Attachment 2 - Specification.pdf

USCGC MANOWAR (WPB 87330)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2026

Developed By: Larry M Hatalla

(Rev-0, 28 April 2025)

USCGC MANOWAR (WPB-87) DRYDOCK AVAILABILITY FY2026

ii (Rev-0)

TABLE OF CONTENTS

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

System Configuration iii (Rev-0)

REVISIONS RECORD

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

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

iv (Rev-0)

CONSOLIDATED LIST OF REFERENCES

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at the time of specification writing and during contract execution.

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

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

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

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

Fire Prevention and Response

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

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

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

Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), Latest Version, Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), Latest Version, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Occupational Safety and Health Standards for Shipyard Employment

Installation of MTU Electronic Systems E 530 606/06E

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

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

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

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

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

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

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

MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED v (Rev-0)

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

MTU Exhaust Turbocharger ZR140 M040052/10E

MTU Fluids and Lubricants Specification A001061/35E

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

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

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

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

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

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

MTU Tool List M004021/20DE

NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), July 2012, Requirements for Fabrication, Welding, and Inspection of Submarine Structure vi (Rev-0)

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

WORK

ITEM

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

1 Y Cylinder Head NSN: 2815-12-345-1076 16 3274.71 1 Y “A†Bank

Turbocharger

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

1 Y “B†Bank Turbocharger

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

1 Y Sea Water Pump NSN: 2930-12-344-4810 2 15,086.29 1 Y Jacket Water Pump NSN: 2930-12-344-4606 2 3799.67 1 Y Starter NSN: 2920-12-156-2556 2 3255.35 1 Y **Charge Air Cooler NSN: 2930-12-354-2436 Tbd 32,974.85 1 Y **Injector with retainer NSN: 2910-12-341-9988 Tbd 706.45 1 N **Cylinder Liner NSN: 2815-12-315-7282 Tbd 1103.14 1 N **Piston NSN: 2815-12-362-8999 Tbd 3816.34 1 N Engine Acceptance

Test Record

N/A 1/MDE N/A

*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 vii (Rev-0)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)):

Work Item

Title

This section is not applicable to this package.

viii (Rev-0)

PRINCIPAL CHARACTERISTICS

87' WPB

PHYSICAL

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

HULL

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

MACHINERY

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

TANK CAPACITIES

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

1 (Rev-0)

00000_0824_FLT

REC_00000_FLT_Commercial Project @ Contractor’ Facility (0121)

General Requirements

1. SCOPE

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

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

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

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

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

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

Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), Latest Version, Fire Prevention and Response

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

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Occupational Safety and Health Standards for Shipyard Employment

NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), July 2012, Requirements for Fabrication, Welding, and Inspection of Submarine Structure

2 (Rev-0)

3. REQUIREMENTS

3.1 General. The Contractor must conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability. The requirements in this WI applies to all work under the scope of this contract, whether explicitly stated in all following work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.1.1 The Contractor must conform to all requirements specified in SFLC Std Spec 5550 and in the Fire Protection and Response work item, as applicable, during the performance of this availability.

3.1.1.1 Fire Safety Plan submission. The Contractor must submit a copy of the CFR 1915, Subpart P, Fire Safety Plan with the Contractor’s bid when work will be conducted in a Contractor–owned facility. Include any MOA(s) with local firefighting facilities.

3.1.1.2 Fire Plan submission. The Contractor must submit a copy of the developed availability specific fire plan as requested in the Fire Protection and Response work item, with the Contractor’s bid.

NOTE

NAVSEA drawings listed will be available FOR INSPECTION ONLY from the Coast Guard Port Engineer post-award. SFLC will not redistribute NAVSEA documents.

Contractors can apply to NAVSEA headquarters directly for copies.

3.1.1.3 SFLC-PBPL Availabilities (87 WPB, 110 WPB, & 154 WPC). The Contractor must conform to SFLC Std Spec 5550 with the following amendments and supplements:

• For contracts executed at a Contractor’s facility, submit (pre-award) the facility’s Fire Safety Plan document described in 29 CFR 1915.502 – “Fire Safety Plan”. For planning assume that Coast Guard personnel will not be available to fight a fire.

• For all contracts at all facilities, submit the following information pre-award, taking into consideration how the maintenance/repairs specified in the work items will affect uninterrupted operation of the subject systems; make all necessary amendments to this submission after discussions with the COR at the arrival conference and during contract execution as emerging conditions warrant:

o Describe all anticipated needs for fire detection/alarm, fire-fighting, and shipboard lighting and communication systems supplementation (see below) and a description of the proposed remedies/solutions (include pricing for maintaining capability in pre-award quote).

o Describe how any required temporary/supplemental fire detection/alarm systems will notify fire responders.

o Describe all anticipated breaches of the cutter’s Fire Protection Boundaries and the proposed temporary solutions that will minimize impact on the Fire Protection Boundary’s proper function (e.g. removal of cables/hoses/etc. at the end of work day or installation of quick disconnects, installation of temporary fire curtains, etc.).

• Whenever maintenance/repairs described in work items or Change Requests necessitate securing, or making inoperable, all or part of the vessel’s fire detection or fire alarm system, submit a proposal to the COR/KO describing an equivalent method(s) for temporarily maintaining all lost functionality of the system(s). Select the

3 (Rev-0) most economical option(s) available (i.e. for extended loss of service of the entire system the temporary fire detections/alarm system described in SFLC Std Spec 5550 may be the best option, for shorter durations temporary watch standers may be more economical, etc.). After the COR has agreed to the proposal, maintain the capability of these systems for the duration of the contract to the greatest practicable extent.

• Whenever maintenance/repairs described in work items or Change Requests necessitate securing, or making inoperable, all or part of the vessel’s firefighting (e.g. fire main system, P100 and other dewatering systems, halon systems, portable fire extinguishers, etc.), lighting, and communications systems, submit a proposal to the COR/KO describing equivalent method(s) for temporarily maintaining all lost functionality of the system(s). Select the most economical option(s) available. After the COR has agreed to the proposal, maintain fire detection/alarm/fighting and lighting/communications capability for the duration of the contract to the greatest practicable extent.

• All Fire Protection Boundaries must be left intact and functional at all times to the greatest practicable extent. Notify the COR in writing whenever a breached Fire Protection Boundary will be left unattended outside of normal working hours (e.g. a door/hatch is made un-closable/un-securable due to repair work, an access cut is made into deck/bhd that is part of a Fire Protection Boundary, etc.). When a Fire Protection Boundary must be breached to facilitate contract work, minimize the impact using industry-standard methods (e.g. fire curtains, quick-disconnect fittings, etc.)

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

Provide portable fire extinguishers for Coast Guard fire watch personnel. Coast Guard fire watch is in lieu of contractor personnel during the hours of 0800-1600, Monday through Friday, and limited to two Coast Guard fire watch personnel.

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 must accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

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

3.3.2 Coating colors and system color schemes. The Contractor must obtain a written KO authorization to deviate from any coatings required in SFLC Std Spec 6310 Appendix C before work.

3.3.3 In-process quality control measures. The Contractor must abide by all the safety, preservation, and quality control requirements specified in SFLC Std Spec 0000, paragraph 3.2.4.2 (In-process QC measures for “critical-coated surfaces”).

3.3.3.1 Quality control requirements. The Contractor must abide by the following when performing preservation related inspections. The following measurements must be randomly spaced throughout for the purposes of providing a representation of the entire prepared or coated surface.

3.3.3.1.1 Surface profile measurements. One surface profile measurement must be taken for every 200 square feet for the first 1000 square feet; for each additional 500 square feet or less, one profile measurement must be taken.

Profile measurements must be taken in accordance with SFLC Std Spec 6310, paragraph 3.1.8.3 (Surface profile measurements). A “measurement” for surface profile is defined as follows:

ASTM D4417, Method B: One profile measurement is the average (mean) of 10 individual readings.

4 (Rev-0)

ASTM D4417, Method C: One profile measurement is the average (mean) of 2 individual readings.

3.3.3.1.2 Soluble salt conductivity measurements. 5 conductivity measurements must be taken every 1000 square feet. For submerged (immersed) applications conductivity measurements must not exceed 30 microsiemens/cm.

For non-submerged (non-immersed) applications conductivity measurements must not exceed 70 microsiemens/cm. If a conductivity check fails, clean the surface in accordance with SFLC Std Spec 6310, paragraph 3.1.8.5 (Soluble salt removal).

3.3.3.1.3 Coating thickness measurements. Three area measurements must be taken for the first 1000 square feet;

for each additional 1000 square feet, perform an additional area measurement. A “measurement” for coating thickness is defined as follows:

SSPC-PA 2 defines an area measurement as 5 separate spot measurements randomly spaced throughout a 100 square foot area.

SSPC-PA 2 defines a spot measurement as 3 gage readings and each new gage reading the probe must be moved to a new location within a 1.5-inch diameter circle defining the spot.

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

3.4.1 HY-130 material substitution. The Contractor must be aware that HY-130 steel plating is no longer commercially available. For the purpose of performing flight deck repairs on US Coast Guard WMEC-270 “B- Class” cutters, Weldox 900 steel plating has been approved as a replacement for HY-130. Due to the similarity in material properties and weldability of HY-130 and Weldox 900, all welding procedures and welder qualifications for welding Weldox 900 must be the same as those outlined in NAVSEA TP 1688 as applicable for welding HY- 130.

3.4.2 Standard spec modification. For any welding involving HY-130 on the flight deck of WMEC-270 “B-Class” cutters, perform all welding and allied processes, and non-destructive evaluation (NDE) in accordance with NAVSEA TP 1688. The Contractor must be aware that the welding requirements specified in this document take precedence over paragraph 3.3.6 of SFLC Standard Spec 0000 for the purpose of welding involving HY-130.

3.4.3 Approval to weld HY-130. To obtain Coast Guard approval to weld on HY-130 steel for WMEC-270 “B- Class” cutters, the Contractor must provide written Performance Qualification Records (PQR’s) for each process to be used. The PQR’s must be approved by one of the regulatory agencies affirming that the WPS meets the welding requirements of NAVSEA TP 1688. In addition, the Contractor must ensure that all subcontractors, prior to performing welding operations, have qualified procedures by meeting all the requirements set forth in this document.

NOTE

NAVSEA approval is NOT required for welding procedures submitted but the procedures must be reviewed and shown to satisfy the requirements set forth in NAVSEA TP 1688, by a welding regulatory agency. The requirements for welding Weldox 900 are considered the same as those for welding HY-130.

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

3.5.1 Contractor operated (non USCG) facilities. The Contractor must provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix A, Requirements for Environmental Protection at Contractor Operated (Non USCG) Facilities, as applicable, during the performance of this availability. Contractor

5 (Rev-0) must plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor must comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item must not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

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

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

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

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

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

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

3.5.3 Regulatory notifications. The Contractor is 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 must submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications must be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

3.5.4 Environmental manager. The Contractor must appoint in writing an Environmental Manager for the project, who is responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager must ensure compliance with Hazardous Waste Program requirements, including hazardous waste handling, storage, manifesting, and disposal; implement the Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out;

ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas; ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the Environmental Records binder and required documentation, including environmental permits compliance and close-out.

3.5.5 HW disposal. Contractor must comply with SFLC Std Spec 0000 Appendix A, Requirements For Environmental Protection At Contractor Operated (Non USCG) Facilities for HW disposal.

6 (Rev-0)

3.6 Local Policy. The Contractor must refer to site (e.g., Base) Regulations and Instructions for details regarding local policies (e.g., crane services, parking, or facility usage).

3.7 SFLC Standard Specification approved changes. Approved updates to the 2022 SFLC Standard Specifications will appear here.

3.7.1 None.

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.

7 (Rev-0)

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

VESSEL NAME HULL # WORK ITEM

WORK ITEM TITLE

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

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

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

CHECKPOINT 2 - PAINT STORAGE

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

CHECKPOINT 3 - AMBIENT CONDITIONS

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

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

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

CHECKPOINT 4 - PRE-SURFACE PREPARATION

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

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

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

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

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

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

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

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

CHECKPOINT 9 – FINAL INSPECTION

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

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

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

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

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

CHECKPOINT 10 – RECORD KEEPING

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

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

NAME OF CG REPRESENTATIVE SIGNATURE UNIT DATE/TIME

8 (Rev-0)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

VESSEL NAME HULL #

WORK ITEM

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

DATE

TIME

ACTIVITY (SURFACE

PREPARATION, PRIMER COAT,

BARRIER COAT, TOP COAT,

ETC…)

LOCATION (FRAME &

DECK, RELATION TO

EQUIPMENT, ETC.)

TEMPERATURE % REL.

HUMID-

ITY

DEW

PT.

SURFACE AMBIENT ΔT

| DP -

SURFACE |

9 (Rev-0)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL # WORK ITEM

LOCATION OF WORK (FRAME REFERENCES) AREA (SQFT)

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/AMPP No. 2

SSPC-SP WJ-2/AMPP WJ-2

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/AMPP INSPECTOR SIGNATURE CERT. # DATE /

TIME

10 (Rev-0)

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL # WORK ITEM

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/AMPP No. 2

SSPC-SP WJ-2/AMPP WJ-2

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 Mils Reading (IAW ASTM D4417-Method B for above 10 readings (by column):

Mean Reading (mils)

11 (Rev-0)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

VESSEL NAME HULL # WORK ITEM

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15.

DATE TEST LOCATIONS CONDUCTIVITY (MICROSIEMENS/CM)

12 (Rev-0)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

VESSEL NAME HULL #

WORK ITEM

COATING MFG PRODUCT NAME

BATC

H #

INDUCTI

ON TIME

COATING SYSTEM

SEQUENCE

(PRIMER/TOUCHUP/3RD

COAT, ETC.)

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

SPOT 1 2 3 4 5

AVERAGE

VALUE

*BASE METAL READING

(BMR)

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

LOCATION (FRAME REFERENCE):

SPOT 1 2 3 4 5 OVERALL AVG. DFT ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE ADJUSTMENTS AFTER ADJUSTMENTS

AVG.

LOCATION (FRAME REFERENCE):

SPOT 1 2 3 4 5 OVERALL AVG. DFT ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE ADJUSTMENTS AFTER ADJUSTMENTS

AVG.

LOCATION (FRAME REFERENCE):

SPOT 1 2 3 4 5 OVERALL AVG. DFT ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE ADJUSTMENTS AFTER ADJUSTMENTS

AVG.

APPLICATION METHOD (AIRLESS,

CONVENTIONAL SPRAY, ROLLED)

AVERAGE DFT

13 (Rev-0)

4.2 Tank and Void Assessment form.

14 (Rev-0)

15 (Rev-0)

23002_NET_0523_87WPB

WORK ITEM 1: Main Diesel Engine Assemblies, Perform W-5 Maintenance And Update Control System Configuration

1. SCOPE

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

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

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

Record

N/A 1/MDE N/A

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

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

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

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

OTHER REFERENCES

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

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

16 (Rev-0)

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

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

MTU Tool List M004021/20DE

MTU Exhaust Turbocharger ZR140 M040052/10E

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

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

MTU Fluids and Lubricants Specification A001061/35E

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

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

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

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

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

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

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

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

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

Installation of MTU Electronic Systems E 530 606/06E

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

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

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

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

Advise on manufacturer's proprietary system information.

Assist with installation and repair method(s)

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

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

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

17 (Rev-0)

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

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

Piping

Valves

Electrical Wiring

Insulation

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

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

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

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

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

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

3.2.2 W5 Maintenance. Perform an in-place MTU 8V396TE94 Maintenance Operation W-5 in accordance with the references listed beneath Section 2 above. Remove and properly dispose of all fluids in accordance with technical publications in conformance with local and federal laws. Furnish and fill all engine systems with the appropriate fluids in accordance with the technical publications. Submit Condition Found Reports (CFRs) for all inspections.

NOTE

All necessary fluids, such as oils, coolants and inhibitors, will be supplied and disposed of by the contractor.

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

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

18 (Rev-0)

“A” Bank Turbocharger

“B” Bank Turbocharger

Cylinder Heads

Jacket Water Pump

Sea Water Pump

Starter Motor

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

Submit CFR for all inspections.

Sequential Turbo Charging Actuator

Sequential Turbo Charger Mechanism

Lube Oil Cooler

Plate Cooler

Charge Air Manifold

Fuel Injectors

Charge Air Cooler (must be cleaned ultrasonically)

Exhaust sleeves

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

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

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

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

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

3.3.2 Contractors calibration system. The Contractor, as well as any Subcontractors, must be required to maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540-3. The system must include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to ensure adherence to calibration schedules. Calibration standards must be traceable to the

19 (Rev-0)

National Institute of Standards and Technology (NIST). Documentation in support of this requirement must be readily available for Government review.

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

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

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

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

4. NOTES

4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all tests.