Attachment_1_-_BERTHOLF_DS_MPDE_FQ4_FY19_Rev-2.pdf

USCGC BERTHOLF (WMSL 750)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2019

Developed By: Jason P Stonehouse

(Rev-2, 11 July 2019)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property .................................................................................. v Consolidated List of Critical Inspection Items ............................................................................................. vi Principal Characteristics ............................................................................................................................. vii General Requirements WORK ITEM 1: Main Propulsion Diesel Engine, Diesel Engine Inspection, Perform WORK ITEM 2: Main Propulsion Diesel Engine (No.2), 16,000 Hour Maintenance WORK ITEM 3: Cofferdam, Install

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

7/10/2019 1 2 Updated Table 1, Removed vibration damper inspection

7/10/2019 1 2 Added, 3.2.2 The Contractor shall provide new engine oil.

7/10/2019 1 2 Added, 3.2.3 The Contractor shall provide Oil waste removal services as required.

7/11/2019 2 2 Updated Table 1, Added Renew Conrod Bearings (W1083)

7/11/2019 2 2

Updated GFP Table to include Conrod Bearings

NIIN: 123587417

7/11/2019 2 2 Updated Table 1, Added Remove clean and descale

Low/High Pressure Coolers (Air/Water Side)

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 750-WMS-100-001, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750-WMSL-101-030, Rev C, Shell Expansion Scantlings (AS3101017)

Coast Guard Drawing 750-WMSL-100-031, Rev E, Unit 2300 Structure - Inner Bottom - FR 52 to FR 64

(ASC100230)

Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

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

Coast Guard Technical Publication (TP) 7025A, 30-OCT-17, Main Diesel Engine - Fluids and Lubricants

Specifications (A001061/37E)

Coast Guard Technical Publication (TP) 7026, 31-MAY-07, Main Diesel Engine - Repair Tools

Coast Guard Technical Publication (TP) 7027, 31-MAY-07, Main Diesel Engine - Operating Instructions

Coast Guard Technical Publication (TP) 7028, 31-MAY-07, Main Diesel Engine - Maintenance Manual

Coast Guard Technical Publication (TP) 7031, 09-MAY-18, Main Diesel Engine - Parts Catalog

(M034562/01DE)

Coast Guard Technical Publication 7024A, 27-NOV-18, Main Diesel Engine - Removal Spaces and

Weights (M061891/21E)

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

Code of Federal Regulations (CFR) Title 29, Part 1915, Subpart E, Sep 2015, Scaffolds, Ladders and

Other Working Surfaces

MTU Maintenance Schedule M050711/06E.

MTU Technical Documentation S000082/00E (MTU Tech Doc S000082/00E), 2011, Functional

Descriptions, Operating Instructions, and Instructions for General Overhaul

The Society for Protective Coatings (SSPC) Paint Application Specification No. 1 (SSPC-PA Guide 1), 2004, Shop, Field, and Maintenance Painting of Steel

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)

1 N Parts Kit, Diesel

Engine

2815-01-628-0945

584-DEI-KIT

1 ea. $3,068.69

2 Y Injector Replacement

Kit

584-INJ-RPL-KIT

NSN: 015911763

20 ea. $5,000.00

2 N Cylinder Liner Kit 584-CYL-LNR-KIT

NSN: 016192672

20 ea. $5,000.00

2 N Cylinder Head

Replacement Kit

584-CYL-HD-RPLM

NSN: 016192838

20 ea. $15,000.00

2 Y Fuel Injection Pump

Kit

584-FL-INJ-PMP-KIT

NSN: 016192228

20 ea. $3,000.00

2 Y HP Turbocharger

Replacement Kit

584-HPTURBO-RPLM

NSN: 016200381

5 ea. $10,000.00

2 Y LP Turbocharger

Replacement Kit

584-LPTURBO-RPLM

NSN: 016194969

5 ea. $10,000.00

2 Y Jacket water pump LS

Replacement Kit

584-JWPMPLS-RPLM

NSN: 016263405

1 ea. $4,000.00

2 Y Jacket water pump RS

Replacement Kit

584-JWPMPRS-RPLM

NSN: 016192545

1 ea. $4,000.00

2 Y Sea water pump

Replacement Kit

584-SWPMP-RPLM

NSN: 016192264

1 ea. $8,000.00

2 Y Conrod Bearing NIIN: 123587417 20 ea. $941.03 *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

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 Main Propulsion Diesel Engine, Diesel Engine Inspection, Perform

2 Main Propulsion Diesel Engine (No.2), 16,000 Hour Maintenance

PRINCIPAL CHARACTERISTICS

418' WMSL

PHYSICAL

Length overall 418' 0"

Length between perpendiculars 390' 0"

Maximum beam 54' 0"

Beam @ 01 level 47' 9-1/8"

Depth (01 level @ side to baseline) 39' 2-3/4"

01 deck camber foredeck 1/4" in 1'-0"

Minimum berth depth 20' 0"

Height of highest projection Approximately 119'

Draft, design 14.40'

Design displacement 3925 long tons

MACHINERY

Two diesel engines MTU 20V, 20-cylinder 9,730 SHP each

One gas turbine General Electric LM2500; 29,500 SHP

Type of propulsion CODAG

Electrical system 24 Volt DC

Two controllable pitch propellers Rolls-Royce 5 blade, 14' 0" diameter; 229 RPM max

Two reduction gears RENK

One cross connect gear RENK

HULL

Hull material 5086 Aluminum

HSLA-80 Steel

ABS EH 36 Steel

ABS AH 36

Frame spacing

FWD of FR 9 2' 3"

FR 9 to FR 10 6' 9"

FR 10 to FR 98 4' 1"

FR 98 to FR 99 3'-8"

ELECTRICAL

Power Three 1360 kW, 450 V, 60 Hz, 3 Phase, 1800 RPM Caterpillar 3512B diesel engines with Baylor ship service generators

Shore tie cable Seven MIL-C-24368/2 (NATO) shore power receptacles, 400 A each

TANK CAPACITIES

Diesel oil 220,359 gal

Fresh water 12,454 gal

JP-5 Fuel 35,182 gal

00000_0618_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.

3.3 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 NDE 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 7690390037.

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 Change to 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.”

3.7.1.1 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)).”

3.7.2 Change to Std Spec 5000, paragraph D2.2.1.1 bullet, "For running rigging, furnish class 6x37, uncoated, independent wire rope core (IWRC), right regular lay (RRL) wire rope or Dyform-18, rotation resistant wire rope," to "For running rigging, furnish class 6x36, uncoated, independent wire rope core (IWRC), right regular lay

(RRL) wire rope or Dyform-18, rotation resistant wire rope."

3.7.2.1 Change to Std Spec 5000, page D-2, Table D-1 title from "DYFORM-18, 6X19 AND 6X37 IWRC RRL," to " DYFORM-18, 6X19 AND 6X36 IWRC RRL"

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)

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

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

VESSEL NAME HULL #

WORK

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.

SURFAC

E

AMBIEN

T

ΔT

| DP -

SURFACE |

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

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL # WORK

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area)

Brush-blasting (non-metallic substrate)

ABRASIVE MANUFACTURER: ABRASIVE SIEVE SIZE:

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

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

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

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

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

Place Surface Profile

Replica Tape Here

Place Surface Profile

Replica Tape Here

Place Surface Profile

Replica Tape Here

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

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

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

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

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

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

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

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

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

TIME

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL # WORK

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).

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

VESSEL NAME HULL # WORK

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15.

DATE TEST LOCATIONS CONDUCTIVITY (MICROSIEMENS/CM)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

VESSEL NAME HULL #

WORK

COATING MFG PRODUCT NAME

BATC

H #

INDUCTI

ON TIME

COATING SYSTEM

SEQUENCE

(PRIMER/TOUCHUP/3RD

COAT, ETC.)

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

SPOT 1 2 3 4 5

AVERAGE

VALUE

*BASE METAL READING

(BMR) Required, If Magnetic

Pull-Off (Type I/Banana) Gauge

Is Used.

LOCATION (FRAME REFERENCE):

SPOT 1 2 3 4 5 OVERALL AVG. DFT ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE

ADJUSTMENTS

AFTER ADJUSTMENTS

AVG.

1 AVG. BMR DEVIATION

3 BEFORE

ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE

ADJUSTMENTS

APPLICATION METHOD (AIRLESS,

CONVENTIONAL SPRAY, ROLLED)

AVERAGE DFT

23300_TAB_0217_418

WORK ITEM 1: Main Propulsion Diesel Engine, Diesel Engine Inspection, Perform

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform Diesel Engine

Inspection (DEI) on the Main Propulsion Diesel Engines (MPDE) listed in Table 1.

1.1.1 Bidding. For bidding purposes, the Contractor shall perform DEI on No.1 Engine and LOS data download from No.2. The DEI on No.2 Engine shall be completed as part of Work Item: Main Propulsion

Diesel Engine (No.2), 16,000 Hour Maintenance.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST ($/UNIT)

N Parts Kit, Diesel Engine 2815-01-628-0945

584-DEI-KIT

1 ea. $3,068.69

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMS-100-001, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication 7024A, 27-NOV-18, Main Diesel Engine - Removal Spaces and Weights (M061891/21E)

Coast Guard Technical Publication (TP) 7025A, 30-OCT-17, Main Diesel Engine - Fluids and

Lubricants Specifications (A001061/37E)

Coast Guard Technical Publication 7026, 31-MAY-07, Main Diesel Engine - Repair Tool Catalog

Coast Guard Technical Publication 7027, 31-MAY-07, Main Diesel Engine - Operating

Instructions

Coast Guard Technical Publication 7028, 31-MAY-07, Main Diesel Engine - Workshop Manual

Coast Guard Technical Publication (TP) 7031, 09-MAY-18, Main Diesel Engine - Parts Catalog

(M034562/01DE)

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

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Subpart E, Sep 2015, Scaffolds, Ladders and Other Working Surfaces

The Society for Protective Coatings (SSPC) Paint Application Specification No. 1 (SSPC-PA

Guide 1), 2004, Shop, Field, and Maintenance Painting of Steel

3. REQUIREMENTS

3.1 General.

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

3.2.1.1

3.1.2 Technical representative. The Contractor shall provide the services of qualified Tech Rep, who is familiar with the MTU 20V1163TB93 Diesel Engine to accomplish the following tasks – on site:

Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

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

Technical Representative shall be present for all disassembly, inspection, and reassembly of the Diesel Engine.

3.1.2.1 The Contractor shall ensure that the Tech Rep is a certified representative of MTU America Inc.

3.1.2.2 The Contractor shall submit the name of the Tech Rep to the COR at the Arrival Conference.

3.1.2.3 The Contractor shall be required to have this Tech Rep present (mandatory), on site, while the following engine work is being performed:

Disassembly

Inspection and qualification of parts

Diesel engine inspection

Re-assembly

NOTE

The MTU America Inc. Technical Representative may be present at other times in addition to the mandatory times listed above. The above represents the minimum required Technical Representative usage.

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

Access covers.

Exhaust stack.

Piping.

Vent ducting.

Electrical Cables

Removed Fluids (Oils and coolant)

3.1.5 Work location. The concerned work area is AFT Main Machinery Room (AMMR) 5-52-01-E. See the applicable drawings in References in Paragraph 2 for guidance, locations, and details.

3.1.6 MPDE information. The MPDE name plate data is listed in the Table 1.

TABLE 1 – MPDE NAME PLATE DATA

EQUIPMENT MODEL NUMBER LOCATION

Main Propulsion Diesel Engine, 9666 HP, MTU America Inc., Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

Main Propulsion Diesel Engine, 9666 HP, MTU America Inc., Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

3.1.7 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.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.1.8 Scaffolding. The Contractor shall, in accordance with CFR Title 29, Part 1915, Subpart E, erect suitable staging or scaffolding, as required, to facilitate work.

3.1.9 Safety precaution. The Contractor shall rig suitable safety netting, to protect workers during possible falls, and to protect the Engine Room and machinery from falling tools.

3.1.10 Materials. The Contractor shall provide all consumable materials, equipment, and tools required to perform the inspection except for parts listed as GFP.

3.1.11 The contractor shall dispose all fluids in accordance with all applicable Federal, state, and local regulations and SFLC STD SPEC 0000.

3.1.12 Rigging. The Contractor is responsible for rigging of all and necessary tools, materials, including

GFP form and to the pier as well as from and to the engine room. When necessary, the Contractor shall provide crane service to move materials, tools and GFE to and from pier, deck and engine room.

3.2 Diesel Engine Inspection. The Contractor shall follow directions from Tech Rep, OEM instructions and applicable Technical Publications referenced above; to perform the standard OEM recommended tasks for DEI.

3.2.1 The Contractor shall submit a CFR at earliest opportunity to report any discrepancies, defects or unexpected wear discovered during this DEI for the tasks listed below:

Visual Inspections

Cylinder Compression Readings

Valve Clearance Readings

Engine coolant and Fuel

Turbocharger Inspections

Gear Case Inspections

Cylinder Liner Inspections

Air Bank Inspections

Filter Element Inspection and replacement

High pressure and low pressure air coolers

Piston oil cooling filters

NOTE

The items inspected during a DEI have been identified by the OEM and/or

Coast Guard as being major inspection items or items that have determined that need to be inspected from prior failure.

3.2.1.1 The Contractor shall complete the DEI work within the first 25% of the contract period to allow the Coast Guard to contract for any additional repairs. Submit a CIR.

3.2.2 Download engine operation data from the LOS program aboard the cutter.

3.2.3 Submit a separate final report for each engine noting the condition of each engine, any inspection results and LOS data plots.

3.2.4 Reassemble all parts of each engine which were disassembled to perform inspections.

3.3 Operational test – post repairs. After completion of work, the Contractor shall thoroughly test, in the presence of the Coast Guard Inspector and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

3.4 Touch-up preservation. The contractor shall prepare all new and disturbed surfaces with solvent wipes

IAW SSPC SP-1 and by cleaning all surfaces to be free of grease and oil before applying paint. The contractor shall coat all new and disturbed surfaces to ASNI Gray 61 color.

4. NOTES

23300_TAB_1018_750

WORK ITEM 2: Main Propulsion Diesel Engine (No.2), 16,000 Hour Maintenance

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform 16,000-hour maintenance for the MPDE listed on table 1.

TABLE 1 – MAINTENANCE ITEMS FOR MPDE #2

ITEM MAINTENANCE TASK TASK # MPDE #2

Lubrication points Lubricate X

Oil filters Inspect, Renew X

High pressure cooler Inspect X

Air filters Inspect X

Emergency air shut-off flaps Inspection Only W1024 X

Jacket water thermostat Renew

X

Centrifugal oil filter Check and replace elements

Fuel filter Replace element

Valve gear Check valve clearance

Engine mounts Check Buffer clearance W1026 X

Fuel injectors Renew

Engine coolant pump Renew W1384 X

Raw water pump Renew W1383 X

Turbochargers Renew W1038 X

Cylinder heads Renew W1063 X

Cylinder liners Renew W1101 X

Fuel prefilter Replace filter element X5900 X

Preheater / Jacket water heater Inspect for leaks

X5602 X

Preheater Renew X5601 X

Level probes (expansion tank) Inspect

X5501 X

Lube-oil tank Inspect

Auxiliary priming unit Inspect

Cooler installation

Clean cooler and replace seals

(PCHE)

Pressure reducing station

Clean air filter, renew if necessary. Renew diaphragm

(Block)

X7650

X7651

Torsional resilient coupling Inspect X5351 X

Compressed-air starting system Inspect

Fuel Injection pumps Renew

Charge-air preheating

Remove, clean and check control valve (TC valve)

Intercooler (low pressure)

Clean interior of cooler, check for damage

W1133 X

Conrod bearings Renew W1083 X

Gear train Perform visual inspection W1086 X

Governor actuator Inspect governor linkage

Turbocharger control system

Overhaul exhaust flaps, air flaps, actuating cylinders and solenoids

W1131 X

Pistons

Inspect skirts and crowns, fit new piston rings

W2044 X

Oil thermostat Inspect W1128 X

Component maintenance

Starting air distributor: Inspect components, check settings.

Adjust if Necessary

Fuel thermostat (if fitted): Fit new thermostat actuator.

Check rockers, roller tappets, pushrods and pushrod ball heads for wear.

Check engine alignment

W2041

W2036

W2084

X

Low/High Pressure coolers

(Air/Water Side) Remove clean and descale

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST ($/UNIT)

Y Injector Replacement Kit

584-INJ-RPL-KIT

NSN: 015911763

20 ea. $5,000.00

N Cylinder Head Replacement

Kit

584-CYL-HD-RPLM

NSN: 016192838

20 ea. $15,000.00

N Cylinder Liner Kit 584-CYL-LNR-KIT

NSN: 016192672

20 ea. $5,000.00

Y Fuel Injection Pump Kit

584-FL-INJ-PMP-KIT

NSN: 016192228

20 ea. $3,000.00

Y HP Turbocharger

Replacement Kit

584-HPTURBO-RPLM

NSN: 016200381

5 ea. $10,000.00

Y LP Turbocharger

Replacement Kit

584-LPTURBO-RPLM

NSN: 016194969

5 ea. $10,000.00

Y Jacket water pump LS

Replacement Kit

584-JWPMPLS-RPLM

NSN: 016263405

1 ea. $4,000.00

Y Jacket water pump RS

Replacement Kit

584-JWPMPRS-RPLM

NSN: 016192545

1 ea. $4,000.00

Y Sea water pump

Replacement Kit

584-SWPMP-RPLM

NSN: 016192264

1 ea. $8,000.00

N Conrod Bearing 5840301960 NIIN:

NIIN: 123587417

20 ea. $941.03

*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.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL-100-001, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

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

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

Coast Guard Technical Publication (TP) 7025A, 30-OCT-17, Main Diesel Engine - Fluids and

Lubricants Specifications (A001061/37E)

Coast Guard Technical Publication (TP) 7026, 31-MAY-07, Main Diesel Engine - Repair Tools

Coast Guard Technical Publication (TP) 7027, 31-MAY-07, Main Diesel Engine - Operating

Instructions

Coast Guard Technical Publication (TP) 7028, 31-MAY-07, Main Diesel Engine - Maintenance

Manual

Coast Guard Technical Publication (TP) 7031, 09-MAY-18, Main Diesel Engine - Parts Catalog

(M034562/01DE)

OTHER REFERENCES

MTU Technical Documentation S000082/00E (MTU Tech Doc S000082/00E), 2011, Functional

Descriptions, Operating Instructions, and Instructions for General Overhaul

MTU Maintenance Schedule M050711/06E.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

3.2.1

3.1.2 Technical Representative. The Contractor shall provide the services of an OEM-certified Tech Rep, who is familiar with the MTU 20 V Series 1163 TB93 Main Propulsion Diesel Engine and its intake air and exhaust turbocharger controls, to accomplish the following tasks – on site:

Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

Perform proper repair methods and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, reassembly, and operational testing of the equipment/system.

3.1.2.1 Ensure that the Tech Rep is a Certified Representative of MTU America, Inc., the OEM.

3.1.2.2 Submit the Tech Rep’s name and résumé to the COR at the arrival conference .

3.1.2.3 The Contractor shall be required to have this Technical Representative present (mandatory), on site, while the following engine work is being performed:

Disassembly

Inspection and qualification of parts

Reassembly

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:

Piping systems

Engine parts including exhaust piping

Electrical cables

Catwalks

Engine oil

Jacket Water

3.1.5 After repairs pest plan. At the arrival conference, The Contractor shall provide dockside and under way post repairs test plan.

3.1.6 Work location. The concerned work area is AFT Main Machinery Room (AMMR) 5-52-01-E. See the applicable drawings in References in Paragraph 2 of this work item for guidance, locations, and details.

3.1.6.1 The Contractor shall make arrangements with COR regarding use shipboard space for tools, materials and additional work space.

3.1.7 MPDE Information. The MPDE Name plate data is listed in the Table 2.

TABLE 2 – MPDE NAME PLATE DATA

EQUIPMENT MODEL NUMBER LOCATION

Port: Main Propulsion Diesel

Engine,9666 HP, MTU America , Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

STBD: Main Propulsion Diesel

Engine,9666 HP, MTU America, Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

3.1.8 Rigging. The Contractor shall be responsible for rigging of materials, cores, tools and GFE materials form dock-engine room and back to dock as necessary.

3.1.9 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.

3.2 Maintenance and Inspection. The Contractor shall follow directions from Tech Rep, TP 7028 and

MTU Technical Documentation S000082/00E as needed to accomplish the maintenance, inspections and repairs required for the 16,000 hour Maintenance Schedule items listed on Table 1.

3.2.1 The Contractor shall complete cylinder bore inspections and submit CIR within the first 25% of time for the availability.

3.2.2 The Contractor shall provide new engine oil.

3.2.3 The Contractor shall provide Oil waste removal services as required.

3.3 Materials with core return. The Contractor shall use the boxes and packing materials from the new parts to pack the used cores. Deliver the boxes with the used parts to COR.

NOTE

Contractor shall include underway sea trial and testing in bid.

3.4 Operational test – post repairs. After completion of all authorized work, the Contractor and CG

Inspector shall witness an operational test (by Coast Guard personnel) of the main diesel engines to prove satisfactory operating condition. Submit a CFR.

3.5 Touch-up preservation. The Contractor shall prepare and touch-up coat all disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, Appendix B (Cutter and Boat

Interior Painting Systems). Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

This section is not applicable to this work item.

63110_GBS_0317_418

WORK ITEM 3: Cofferdam, Install

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to install cofferdams at the sea chest related Work Item: Main Propulsion Diesel Engine (No.2), 16,000 Hour Maintenance.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL-100-001, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750-WMSL 100-031, Rev E, Unit 2300 Structure - Inner Bottom - FR 52 to FR 64 (ASC100230)

Coast Guard Drawing 750-WMSL 101-030, Rev C, Shell Expansion Scantlings (AS3101017)

Coast Guard Drawing 750-WMSL-801-004, Rev B, Booklet of General Plans (ASC801001C)

COAST GUARD PUBLICATIONS

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

OTHER REFERENCES

Naval Sea Systems Command (NAVSEA) S0600-AA-PRO-160, 8/15/2008, Underwater Ship

Husbandry Manuals - Chapter 16 (Cofferdams)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

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).

3.1.5 Work coordination. The Contractor shall coordinate work on this item with Work Item, Main

Propulsion Diesel Engine (No.2), 16,000 Hour Maintenance.

3.2 Work Location. The concerned work area(s) is:

Main Propulsion Diesel Engine, Raw Water Pump sea chest and overboard discharge.

3.3 Cofferdam Fabrication.

3.3.1 The Contractor shall fabricate and install a cofferdam (blank cover) over the port and starboard sea chests for Raw Water Pump sea chest. See Coast Guard Drawings 750-WMSL-100-031, 750-WMSL-

101-030 and 750-WMSL-801-004 for guidance.

3.3.2 Cofferdam fabrication and installation shall be accordance with the NAVSEA S0600-AA-PRO-160.

3.3.3 The Contractor shall fabricate and install a plug on the outside overboard discharge and blank flanges inside the overboard discharge piping for the Raw Water Pump sea chest.

3.3.4 Inspect the structure surrounding the cofferdam for deterioration and corrosion and submit a

Condition Found Report to the Coast Guard Inspector.

This section is not applicable to this work item.