Attachment 2_ Statement of Work_Specification.03.22.2024.pdf

USCGC BERTHOLF (WMSL 750)

SPECIFICATION FOR DOCKSIDE REPAIRS

March 22, 2024

USCGC BERTHOLF (WMSL-418) DOCKSIDE AVAILABILITY FY2024

ii (Rev-2)

TABLE OF CONTENTS

Consolidated List of References .................................................................................................................. iii Consolidated List of Government-furnished Property ................................................................................. vi Consolidated List of Critical Inspection Items ........................................................................................... vii Principal Characteristics ............................................................................................................................ viii General Requirements WORK ITEM 1: Main Propulsion Diesel Engine, 24,000 hour, Overhaul iii (Rev-2)

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 418A-WMSL-100-001, Rev B, General Arrangements

Coast Guard Drawing 750-WMSL 100-034, Rev K, Unit 2330 Structure – 2nd Deck to Main Deck - Fr 52 to Fr 64 (ASC100233)

Coast Guard Drawing 750-WMSL 100-039, Rev M, Unit 3140 Structure Mn Dk to 01 Lvl - Fr 64 to Fr 76

(ASC100314)

Coast Guard Drawing 750-WMSL 100-043, Rev L, Unit 3240 - Main Deck to 01 Level - Fr 76 to Fr 82

(ASC100324)

Coast Guard Drawing 750-WMSL 100-052, Rev K, Unit 4320 Structure 02 Lvl and Above - Fr 48 to Fr

53 (ASC100432)

Coast Guard Drawing 750-WMSL 100-053, Rev K, Unit 4420 Structure - 01 Level and Abv - Fr 52 to Fr

67 (ASC100442)

Coast Guard Drawing 750-WMSL 100-533, Rev -, Lifting Padeyes Aft Main Machinery Room 5-52-01E and Uptake Stack Region

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

Coast Guard Drawing 750-WMSL 600-046, Rev G, Fab & Instl of Hull Outfit Design, Unit 4130

(ASC600413)

Coast Guard Drawing 750-WMSL 635-001, Rev -, Thermal & Acoustic Insulation (ASC635001)

Coast Guard Drawing 750-WMSL-100-542, Rev A, MPDE Transfer Structural Installs & Lifting Devices

Coast Guard Drawing 750-WMSL-259-003, Rev G, Main Prop DSL/SS DSL Gen Air Intake/Exhaust Diagram (ASC259002)

Coast Guard Drawing 750-WMSL-259-011, Rev D, Main Engine Combustion Air Intake & Exhaust Arr, Dets & L/M Below 2nd Deck (ASC259009)

Coast Guard Drawing 750-WMSL-259-013, Rev B, Main Engine Combustion Air Intake & Exhaust Arr, Dets & L/M 2nd Deck Up - 02 Lvl (ASC259011)

Coast Guard Drawing 750-WMSL-259-014, Rev C, Main Engine Combustion Air Intake & Exhaust Supports, Dets & L/M 2nd Deck Up - 02 Lvl (ASC259012)

Coast Guard Drawing 750-WMSL-259-015, Rev D, Mn Engine Comb Air Intake & Exh Arr, Dets & L/M Abv 02 Lvl (ASC259013)

Coast Guard Drawing 750-WMSL-259-016, Rev B, Main Engine Combustion Air Intake & Exhaust Supports, Dets & L/M Above A 02 Lvl (ASC259014)

Coast Guard Drawing 750-WMSL-508-001, Rev C, Piping and Machinery Insulation Schedule and L/M

(ASC508001)

Coast Guard Dwg FL-1204-3 iv (Rev-2)

NAVSEA Drawing 804-5773931, Rev A, Acoustic & Thermal Insulation for Compartments Installation Details

COAST GUARD PUBLICATIONS

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

Coast Guard Technical Publication 7024A, 27-NOV-18 Main Diesel Engine (MDE) - MODEL 20 V 1163 TB93 - Removal Spaces & Weights (M061891/21E)

Coast Guard Technical Publication 7930, 23-FEB-17, Main Diesel engine (MDE) - MODEL 20V1163 TB93 - Maintenance schedule (M050711/06E)

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

(M034562/01DE)

Coast Guard Technical Publication 7025A, 30-OCT-17 Main Diesel Engine (MDE)-Fluids & Lubricants Specifications (A001061/37E)

Coast Guard Technical Publication 7026 31-MAY-07 Main Diesel Engine (MDE)-Model 20V1163TB93- Repair Tool Catalog

Coast Guard Technical Publication 7948, 07-NOV-16 Main Diesel Engine (MDE)-Model 20V1163TB93- Plant Documentation (S000083/00E)

Coast Guard Technical Publication 7231A, Main Diesel Engine (MDE)-Model 20V1163TB93-System Documentation-Major Overhaul Instructions

Coast Guard Full Power Trial Procedure M-A-Z013

COMDTINST M10360.3D Coatings and Color Manual

Fire Prevention and Response

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, 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), 2020, Welding and Allied Processes

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), 2020, Requirements for Preservation of Ship Structures

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

WMSL Crankshaft Removal Report

OTHER REFERENCES

American Welding Society, AWS D1.2-96, 1996, Structural Welding Code, Steel

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

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

MIL-DTL-15024, Nov 1997, Plates, Tags and Bands for Identification of Equipment, General Specification for v (Rev-2)

MIL-PRF-1149, Jun 1998, Gasket Materials, Synthetic Rubber, 50 and 65 Durometer Hardness

MIL-PRF-900, Mar 1991, Rubber Gasket Material, 45 Durometer Hardness

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

Society of Automotive Engineers (SAE) J1942-1, 2008, Qualified Hoses for Marine Applications

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

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2004, Solvent Cleaning vi (Rev-2)

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 Crankshaft X51403100006/32 1 $242.000 1 Y Engine Rotation Tool NIIN 01F206038 PN 584-

1163RTN-TLN

1 $70,000

1 Y Cylinder Head Replacement Kit

P/N: 584-CYL-HD-RPLM

NSN: 016192838

40 ea 15450.56

1 Y Cylinder Liner Kit P/N: 584-CYL-LNR-KIT

NSN: 016192672

40 ea 3672.81

1 N Piston Engine P/N: 5840301117 NSN:

123349610

40 ea 10180.72

1 Y LP Turbocharger Replacement Kit

P/N: 584-LPTURBO-RPLM

NSN: 016194969

10 ea. 36564.41

1 Y HP Turbocharger Replacement Kit

P/N: 584-HPTURBO-RPLM

NSN: 016200381

10 ea. 22072.33

*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

2vii (Rev-2)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

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

Work Item

Title

1 Main Propulsion Diesel Engine, 24,000 Hour, Overhaul viii (Rev-2)

PRINCIPAL CHARACTERISTICS

418' WMSL

PHYSICAL

Length overall 418' 0" Length between perpendiculars 390' 0" Maximum beam 54' 0" Beam @ 01 level 47' 9-1/8" Depth (01 level @ side to baseline) 39' 2-3/4" 01 deck camber foredeck 1/4" in 1'-0" Minimum berth depth 20' 0" Height of highest projection Approximately 119' Draft, design 14.40' Design displacement 3925 long tons

MACHINERY

Two diesel engines MTU 20V, 20-cylinder 9,730 SHP each One gas turbine General Electric LM2500; 29,500 SHP Type of propulsion CODAG Electrical system 24 Volt DC Two controllable pitch propellers Rolls-Royce 5 blade, 14' 0" diameter; 229 RPM max Two reduction gears RENK One cross connect gear RENK

HULL

Hull material 5086 Aluminum HSLA-80 Steel ABS EH 36 Steel

ABS AH 36

Frame spacing FWD of FR 9 2' 3" FR 9 to FR 10 6' 9" FR 10 to FR 98 4' 1" FR 98 to FR 99 3'-8"

ELECTRICAL

Power Three 1360 kW, 450 V, 60 Hz, 3 Phase, 1800 RPM Caterpillar 3512B diesel engines with Baylor ship service generators Shore tie cable Seven MIL-C-24368/2 (NATO) shore power receptacles, 400 A each

TANK CAPACITIES

Diesel oil 220,359 gal Fresh water 12,454 gal JP-5 Fuel 35,182 gal

1 (Rev-2)

00000_0623_FLT

REC_00000_FLT_Commercial Project @ CG Facility (0121)

General Requirements

1. SCOPE

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

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

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

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

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 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-2)

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.

3.1.1.2 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, seven (7) days before the Arrival Conference.

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.

3.2 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.

3.3.3 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.

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 (Rev-2)

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 USCG facilities. The Contractor must provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, during the performance of this availability. Contractor 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 7690390037.

4 (Rev-2)

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 B, Requirements For Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.5.6 Additional Requirements. The Contractor must be aware of the following:

3.5.6.1 No Contractor or Subcontractor must have the authority to sign a Hazardous Waste Manifest using the Coast Guard facility’s EPA Generator ID Number or remove contract generated hazardous waste from the Coast Guard facility without COR or KO-approval.

3.5.6.2 Local environmental regulations at the Government facilities may be more stringent. As with all environmental regulations, the Contractor must prepare for and comply with local and state regulations.

5 (Rev-2)

3.5.6.3 Coast Guard facilities do not maintain Facilities Response Plans (FRPs) per 33 CFR 154. Contractor must furnish the FRP when required for over-the-water liquids transfers to and from vessels, and is required for oil/fuel transfers to/from vessels for 250 barrels (10,500 gallons) or more.

3.6 Local Policy. 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.

6 (Rev-2)

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/NACE INSPECTOR SIGNATURE CERT. # DATE / TIME

NAME OF CG REPRESENTATIVE SIGNATURE UNIT DATE/TIME

7 (Rev-2)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

VESSEL NAME HULL #

WORK

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

DATE

TIME

ACTIVITY (SURFACE

PREPARATION, PRIMER

COAT, BARRIER COAT, TOP

COAT, ETC…)

LOCATION (FRAME &

DECK, RELATION TO

EQUIPMENT, ETC.)

TEMPERATURE % REL.

HUMID-

ITY

DEW

PT.

SURFAC

E

AMBIEN

T

ΔT

| DP -

SURFACE |

8 (Rev-2)

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/NACE No. 2

SSPC-SP WJ-2/NACE 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/NACE INSPECTOR SIGNATURE CERT. # DATE /

TIME

9 (Rev-2)

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-2/NACE 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)

10 (Rev-2)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

VESSEL NAME HULL # WORK

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15.

DATE TEST LOCATIONS CONDUCTIVITY (MICROSIEMENS/CM)

11 (Rev-2)

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

12 (Rev-2)

4.2 Tank and Void Assessment form.

13 (Rev-2)

14 (Rev-2)

23300_TAB_0523_750

WORK ITEM 1: Main Propulsion Diesel Engine, 24,000 hour, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform shipboard 24K hour Overhaul on the Main Propulsion Diesel Engines (MPDEs ) listed in Table 1. Renew Crankshaft for MPDE #2 Only.

TABLE 1 – MPDE NAME PLATE DATA

EQUIPMENT MODEL NUMBER LOCATION

USCG Bertholf

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

20V 1163 TB 93

MPDE #1

AFT Main Machinery Room (5-52-01-E)

USCG Bertholf Main Propulsion Diesel Engine,9666

HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93

MPDE #2

AFT Main Machinery Room (5-52-01-E)

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST ($/UNIT)

Y Crankshaft X51403100006/32 1 $242.000 Y Engine Rotation Tool NIIN 01F206038

PN 584-1163RTN-TLN

1 $70,000

Y Cylinder Head Replacement Kit

P/N: 584-CYL-HD-RPLM

NSN: 016192838

40 ea 15450.56

Y Cylinder Liner Kit P/N: 584-CYL-LNR-KIT

NSN: 016192672

40 ea 3672.81

N Piston Engine P/N: 5840301117

NSN: 123349610

40 ea 10180.72

Y LP Turbocharger Replacement Kit

P/N: 584-LPTURBO-

RPLM

NSN: 016194969

10 ea. 36564.41

Y HP Turbocharger Replacement Kit

P/N: 584-HPTURBO-

RPLM

NSN: 016200381

10 ea. 22072.33

2. REFERENCES

COAST GUARD DRAWINGS

15 (Rev-2)

Coast Guard Drawing 418A-WMSL-100-001, Rev B, General Arrangements

Coast Guard Drawing 750-WMSL 100-034, Rev K, Unit 2330 Structure – 2nd Deck to Main Deck - Fr 52 to Fr 64 (ASC100233)

Coast Guard Drawing 750-WMSL 100-039, Rev M, Unit 3140 Structure Mn Dk to 01 Lvl - Fr 64 to Fr 76 (ASC100314)

Coast Guard Drawing 750-WMSL 100-043, Rev L, Unit 3240 - Main Deck to 01 Level - Fr 76 to Fr 82 (ASC100324)

Coast Guard Drawing 750-WMSL 100-052, Rev K, Unit 4320 Structure 02 Lvl and Above - Fr 48 to Fr 53 (ASC100432)

Coast Guard Drawing 750-WMSL 100-053, Rev K, Unit 4420 Structure - 01 Level and Abv - Fr 52 to Fr 67 (ASC100442)

Coast Guard Drawing 750-WMSL 100-533, Rev -, Lifting Padeyes Aft Main Machinery Room 5- 52-01E and Uptake Stack Region

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

Coast Guard Drawing 750-WMSL 600-046, Rev G, Fab & Instl of Hull Outfit Design, Unit 4130

(ASC600413)

Coast Guard Drawing 750-WMSL 635-001, Rev -, Thermal & Acoustic Insulation (ASC635001)

Coast Guard Drawing 750-WMSL-100-542, Rev A, MPDE Transfer Structural Installs & Lifting Devices

Coast Guard Drawing 750-WMSL-259-003, Rev G, Main Prop DSL/SS DSL Gen Air Intake/Exhaust Diagram (ASC259002)

Coast Guard Drawing 750-WMSL-259-011, Rev D, Main Engine Combustion Air Intake & Exhaust Arr, Dets & L/M Below 2nd Deck (ASC259009)

Coast Guard Drawing 750-WMSL-259-013, Rev B, Main Engine Combustion Air Intake & Exhaust Arr, Dets & L/M 2nd Deck Up - 02 Lvl (ASC259011)

Coast Guard Drawing 750-WMSL-259-014, Rev C, Main Engine Combustion Air Intake & Exhaust Supports, Dets & L/M 2nd Deck Up - 02 Lvl (ASC259012)

Coast Guard Drawing 750-WMSL-259-015, Rev D, Mn Engine Comb Air Intake & Exh Arr, Dets & L/M Abv 02 Lvl (ASC259013)

Coast Guard Drawing 750-WMSL-259-016, Rev B, Main Engine Combustion Air Intake & Exhaust Supports, Dets & L/M Above A 02 Lvl (ASC259014)

Coast Guard Drawing 750-WMSL-508-001, Rev C, Piping and Machinery Insulation Schedule and L/M (ASC508001)

Coast Guard Dwg FL-1204-3

NAVSEA Drawing 804-5773931, Rev A, Acoustic & Thermal Insulation for Compartments Installation Details

COAST GUARD PUBLICATIONS

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

(M034562/01DE)

Coast Guard Technical Publication 7024A, 27-NOV-18 Main Diesel Engine (MDE) - MODEL 20V1163TB93 - Removal Spaces & Weights (M061891/21E)

16 (Rev-2)

Coast Guard Technical Publication 7930, 23-FEB-17, Main Diesel engine (MDE) - MODEL 20 V1163TB93 - Maintenance schedule (M050711/06E)

Coast Guard Technical Publication 7025A, 30-OCT-17 Main Diesel Engine (MDE)-Fluids & Lubricants Specifications (A001061/37E)

Coast Guard Technical Publication 7026 31-MAY-07 Main Diesel Engine (MDE)-Model 20V 1163TB93-Repair Tool Catalog

Coast Guard Technical Publication 7948, 07-NOV-16 Main Diesel Engine (MDE)-Model 20V1163TB93-Plant Documentation (S000083/00E)

Coast Guard Technical Publication 7231A, Main Diesel Engine (MDE)-Model 20V1163TB93- System Documentation-Major Overhaul Instructions

Coast Guard Full Power Trial Procedure M-A-Z013

COMDTINST M10360.3D 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

WMSL Crankshaft Removal Report

OTHER REFERENCES

American Welding Society, AWS D1.2-96, 1996, Structural Welding Code, Steel Code of Federal Regulations (CFR) Title 29, Part 1915, Subpart E, Sep 2015, Scaffolds, Ladders and Other Working Surfaces MIL-DTL-15024, Nov 1997, Plates, Tags and Bands for Identification of Equipment, General

Specification for MIL-PRF-1149, Jun 1998, Gasket Materials, Synthetic Rubber, 50 and 65 Durometer Hardness MIL-PRF-900, Mar 1991, Rubber Gasket Material, 45 Durometer Hardness Society of Automotive Engineers (SAE) J1942-1, 2008, Qualified Hoses for Marine Applications The Society for Protective Coatings (SSPC) Paint Application Specification No. 1 (SSPC-PA Guide 1), 2004, Shop, Field, and Maintenance Painting of Steel The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2004, Solvent Cleaning

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The contractor must submit a CIR for the inspections listed in the following paragraph:

3.3.2 Contractor furnished equipment (CFE)

3.1.2 Tech Rep. The Contractor must provide the services of a qualified Tech Rep with past experience maintaining the MTU 20V1163TB93 Diesel Engine, to accomplish the following tasks – on site:

17 (Rev-2)

Provide all information, software, and tools pertinent to the equipment/system required in order to perform a 24,000 Overhaul of a MTU 20V1163TB93 Diesel Engine on a National Security Cutter or an equivalent sized vessel.

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

3.1.2.1 Ensure the Tech Rep is a qualified maintenance provider who has successfully executed major engine overhauls on 20V1163TB93 MTU engines as demonstrated on their resume.

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

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 Receipt of GFP. The contractor will receive the GFP listed above using the Coast Guard 1149. After receipt of the GFP, the contractor must inventory and inspect the condition of the GFP upon receipt and provide a CFR documenting all GFP received and condition.

NOTE

Due to long lead time for Geislinger Spring couplings, (Geislinger) the couplings currently in Michigan with the spare engines will be used in order to accomplish this work item.

3.1.5 Geilsinger Spring Couplings and Carbon Couplings. Contractor must make the necessary arrangements with OEM to remove, package and ship the Geslinger and carbon couplings from spare engines in Michigan and ship to Cutter’s home Port. One set per engine.

3.1.6 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, par. 3.3.5 (Interferences). Known interferences include, but are not limited to the below-listed:

Access covers

Bulkhead

Bulkhead insulation

Catwalks

CMWD/AFFF nozzles

Cofferdams on sea suction are required

CPP head tanks, maintain oil pressure to CPP system

Crankcase breathers

Cross connect gear piping and console

Engine block and accessories

Engine oil

Exhaust hard insulation

Exhaust insulation blankets

Exhaust manifold

Exhaust pipe expansion joints

18 (Rev-2)

Exhaust stack

Geislinger coupling

Jacket water

JW expansions tanks

Pipe insulation

Piping

Vent ducting

Wiring

WARNING

Positive oil pressure must be maintained to CPP system at all times

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

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

3.1.9 Fluid disposal. The Contractor must drain all existing fluids from designated MPDE, The contractor must dispose all fluids in accordance with all applicable Federal, state, and local regulations and SFLC

STD SPEC 0000.

3.1.10 Rigging. The Contractor is responsible for rigging of all and necessary tools, materials, including GFP from and to the pier as well as from and to and from the engine room. When necessary, the Contractor must provide crane service to move materials, tools and GFP to and from pier, deck and engine room.

3.1.10.1 The Contractor is responsible for all crane services.

NOTE

It is anticipated that the route for renewal of the MPDE Crankshaft is through BERP and out port hangar to flight deck.

3.1.11 Crankshaft Rigging plan. Contractor must follow the USCG provided “WMSL Crankshaft Removal Report”. If contractor needs to deviate from approved plan, submit CFR for additional approval subject to USCG review and approval.

3.1.12 Padeyes. Suitable padeyes welded to the Cutter’s structure. Verify existing padeyes as indicated on 750-WMSL-100-533. Prior to using any of the existing padeyes to lift engine components, the Contractor must visually inspect the padeyes for any signs of corrosion, fractures, defects, or deformation.

3.1.12.1 Contractor must pull test existing padeyes to 150% their “expected working loading”. In no case may a padeye’s “expected working load” (a) exceed the tabulated maximum working load for the padeye’ s size (see Table 2). or (b) exceed the structure’s (that padeye is attached to) ability to carry the load. At conclusion of pull test visually inspect padeye for damage. Submit CFR.

3.1.12.2 Contractor may install additional padeyes, and overhead supports if required or warranted by the approved rigging plan. Newly installed padeyes must be tested to 200% of rated load in accordance with

19 (Rev-2)

CG Dwg FL-1204-3. Submit CFR with test information and padeye details for any newly installed padeyes. Include location and load ratings for each of the new padeyes.

NOTE

For new Contractor installed pad eyes test to 200% of rated load. New padeyes will remain installed for future use.

3.1.12.3 The following Table lists the maximum working loads for various sized padeyes. Expected working loads may be considerably less than maximum working load, i.e. a 1” padeye used in the rigging plan will have an “expected working load” of only 6,000 lbs (not the maximum 9,800 lbs) and pull tested to 9,000 lbs.

TABLE 2 - PADEYE MAXIMUM WORKING LOADS

PADEYE SIZE MAX WORKING LOAD

1/2” 2,400 lbs 3/4” 5,800 lbs

1” 9,800 lbs

1-1/8” 12,100 lbs 1-3/16” 13,300 lbs

3.1.12.4 Welding requirements. The Contractor must perform all welding and allied processes, and nondestructive examination (NDE), in accordance with SFLC Std Spec 0740 and 0000. Submit a CFR for results of all NDE performed.

3.1.12.5 Contractor must fabricate and affix label plates IAW MIL-DTL-15024 for each of the newly installed padeyes. Label plates must include:

Max working load

Dynamic test Load

Test Date

3.1.12.6 Perform touch-up preservation to padeyes and welds in accordance to SFLC Std Spec 6310 paragraph 3.1.10.3 (Touch-ups and minor coating repairs).

3.1.13 Work Coordination. Contractor must coordinate this work item with work item Cofferdam Install.

NOTE

Ensure any systems not directly related to engine work that are identified and to be disturbed to facilitate MPDE(s) renewal need to be tagged out by ships force prior to removal. All disturbed items are to be returned to original configuration within OEM specification and with OEM parts.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

20 (Rev-2)

3.2 Operational test, initial. Prior to commencement of work, the Contractor must witness Coast Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR.

3.3 24,000 hour MPDE Overhaul. Contractor must follow requirements and all required tasks listed on CG TP 7930 to perform an in-place 24,000 hour overhaul for MPDEs listed on table 1. Contractor must perform overhaul using tools as prescribed in CG TP 7026 and procedures listed in CG TP 7231A.

3.3.1 The Contractor must completely disassemble the MPDE listed on Table 1. Inspect engine components as per assembly instructions and repair or fit new components as required.

3.3.2 Contractor furnished equipment (CFE). Prior to starting engine overhaul, the Contractor must submit a CIR with a list of all CFE that is required to perform the engine overhaul. The list must include the part name, part number, and date of delivery (or estimated date, if not currently received) of all CFE to ensure all material arrives on time to support the work schedule.

NOTE

Engine block must be rotated on MPDE #2 only for Crankshaft Renewal.

3.3.3 Renew all elastomeric parts and seals.

3.3.4 Contractor must renew Crankshaft on MPDE #2.

3.3.5 Renew Crankshaft bearings on MPDE #2 Only.

3.3.6 All component inspections, measurements, and final torque actions must be observed by Coast Guard Inspector and Tech Rep.

3.4 Bilge touch-up and preservation. After disassembly of the engines and lifting of the engine blocks, The Contractor must perform touch-up preservation for areas not readily accessible when engines are in normal operating configuration. Include: Bilge, Engine surfaces, Reduction Gear, Foundations, Coupling guards. Prepare and coat surfaces to match existing adjacent surfaces. Apply colors in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs).

3.4.1 The Paint colors are listed in the Coatings and Color Manual COMDTINST M10360.3D

NOTE

The intent of paragraph 3.3.4 is to perform touch-up preservation to areas not readily available when engines are in normal operating configuration.

3.5 Reassemble the engines and restore the engine room. The Contractor must restore the engine and engine room for normal operations.

3.5.1 The Contractor must align the engines and install the Geislinger couplings.

3.5.2 The Contractor must provide engine fluids.

3.6 High and Low Pressure Intercoolers, Air Side Chemical Clean and Inspect. The Contractor must chemically clean and inspect the air sides of the high pressure and low pressure intercoolers and associated pre-heaters of the MPDE. Include CFR borescope pictures showing the condition of the

21 (Rev-2) intercoolers before and after cleaning. Label pictures with date. Cutter name, engine serial number and intercooler identification before and after cleaning.

3.7 Hose renewal. The Contractor must renew the flexible hose assemblies and expansion joints for the in accordance with SFLC Std Spec 5000, Appendix C, Paragraph C2.2 (Hose assemblies). Notify the CG Inspector at least 24 hours prior to removing hoses.

3.7.1 Hose inspection and verification. The attached tables show an approximation of hose lengths, sizes, part numbers, and fittings to be renewed that are listed for bidding purposes only. The Contractor must validate the hoses and fittings requiring renewal, noting any deviations from the tables. To prevent potential delays, submit a CIR providing proof of procurement of materials for the new hoses.

3.7.2 Prior to each hose disconnection, the Contractor must record equipment, supply, and return line information for use in later reconnection. Temporarily tag/label the hoses and transfer tags/labels to the new hoses to aid in reinstallation.

3.7.3 System fluid disposal. The Contractor must drain all existing fluids from the designated hoses;

dispose of removed fluids in accordance with all applicable Federal, state, and local regulations. In the process of removal of hoses, the Contractor must not dispose any fluid in tanks or bilges.

3.7.4 Immediately after disconnecting or removing hoses, the Contractor must completely seal all openings to the rest of the system using threaded caps, threaded plugs, or bolt-on blanks made of durable plastic or sheet-metal that is no less than 1/16-inch thick.

NOTE

Plastic bags, rubber gloves, and rags of any kind are prohibited from being used to prevent leaking from hoses and for system protection.

3.7.5 The Contractor must template new hose length from each removed hose. New hose type and size must be determined from hose removed. Select hoses may require in-place measurement and remain in place until replacement hose is ready for installation to minimize system down time. If hose has excess length, verify with CG inspector if excess length is required. Renew hose end fittings. Renew all o-rings, seals, two-part clamps, and mounting bolts. Dispose of removed hoses in accordance with all applicable Federal, state, and local regulations. Submit a CFR for any additional hose connections that require replacement not on the renewed hose.

3.7.6 Hydrostatic test. The Contractor must hydrostatically test all new hose assemblies with their attached fittings. Test pressure must be 150% of the rated working pressure of the hose. Ensure no leakage from or permanent deformation of pressure-containing parts by repairing all leaks and discrepancies. Submit a CFR documenting all certifications of pressure test results.

3.7.7 Flush the hoses following hydrostatic testing and cap the ends to prevent contamination. Flush to a condition free of grease, oil, flux, scale, dirt, loose particles or loose corrosion products, and all other contamination foreign to the base material of the surface.

3.7.8 Hose tags. The Contractor must provide new stamped or engraved metal hose tags with the following bulleted information, in accordance with SFLC Std Spec 5000, Figure C-1. Tag installation must be done in a manner that does not interfere with the normal hose flexing motion. Attach hose tags to their respective hose using metal strapping. Verify the tag can be slightly moved by hand, allowing the hose to expand and contract as designed while minimizing chaffing.

22 (Rev-2)

Hose Log Item Number (Serial Number)

Hydrostatic Test Pressure (psi)

Hydrostatic Test Date (DD/MM/YY)

Service Life (Replacement Date) Date (QTR "Q"/FY)

3.7.9 Hose Fitting Documentation. For each renewed hose assembly, the Contractor must submit the information listed below in…