial grade (non-synthetic) SAE 10W High Detergent oil, with an API rating of SC or better, in support of flushing operations.

NOTE

Upon completion of lube oil flushing loop, the flushing oil may be returned to clean containers and can be used for the next hot lube oil flush provided cleanliness of lube oil can be maintained.

3.3.4 Component removal/reinstallation tracking. The Contractor shall ensure that all components removed from the engine/lube oil system are match-marked and tracked via a recorded log to ensure proper reinstallation. Submit a CFR as follows:

· Beginning of each flushing stage to document equipment/components removed.

· Completion of each flushing stage to document equipment/components reinstalled.

3.3.5 COR notification. The Contractor shall notify the COR at least 24 hours prior to beginning each flushing operation.

3.3.6 Inspector witnessing and approval. The Contractor shall ensure that the Coast Guard Inspector is present during all flushing oil sampling and inspection. The Contractor’s final sampling and inspection shall be approved in writing by the COR and Coast Guard Inspector.

3.3.7 Pre-flush cleanliness verification. Prior to starting flushing, the Contractor shall perform the following:

3.3.7.1 Remove and dispose of engine filters.

3.3.7.2 Drain and clean engine sump, screens, filter housing(s), and strainer housing(s).

3.3.7.3 Remove and clean oil strainers.

3.3.7.4 Wipe clean and oil-wet engine interior surfaces and components (e.g., crankcase, crankshaft, connecting rods, bearing caps, gears, etc.) to prevent “flash rusting”.

3.3.8 Post-flush report requirements. After each flushing stage, the Contractor shall submit a detailed report to the COR within 24 hours, to include the following at a minimum:

· Method used to obtain the particulate contamination reading.

· Method used to determine particle size.

· Final contamination level readings.

· List of all particles collected and description (size, nature, etc)

3.4 Flushing procedure. Using the Coast Guard Drawings and Technical Publications listed in Section 2 “References” as guidance, the Contractor shall conduct a staged flush of the MDE lube oil system as follows:

3.4.1 Flushing sequence.

3.4.1.1 Conduct the MDE hot lube oil flush in the following sequence:

· External

· Internal

· Combined external and internal

3.4.1.2 The following flushes / cleanings may be accomplished in any sequence (prior to, concurrent, or after) the flushing of Para 3.4.1.1, but prior to system restoration:

· Outflushes of disconnected instrumentation, drain, and vent lines.

· Cleaning of all “jumpered” components (system pumps, filters, and associated “dead” legs)

· Lube oil cooler.

3.4.2 Pre-flushing preparations. The Contractor shall perform the following prior to commencing the applicable flushing stage procedure:

· Blank off bearing oil feed lines.

· Disconnect & blank the pre-lube oil and main oil pumps, installing jumper lines to by-pass.

· Disconnect the lube oil cooler and install jumper line with valve to by-pass the cooler.

· Disconnect main bearing jumper lines and end plugs on main internal lube oil header; hand clean accessible ports and plug.

· Disconnect all lube oil supply lines to internal components including cam bearing, gear train, governor, and cylinders, as applicable.

3.4.3 Flushing acceptance criteria. The Contractor shall flush each loop until the following cleanliness criteria is maintained for a 2-hour period.

3.4.3.1 Differential…