Attachment 2 Statement of Work.pdf

USCGC JOHN F. MCCORMICK (WPC 1121)

SPECIFICATION FOR UNPLANNED DOCKSIDE REPAIRS

FY2022

Developed By: Jason M Devin

(Rev-2, 25 October 2021)

USCGC JOHN F. MCCORMICK (WPC-154) UNPLANNED AVAILABILITY FY2022

ii (Rev-0)

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: #2 MDE, Renew WORK ITEM 2: Temporary Services, Provide - Cutter WORK ITEM 3: Drydocking iii (Rev-0)

REVISIONS RECORD

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

DATE

REV#

WORK

ITEM#

CHANGES MADE

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

iv (Rev-0)

CONSOLIDATED LIST OF REFERENCES

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

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

COAST GUARD DRAWINGS

Coast Guard Drawing 154 WPC 079-900, Rev D, Stability and Loading Data Booklet Coast Guard Drawing 154WPC 085-201 Rev A, Propulsion System, SSDG, EDG Installation Drawings Coast Guard Drawing 154WPC 151-301 Rev E, Scantlings Superstructure Coast Guard Drawing 154WPC 200-301 Rev -, Machinery Arrangement Drawings Coast Guard Drawing 154WPC 204-301 Rev F, Equipment Removal Plan

Coast Guard Drawing 154 WPC 997-302, Rev -, Docking Plan

COAST GUARD PUBLICATIONS

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

Manual Coast Guard Technical Publication 8019 (TP-8019), Sections A, B, C, D, and E, Main Propulsion Engine

MTU 20V4000M93L, Volume 1, 2, 3, 4, 5 Coast Guard Technical Publication 8902B (TP-8902B), Sections A, B, Technical Repair Standard, Depot

Level, for use on Fast Response Cutter (FRC-B), Sentinel Class, Main Propulsion Diesel Engine, MC/OR and ETRAR Datasheets, MTU 20V4000M93L, Volume 1, 2

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

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

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

OTHER REFERENCES

None v (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 FRC MDE NIIN: 0C 2815-12-392-7931 1 $1,861,153.95

1 N FRC MDE Container NIIN: 8145-01-F13-3476 1 $47,857.63 1 Y Spreader Bar, Main

Engine

NIIN: 01-F18-5444 1 $50,000.00

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

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

***Government-furnished property, which is to be supplied by either the vessel or the C5IT Service Center vi (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.

vii (Rev-0)

PRINCIPAL CHARACTERISTICS

154' WPC (SENTINEL CLASS)

PHYSICAL

Anchor ROCNA, anchor, 150 KG/ 331 LB, Stainless Steel Bulkheads (7), Watertight Bulkheads located below the Main Deck Displacement, delivery, light ship 302 Metric Tons Draft, full load 2.58 Meters (8.46 Feet) End of service life displacement 353 Metric Tons Framing Longitudinal Full load displacement 353 Metric Tons Height of highest projection 17.22 Meters (56.5 Feet) Length overall (loa) 46.80 Meters (153.5 Feet) Maximum beam 7.75 Meters (25.43 Feet) Minimum operating displacement 314 Metric Tons Waterline length (lwl) 44.35 Meters (145.5 Feet)

HULL

Hull/main weatherdeck material AH-36 Steel Superstructure 5456-H1111 Aluminum

MACHINERY

Bow thruster Schottel STT 60 LK Diameter of propeller 1900 mm Emergency service generator (edg) Cummins 6BTA5.9-DM Diesel with Stanford 93KW Generator Fin stabilizer (2), Quantum QC1500 Main propulsion (2), MTU 20V4000 M93L, Sequential Turbo-Charged Diesels Number of blades 6 Number of propellers (2) Michigan Wheel Marine Propeller pitch capability Fixed Propulsion shafts (2), Electralloy Nitronic 50HS (9430mm) Shafts Reduction gears (2), ZF 23560C/D Series Rudders (2), 316L Stainless Steel Shaft rotations per minute 478 Shaft(s) bearing, aft (2), Duramax Bearings Shaft(s) bearing, intermediate (2), Duramax Bearings Shaft(s) diameter 8 Inches Shaft(s) Seal (2), Wartsila Mechanical Seals Ship service generators (2), Cummins QSM11-DM Diesels with Stanford 317KW Generator

TANK CAPACITIES AT 95% LIQUID LOAD (22,958 TOTAL GALLONS)

Fresh water tank, port (3-38-2-w) 708 gal Fresh water tank, stbd (3-38-1-w) 756 gal Fuel oil edg day tank (1-10-1-f) 134 gal Fuel oil gen. ovrflw tnk, ctr. (3-40-0-f) 1,159 gal Fuel oil overflow tank, center (3-10-0-f)

616 gal

Fuel oil service tank, #1 port (3-17-2-f) 1,750 gal Fuel oil service tank, #1 stbd (3-17-1-f) 1,750 gal Fuel oil service tank, #2 port (3-40-2-f) 890 gal Fuel oil service tank, #2 stbd (3-40-1-f) 890 gal Fuel oil storage tank, #1 center (3-11-0- 5,040 gal viii (Rev-0) f)

Fuel oil storage tank, #2 center (3-23-0-f)

5,350 gal

TANK CAPACITIES AT 95% LIQUID LOAD (22,958 TOTAL GALLONS)

Grey water tank, (3-17-0-w) 2,668 gal.

Lube oil storage tank, (2-35-2-f) 146 gal.

Oily water tank, (3-34-1-w) 336 gal.

Sewage collection tank, (3-6-0-w) 429 gal.

Waste oil tank, (3-34-2-f) 336 gal.

1 (Rev-0)

00000_0521_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 PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General

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

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

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 of 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.

2 (Rev-0)

3.1.1 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.

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

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

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

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

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

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

3.5.1 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 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.

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

3.5.3 Regulatory notifications. The Contractor must be responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, 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 and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

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

3 (Rev-0) 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.

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

3.7.1 SFLC Standard Specification 8636. Add missing paragraphs between 3.2 and 3.5 of Std Spec 8636 as follows:

3.3 Access cut boundaries. The Contractor must ensure that access cuts comply with the requirements and restrictions detailed in the following and in SFLC Std Spec 0740, and referenced codes.

3.3.1 Location of boundaries. Boundaries of access cuts and closure plates must, in general, be located between principal ship framing, bulkheads, and other structural members and must be at least three inches from any of these members or from the toes of other welds. A reduction in this three inch minimum may be approved by the KO on a case by case basis provided sufficient clearance is maintained for welding and inspection requirements. The boundaries of access cuts and closure plates should land on existing butts or seams, wherever practicable. The boundaries of prior access cuts should be utilized wherever possible. Boundaries may extend across one or more frames as required for the size of the opening.

3.3.2 Access hole dimensions and arrangements. Holes or access cuts must be the minimum size necessary and must be in accordance with the following:

• Rectangular access cuts and closure plates welded into primary hull structure must be at least 12 inches wide in the lesser dimension.

• For circular access cuts, the minimum diameter must be 4T, where T = thickness of the involved structural member, but not less than three inches.

• Circular closure plates for access cuts less than two feet in diameter must be dished 1/16 to 1/8 inch to allow for shrinkage when welded.

• Corners of rectangular access cuts and closure plates must have a minimum radius of 6 inches except when a boundary lands on an existing hull longitudinal seam or transverse butt weld.

• Corners at an existing seam or butt must intersect at a 90 degree angle.

• Cuts that are to cross existing butts or seams must do so at an angle of 90 degrees plus or minus

15 degrees.

• In primary hull structure, existing welds forming the boundary of a cut must be cut back 3 inches beyond the toe of the access cut, except that the cut back must not intersect or cross an existing weld, frame, or structural member. In which case, the cut back may be reduced to a minimum of two inches in length.

• Existing welds crossed by the cut must not be cut back.

4 (Rev-0)

3.3.3 Primary hull structure. Primary Hull Structure includes the shell, main strength decks, principal longitudinal bulkheads, vertical keel, deep web girders and stiffeners designed to withstand the ship bending stress.

3.3.4 Mechanically fastened joints. Welding closer than six inches to a mechanically fastened joint should be avoided. When access cuts cross or come within six inches of a mechanically fastened joint, the fasteners must be checked for tightness and if necessary, loose fasteners must be seal welded or removed, and replaced for a distance of 6 inches beyond the edge of the cut. When a cut crosses a mechanically fastened seam the cut plates must be repaired using single V welds backed with glass tape (MIL-C-20079) to prevent fusion between the mechanically fastened plates.

3.4 Ship integrity maintenance. The Contractor must maintain safety and ship integrity by installing temporary guarding and coaming, in addition to weathertight and watertight closures. Remove these temporary fabrications after closing the hull access, and grind surfaces flush in way of removals. For shell plating cuts made at or below the waterline where temporary closures are impractical, the Contractor must secure each vulnerable compartment and subdivision to minimize potential damage to the extent permitted by the scope and urgency of the work.

3.4.1 Guarding. Install temporary guards in accordance with 29 CFR 1915.73.

3.4.2 Coaming. Ensure that in areas where flammable liquids may be stored, a 4 inch high metal coaming must be installed on the surface of the deck with tack welds and fully sealed with caulking compound.

The coaming must encircle the access cut in the deck.

3.4.3 Weathertight and contamination closures. Fabricate temporary closures, using fire retardant material, before cutting access openings and install closures whenever access is not in use. Closures must be:

• Constructed to protect the access from inclement weather and entry of contaminants (must include a coaming or dam on the deck to redirect rain runoff away from the opening).

• Fitted with fasteners that permit rapid installation and removal.

• Able to support a minimum of 150 pounds per square foot for horizontal deck closures.

• Where the access opening is in way of a removed hatch, scuttle or door, the closure must be configured to allow normal passage of ship’s personnel and equipment.

3.4.4 Watertight closures. Ensure that access openings created four feet or less above the maximum anticipated waterline must include temporary watertight closures when the vessel is waterborne.

NOTE

NAVSEA S0600-AA-PRO-160/CH16 provides requirements for design, fabrication, and installation of temporary watertight closures.”

5 (Rev-0)

4. NOTES

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

QA-6 - QUALITY ASSURANCE INSPECTION FORM

6 (Rev-0)

(PRESERVATION CHECKLIST)

VESSEL NAME HULL # WORK ITEM

WORK ITEM TITLE

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

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

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

CHECKPOINT 2 - PAINT STORAGE

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

CHECKPOINT 3 - AMBIENT CONDITIONS

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

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

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

CHECKPOINT 4 - PRE-SURFACE PREPARATION

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

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

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

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

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

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

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

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

CHECKPOINT 9 – FINAL INSPECTION

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

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

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

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

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

CHECKPOINT 10 – RECORD KEEPING

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

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

QA-7 - QUALITY ASSURANCE INSPECTION FORM

7 (Rev-0)

(ENVIRONMENTAL READINGS)

VESSEL NAME

HULL #

WORK ITEM

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

DATE

TIME

ACTIVITY (SURFACE

PREPARATION, PRIMER COAT,

BARRIER COAT, TOP COAT,

ETC…)

LOCATION (FRAME &

DECK, RELATION TO

EQUIPMENT, ETC.)

TEMPERATURE % REL.

HUMID-

ITY

DEW

PT.

SURFACE AMBIENT ΔT

| DP -

SURFACE |

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

8 (Rev-0)

QA-3A - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL # WORK ITEM

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area)

Brush-blasting (non-metallic substrate)

ABRASIVE MANUFACTURER: ABRASIVE SIEVE SIZE:

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

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

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

Place Surface Profile Replica Tape Here

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

9 (Rev-0)

QA-3B - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL # WORK ITEM

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area)

Brush-blasting (non-metallic substrate)

ABRASIVE MANUFACTURER: ABRASIVE SIEVE SIZE:

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

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

SEPARATE SECTIONS, MAINTAIN A SEPARATE LOG FOR EACH SECTION.

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Mean Reading (mils)

Mean Reading (mils) IAW ASTM DD4417).

10 (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)

11 (Rev-0)

(Use one sheet for each sequence)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

VESSEL NAME

HULL #

WORK ITEM

COATING MFG

PRODUCT NAME

BATC

H #

INDUCTI

ON TIME

COATING SYSTEM

SEQUENCE

(PRIMER/TOUCHUP/3RD

COAT, ETC.)

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

SPOT 1 2 3 4 5 AVERAGE

VALUE

*BASE METAL READING

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

LOCATION (FRAME REFERENCE):

SPOT 1 2 3 4 5 OVERALL AVG. DFT ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE ADJUSTMENTS AFTER ADJUSTMENTS

AVG.

1 AVG. BMR DEVIATION

1 AVG. BMR DEVIATION

APPLICATION METHOD (AIRLESS,

CONVENTIONAL SPRAY, ROLLED)

AVERAGE DFT

12 (Rev-0)

20000_JLW_0321_154WPC

WORK ITEM 1: #2 MDE, Renew

1.1 Intent. This work item describes the requirements for the Contractor to renew the Port 154WPC

MDE.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y FRC MDE NIIN: 0C 2815-12-392-7931 1 $1,861,153.95

N FRC MDE Container NIIN: 8145-01-F13-3476 1 $47,857.63 Y Spreader Bar, Main Engine NIIN: 01-F18-5444 1 $50,000.00

Coast Guard Drawing 154WPC 085-201 Rev A, Propulsion System, SSDG, EDG Installation

Drawings Coast Guard Drawing 154WPC 151-301 Rev E, Scantlings Superstructure Coast Guard Drawing 154WPC 200-301 Rev -, Machinery Arrangement Drawings Coast Guard Drawing 154WPC 204-301 Rev F, Equipment Removal Plan

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Coast Guard Technical Publication 8019 (TP-8019), Sections A, B, C, D, and E, Main Propulsion

Engine MTU 20V4000M93L, Volume 1, 2, 3, 4, 5 Coast Guard Technical Publication 8902B (TP-8902B), Sections A, B, Technical Repair

Standard, Depot Level, for use on Fast Response Cutter (FRC-B), Sentinel Class, Main Propulsion Diesel Engine, MC/OR and ETRAR Datasheets, MTU 20V4000M93L, Volume 1, 2

None.

13 (Rev-0)

3.1 General. The Contractor must perform and abide by the following.

3.1.1 Refer to TP-8019 and Coast Guard Drawings 154WPC 085-201, 154WPC 200-301, 154WPC 204- 301.

3.1.2 Qualifications. At least one technician on site must be QL3 certified on MTU4000 series engines, must possess a 1B dongle certification on ECU-7 series governor, and the Contractor must have 20V4000M93L engine prior maintenance experience.

3.1.3 Protective measures - general. 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, 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 must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.1.5. Removal and Reinstallation Plan. In conjunction with, and incorporated into, the submission of the PD per paragraph 3.5.2 of SFLC STD SPEC 0000, prepare and submit detailed removal and reinstallation plans that contain the following. After the final version of the PD is approved by the Coast Guard work may commence.

• An “Interference Removal/Reinstallation and Access Cut Plan” containing a list of items that will be removed as interferences. Describe measures that will be taken to prevent contamination/water/etc. from entering the cutter, and measures that will ensure ship’s structure will not deform after removal of the WERP plates. Describe the control welding techniques that will be used to ensure the WERP plates and adjacent structure will not be warped or damaged, and that final weldment will not crack.

• A “Cutter Stability Plan” containing a description of measures that will be taken to ensure the stability characteristics described below in para 3.5.3.1 Maintain cutter stability parameters are maintained.

• A “Rigging Plan” containing type and rating of crane and a step-by-step description of the rigging evolution. Describe all lifting appliances (e.g. strong-backs, jigs, etc.) that will be used.

• An “Engine Installation and Alignment Plan” containing a brief description of how the new engine will be reconnected to all disturbed interfaces and how the new engine will be aligned/connected to all hard-points (e.g. reduction-gear flange, inlet/exhaust ppg, water ppg, etc.). Describe how engine feet will be removed and reinstalled onto rails, and to what extent Chock-fast liners will be disturbed and why. Describe what types of alignment jigs, instruments, and tools will be used (e.g. laser, dial indicator, etc.)

• An “Operational Test Plan” containing an outline of all of the procedural steps required to

NOTE

An agreement is in place between the Coast Guard and MTU to provide commissioning services and sea trials on new propulsion engines. Ensure MTU technicians are aware of this information prior to scheduling services.

14 (Rev-0) fully prove a satisfactory install of the new engine.

• A “Preservation Plan for F-Condition Engine” that outlines the steps that will be taken to package, preserve, and seal-off the removed engine

3.1.6 Operational test - initial. Prior to commencement of work, witness Coast Guard personnel perform an operational pre-test of all items and shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Inspect engine room bilge areas to determine extent of failed coatings. Prior to engine renewal submit a CFR that details any required growth repairs identified during the operational test based on the observed condition of the systems.

3.1.7 Inspection/Verification Sign-off Sheet. The Contractor must print off and maintain the sign-off sheet shown beneath paragraph 4.1 titled “FRC Engine Change Out Inspection/Verification Form” (or create and maintain an equivalent sheet). Immediately after completion of the predecessor task notify the COR/PE of the pending inspection, show and describe to the COR/PE the items requiring inspection and approval, then pending satisfactory inspection by the COR/PE, have the COR/PE sign the sheet to certify satisfactory completion of the task. Proceed with follow-on tasks only after receiving COR/PE witness, approval, and signature. Submit the filled-out sign-off sheet with the final testing CFR (described beneath paragraph 3.2.8) as certification that a Government representative was present for all listed inspections.

3.1.8 Coordinate with MTU Tech Rep funded by other Coast Guard contract. The Coast Guard will provide an MTU tech rep that will assist in the installation of any pending retrofits, be available for start-up, and sea-trials. The Contractor must coordinate with this tech rep prior to the start of the availability to determine scheduling of engine uncrating, engine rigging date, sea trials, and all other project details.

3.2 Engine Renewal Requirements. The Contractor must renew MDE by performing and abiding by the following. Refer to TP-8902B, Chapter 2 and Chapter 40 for Shipboard Removal and Installation Requirements.

3.2.1 Conduct preliminary inspections and tests. Conduct the preliminary tests specified in TP-8902B, Chapter 2.

3.2.2 Remove interferences and prepare for engine rigging evolution. While removing all interferences, and in conjunction with engine removal/reinstallation, perform the following.

3.2.2.1 General. Take all necessary precautions to prevent all environmental elements (e.g. rain, birds, dirt, etc.) from entering the skin of the cutter while the WERP deck plates are removed. This may involve temporary installation of cofferdams around accesses openings, tents/shelters, etc. or other equivalent methods.

3.2.2.2 Maintain cutter stability parameters. Throughout the entire contract 1) maintain, at a minimum, lightship stability conditions, and 2) maintain a list small enough to allow direct vertical rigging of engine

NOTE

Ship’s Force will perform electrical isolation, tag-out procedures, etc.

Coordinate with Ship’s Force and ensure all of this work is complete prior to performing any maintenance.

Coordinate with Ship’s Force and the COR/PE to schedule pre-engine-removal sea trials for collecting preliminary test data on.

15 (Rev-0) out of the ship with no need to apply a significant horizontal force to guide the engine in/out (e.g.

pulling/guiding engine with tag lines, pushing engine, etc), refer to TP-8902B, Chapter 2. This will involve installation and adjustment of shoring and weights, or an equivalent method. Main deck loading must not exceed 1000 lbs per sqft.

3.2.2.3 WERP removal and reinstallation requirements. Maintain the dimensions of the clear opening created after WERPs are removed by install temporary structural members that will prevent all deformation of the superstructure that may occur after removing WERP plates in accordance with the approved “Removal and Reinstallation Plan” (NOTE: Post WERP removal expansion of the clear opening has been noted in the past and must be prevented.). Coordinate with the COR/PE 24 hours in advance of inspection of the installed temporary structural members and prior to removal of any WERP plate weld joint material, proceed with WERP removal after satisfactory COR/PE inspection of temporary structure. Minimize damage to WERP plate and surrounding structure by only removing existing weld joint material that attaches the WERP plate to the 01 LVL Deck. First saw/grind down into the weld joint approximately 1/8”, then carefully sever the remaining weld (approx 1/16”) using a chisel or equivalent method/tool to release the WERP plate from the 01 LVL Deck. Inspect WERP foundation bar for any damage that will require repairs before final WERP installation. Submit CFR. At reinstallation employ control welding to the greatest practicable extent to ensure no latent defects (e.g. cracks, warping, etc. at a later date).

3.2.3 Prepare installed intake/exhaust ducts and engine for removal. Prior to disturbing engine intake and exhaust ducts, secure (i.e. “cage”) all spring-loaded expansion joints (e.g. clamp together with turn buckles, etc. or equivalent method) to prevent release from their pre-disassembly dimensions/adjustment and label their locations. Measure and record all exhaust hanger distances prior to disassembly to aid in efficient reassembly and exhaust alignment.

3.2.4 Inspect engine intake ducts and exhaust ducts. Coordinate with the COR/PE 24 hours in advance of the inspection. In the presence of the COR/PE, wipe-down and visually inspect all accessible interior surfaces of all intake and exhaust piping and mufflers. Inspect soot trap. Determine if further disassembly and cleaning is required. Submit a CFR describing findings and any recommended additional cleaning.

3.2.5 Remove old engine, install new engine. Perform the following.

3.2.5.1 Preservation of Removed Engine. Prior to engine removal, the port main diesel engine must be preserved IAW TP-8019 chapter 5.3.2 (Service Interruption of more than 3 months), MTU Preservation

16 (Rev-0) and Re-preservation Specifications, A001070/00E. Submit a CFR containing all preservation documentation described in chapter 2.2 (Check sheet for preservation and re-preservation). Ensure all coolant drain lines are opened and all coolant drained from engine.

3.2.5.2 Mark existing alignment adjustments, transfer adjustments to new engine. Coordinate with the COR/PE 24 hours in advance of the inspection. In the presence of the COR/PE, and prior to engine removal, perform the following for efficient install of the new engine:

• Scribe/mark/trace on each existing engine foot liner plate where the engine foot currently rests, then later, at install, place new engine as close as practicable to the marked location.

• Measure and record the “Adjustment Nut Height” of each installed engine foot, then transfer those adjustment dimensions to the feet on the new engine prior to install (ideally while suspended from the crane and immediately after lifting off of shipping crate).

3.2.5.3 Inspect CHOCKFAST liners for damage (e.g. cracks, deformation, etc.). Coordinate with the COR/PE 24 hours in advance of the inspection. Immediately after the existing engine is removed, and in the presence of the COR/PE, conduct a thorough visual inspection of all 12 CHOCKFAST poured liners installed on the engine bed rails. Verify they have no damage, were originally poured correctly, and can be reused. Submit a CFR detailing the inspection results and describe any additional recommended repairs.

3.2.5.3.1 Determine the flatness of the CHOCKFAST/liner assemblies, relative to one another.

Determine how closely the combination of all of the liners emulates a perfectly flat surface for the engine to rest upon. After each engine has been removed, and using a proper planar “datum feature” (e.g. 3 points on one of the liners defining a plane, etc.), determine 4 offset dimensions from that plane for each liner. Each offset dimension must be measured from a point within 1” of a different corner on the liner (4 offset dimensions per liner). Submit a CFR detailing the inspection results and describe any additional recommended repairs.

3.2.5.4 Record existing engine flange to RG flange alignment readings. Coordinate with the COR/PE 24 hours in advance of the inspection, and after removing engine to RG coupling and obtaining alignment instrument readings, show those instrument readings to the COR/PE. Submit CFR.

17 (Rev-0)

3.2.5.5 Clean and touch-up preserve bilges beneath engine. Clean and pressure wash all engine room bilge surfaces to remove all loose contaminates and dirt. Submit a CFR describing the condition of bilge coatings and all discrepancies (e.g. failed coatings, rust, etc.), note all coating discrepancies in excess of 20 sqft total. Coordinate with the COR/PE 24 hours in advance of the inspection, and have the COR/PE inspect all preparation work prior to coating application. Touch-up preserve up to 10 sqft of failed or damaged bilge coating beneath the STBD engine and up to 10 sqft of failed or damaged bilge coating beneath the PORT engine (i.e. include in pre-award quote), and apply one topcoat, up to 5mils, over all intact bilge surfaces. Additional coatings repairs will be authorized/funded by CR/mod to the contract.

See paragraph 3.2.11.1 below for coatings requirements.

3.2.5.6 Renewals. In addition to the Government-furnished engine, renew the following components

• All disturbed soft parts (e.g. seals, gaskets, o-rings, etc.).

• All engine fluids (e.g. jacket water, oil, etc.)

• All exhaust hanger rubber grommets.

• Insulation Blankets covering the Exhaust Silencer only (do not renew blankets covering the exhaust pipe leading to and from the Exhaust Silencer, retain and reuse those blankets).

• All disturbed hardware and fasteners (e.g. nuts, bolts, washers, studs, etc.).

• All flex hoses and expansion joints leading to and from each engine.

• The ASW expansion joint leading to the RG.

• The ASW hose leading to R/G from the jacket water cooler.

• All exhaust pipe gaskets.

3.2.5.7 Align new engine to existing reduction gearbox. Align the engine output flange to the reduction gear flange in accordance with Coast Guard Drawing 154WPC 085-201. Coordinate with the COR/PE 24 hours in advance of the inspection, and after completing the final alignment adjustments and obtaining satisfactory alignment instrument readings, show those instrument readings to the COR/PE. Submit CFR.

3.2.6 Repackage and ship removed engine. Place the preserved F-condition MDE into the new Government-furnished MDE container reusing the foil bag from the “A” condition engine and accomplish the following:

3.2.6.1 Ensure all preserved F-condition MDE valves are closed.

3.2.6.2 Seal off all electrical sockets with a waterproof adhesive tape. Blank all openings and flanged connections over 3 inches diameter with wooden flanges, sealed with adhesive tape. All other openings (e.g. tapped holes, etc.) must be blanked with plastic or metal caps and waterproof adhesive tape.

3.2.6.3 Install all retained engine support components to facilitate safe engine transport. Renew all disturbed fasteners.

NOTE

As of this writing, bilge coating condition does not warrant mandatory QP1 Certification or Independent NACE inspector. If, at the start of the contract performance period, bilge coating condition deteriorates past the thresholds specified in SFLC STD SPEC 6310 and SFLC STD SPEC 0000, these requirements will be invoked and additional associated preservation costs will be compensated by contract mod if necessary.

18 (Rev-0)

3.2.6.4 Return the crankshaft locking devices (provided on "A" condition engine) with the F-condition engine.

3.2.6.5 Install shipping blanks from A-condition engine (turbo, water inlets/outlets, etc) on F-condition engine.

3.2.6.6 Mark the serial numbers on the new Government-furnished containers to reflect the appropriate "F" condition engine serial numbers. Mark the containers condition codes to “F”. Ensure the F-condition engine and container are protected from weather if left outside.

3.2.6.7 Attach the following labels to the removed engine, ensuring that they are in a prominent position, stating:

• “NO OIL OR WATER, DO NOT TURN!”

• “ENGINE REMOVED FROM SERVICE – Date ”.

3.2.6.8 Notify the COR/PE at least 24 hours prior to closing shipping containers, then show the COR/PE that all paragraph 3.2.6 requirements have been met, then close the containers. Turn over crated engine as an MTI item. Dispose of the old shipping crate.

3.2.7 Restore interferences, remove all temporary installations. Restore all interferences, repair all damage incurred in conjunction with maintenance actions performed during this contract. Perform and/or abide by the following:

3.2.7.1 WERP Reinstallation and testing. Notify the COR/PE at least 24 hours prior to weld joint inspections and tests. After WERPs are reinstalled, in the presence of the COR/PE, perform weld joint testing in accordance with SFLC STD SPEC 0740 on 100% of the weld joint areas that seal the WERP plate to the 01 LVL deck. Submit CFR with NDT results.

3.2.7.2 Touch-up preservation requirements. Prepare and coat exterior surfaces to match existing adjacent surfaces, in accordance with SFLC Std Spec 6310, Appendix A (Cutter and Boat Exterior Painting Systems) or Appendix B (Cutter and Boat Interior Painting Systems), and SFLC Std Spec 0000.

Abide by the exception cited below.

3.2.7.2.1 Exception to coating systems specified in SFLC 6310. All coating systems used must be in accordance with Coast Guard Drawing 154 WPC 631-301, do not use the coating systems specified in SFLC Std Spec 6310.

3.2.7.3 Insulation repairs. In conjunction with reinstallation, repair all damage to disturbed bulkhead insulation (e.g. damaged perforated sheathing pieces, damaged insulation, etc.) by renewing appropriate sectional areas.

3.2.8 Conduct final grooming, inspections, and tests.

3.2.8.1 Engine Sea-Trial Testing. Perform all testing specified in TP-8902B Volume 2 and record all associated data. Perform a minimum 4-hour long sea trial and download ECU7 sea trail data, run for a

NOTE

Ensure any parts /assemblies removed for trouble shooting or failure analysis are reinstalled on F-condition engine.

19 (Rev-0) minimum of 3 hours at full speed. Take post-sea-trial, lube oil, coolant, and fuel oil samples and obtain lab test results for submission.

3.2.8.2 Exhaust blanket thermograph survey. During the sea trial, after the engine and exhaust reach a maximum and steady state temperature (after the full-speed/full-power run), conduct an infrared thermographic survey of the entire exhaust blanket assembly on the engine in the presence of the COR/PE. Use an instrument that captures digital thermographic images, and ensure that images of all blanket surfaces have been recorded. Submit these digital images of all surfaces at steady-state temp with the final report. Ensure that no exhaust blanket areas/seams exceed 550 deg F and that all gaps between blanket seams are covered.

3.2.8.3 Final Report. Submit final CFR containing all test results/data and the “FRC Engine Change-out Inspection/Verification Form” with all completed signatures.

4.1. Inspection and verification form.

FRC Engine Change-out Inspection/Verification Form

20 (Rev-0)

1a. Paragraph 3.2.2.3: Temp structure installed satisfactorily, removal of PORT WERP plate may commence.

Contractor Name Signature Date

COR/PE Name Signature Date

1b. Paragraph 3.2.2.3: Temp structure installed satisfactorily, removal of STBD WERP plate may commence.

Contractor Name Signature Date

COR/PE Name Signature Date

2a. Paragraph 3.2.4: PORT intake/exhaust duct and muffler inspection completed, associated CFR accurate.

Contractor Name Signature Date

COR/PE Name Signature Date

2b. Paragraph 3.2.4: STBD intake/exhaust duct and muffler inspection completed, associated CFR accurate.

Contractor Name Signature Date

COR/PE Name Signature Date

3a. Paragraph 3.2.5.1: PORT Liner/feet marking, adjustment measurements, and transfer of adjustment to new engine feet satisfactorily completed.

Contractor Name Signature Date

COR/PE Name Signature Date

3b. Paragraph 3.2.5.1: STBD Liner/feet marking, adjustment measurements, and transfer of adjustment to new engine feet satisfactorily completed.

Contractor Name Signature Date

COR/PE Name Signature Date

4a. Paragraph 3.2.5.2: PORT CHOCKFAST liners either SAT, or renewal plan accurately described and approved by CFR.

Contractor Name Signature Date

COR/PE Name Signature Date

4b. Paragraph 3.2.5.2: STBD CHOCKFAST liners either SAT, or renewal plan accurately described and approved by CFR.

Contractor Name Signature Date

COR/PE Name Signature Date

5a. Paragraph 3.2.5.3: PORT engine existing alignment readings, record dimensions below.

Actual Flange-to-Flange Dimension: Actual Radial Dimension: Actual Face Dimension

Contractor Name Signature Date

COR/PE Name Signature Date

FRC Engine Change-out Inspection/Verification Form

21 (Rev-0)

5b. Paragraph 3.2.5.3: STBD engine existing alignment readings, record dimensions below.

Actual Flange-to-Flange Dimension: Actual Radial Dimension: Actual Face Dimension

Contractor Name Signature Date

COR/PE Name Signature Date

6a. Paragraph 3.2.5.4: SAT inspection of PORT bilge prep work prior to coatings application.

Contractor Name Signature Date

COR/PE Name Signature Date

6b. Paragraph 3.2.5.4: SAT inspection of STBD bilge prep work prior to coatings application.

Contractor Name Signature Date

COR/PE Name Signature Date

7a. Paragraph 3.2.5.6: PORT engine alignment readings are SAT, record dimensions below.

Actual Flange-to-Flange Dimension: Actual Radial Dimension: Actual Face Dimension

Contractor Name Signature Date

COR/PE Name Signature Date

7b. Paragraph 3.2.5.6: STBD engine alignment readings are SAT, record dimensions below.

Actual Flange-to-Flange Dimension: Actual Radial Dimension: Actual Face Dimension

Contractor Name Signature Date

COR/PE Name Signature Date

8. Paragraph 3.2.6.9: F-Condition Engine has been crated in accordance with all packaging requirements.

Contractor Name Signature Date

COR/PE Name Signature Date

9. Paragraph 3.2.7.1: 100% of weld joint connecting WERP plates to the 01 LVL Deck visually inspected and NDTed SAT.

Contractor Name Signature Date

COR/PE Name Signature Date

10. Paragraph 3.2.8.1: Exhaust blankets installed properly and satisfactorily, joints between blanket sections do not leak heat excessively.

Contractor Name Signature Date

COR/PE Name Signature Date

22 (Rev-0)

8635_JLW_0219_154WPC

WORK ITEM 2: Temporary Services, Provide - Cutter

1.1 Intent. This work item describes the requirements for the Contractor to provide temporary services to the Cutter, during the performance of this availability.

1.2 Government-furnished property.

COAST GUARD PUBLICATIONS

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

Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), 2020, Temporary Services

3.1 General.

3.1.1 CIR.

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures. The Contractor must furnish and install all protective coverings to…