CHINOOK (WPB 87) UPDS FQ3 MWS 21R1.pdf

USCGC CHINOOK (WPB 87308)

SPECIFICATION FOR UNPLANNED DOCKSIDE REPAIRS

FY2021

Developed By: Michael W Soost

(Rev-1, 28 April 2021)

USCGC CHINOOK (WPB-87) UNPLANNED DOCKSIDE AVAILABILITY FY2021

ii (Rev-1)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property .................................................................................. v Consolidated List of Critical Inspection Items ............................................................................................. vi Principal Characteristics ............................................................................................................................. vii General Requirements WORK ITEM 1: Main Diesel Engines (MDEs), Port and Starboard - Reinstall WORK ITEM 2: Foundations, Both Main Diesel Engines (MDEs), Repair iii (Rev-1)

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-1)

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 87 WPB 131-001, Rev J, Deck Construction Plan

Coast Guard Drawing 87 WPB 182-001, Rev C, Main Engine & Generator Foundations

Coast Guard Drawing 87 WPB 201-001, Rev G, Machinery Arrangement

Coast Guard Drawing 87 WPB 243-003, Rev -, Propulsion Shaft Details

Coast Guard Drawing 87 WPB 635-001, Rev C, Linings and Insulation Plan & Details

COAST GUARD PUBLICATIONS

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

Coast Guard Technical Publication (TP) 4500, SWBS 233, Sept 2017, Engine Change-Out Guide –

Waterborne Main Diesel

Coast Guard Technical Publication (TP) 4531, SWBS 233, March 2003, Main Diesel Engine -

Description & Operation Manual - Model 8V396TE94

Coast Guard Technical Publication (TP) 4532, SWBS 233, Main Diesel Engine - Parts Catalog - Model

8V396TE94Coast Guard Technical Publication (TP) 4533, SWBS 233, Apr 2016 Main Diesel

Engine - Maintenance Manual - Model 8V396TE94

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

ASTM F10531053M – 94, Standard Guide for Steel Hull Construction Tolerances (Metric) v (Rev-1)

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

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

WORK

ITEM

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

1 N Soft Patch Kit NSN: 8040-01-601-2062 PN:

87SPK CPB-1 PATCH

2 ea.

1 Y *Alignment Kit N/A 1 set

1 N Clamp, synchro (8―

V-clamp), DeAngelo

Marine

NSN: 5340-01-568-6899 PN:

024-007000 4 ea.

1 N Clamp, Turbo Adaptor NSN: 5340-01-593-2913 PN:

024-001200 4 ea.

1 N Clamp, synchro

(12― V-band clamp)

NSN: 5340-01-590-8152 PN:

024-009000 4 ea.

1 N Nut, plain, hexagon NSN: 5310-01-F17-5302 32 ea.

1 N Washer, flat NSN: 5310-01-F17-4971 64 ea.

1 N Screw, cap, hexagon head

NSN: 5305-01-F17-4972

32 ea.

1 N Sealant, Silkolene NSN: 8030-01-593-2919 2 ea.

*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 vi (Rev-1)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

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

(Inspection report particulars)):

This section is not applicable to this specification.

vii (Rev-1)

PRINCIPAL CHARACTERISTICS

87' WPB

PHYSICAL

Length overall 87'

Length between perpendiculars 81' 7"

Depth 10' 11"

Maximum beam 19.4'

Draft, mean to design waterline 5' 9"

Height of highest projection 50.2'

Full load displacement 93.5 long tons

Minimum operating displacement 83.9 long tons

Displacement, light ship 77.9 long tons

Framing Longitudinal

Bulkheads Four watertight bulkheads located below the Main Deck

Anchor 40 lb Fortress with 480 ft. 3 strand 5/8" dia. Line stayset

HULL

Hull/main weatherdeck material ABS Grade AH 36

Superstructure 5086 Aluminum

MACHINERY

Main propulsion Two MTU 8V396TE94, sequential turbo-charged diesels

Reduction gears Two ZF Type BW 255

Propulsion shaft Two AQUAMET 22, 101.6mm

Shaft diameter 4"

Shaft seal Two John Crane mechanical seals

Shaft bearing, intermediate Thordon Elastomeric Bearing

Shaft bearing, aft Thordon Elastomeric Bearing

Number of propellers 2

Number of blades 5

Diameter of propeller 1040mm

Pitch 1230 mm fixed

Shaft RPM 828

Rudders Two 316L Stainless Steel

Ship's service generators Two Man Model D08241F01 diesel with Stanford 60KW Generator

TANK CAPACITIES

3-9-1-f (fuel oil) 1402 gal

3-9-2-f (fuel oil) 1402 gal

3-12-2-f (waste oil) 86 gal

3-12-1-f (oily water) 86 gal

3-7-0-q (sewage collection) 352 gal

3-7-1-q (grey water) 52 gal

3-12-1-w (fresh water) 200 gal

3-12-2-w (fresh water) 200 gal

1 (Rev-1)

00000_0121_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), 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

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.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

2 (Rev-1)

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

3.2 Contractor-provided fire extinguishers. The Contractor must provide portable fire extinguishers.

3.2 Fire watch requirements. The Contractor must refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec

0000, in accomplishing the following task:

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

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

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

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec

6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

3.3.2 Coating colors and system color schemes. Ensure that all colors and color coat/paint schemes are in accordance with COMDTINST M10360.3, Chapter 6 (Cutter and Boat Colors Exterior and Interior).

NOTE

Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes

(provided in Chapter 6 of COMDTINST M10360.3) are strictly prohibited.

3.4 Welding and brazing requirements. The Contractor 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.

3.5.1 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 (Rev-1)

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

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

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

National Pollutant Discharge Elimination System (NPDES) Storm Water (SW) Permit: Unit has an

NPDES SW permit which requires unit-specific procedures be followed for the storage and inspection of equipment and materials which may contribute contaminants to storm water discharges.

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

3.5.2 Test and procedures. The Contractor 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, 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, 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 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.

4 (Rev-1)

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.

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. None.

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:

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.

5 (Rev-1)

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

6 (Rev-1)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

VESSEL NAME HULL #

WORK ITEM

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

DATE

TIME

ACTIVITY (SURFACE

PREPARATION, PRIMER COAT,

BARRIER COAT, TOP COAT,

ETC…)

LOCATION (FRAME &

DECK, RELATION TO

EQUIPMENT, ETC.)

TEMPERATURE % REL.

HUMID-

ITY

DEW

PT.

SURFACE AMBIENT ΔT

| DP -

SURFACE |

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

7 (Rev-1)

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

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

8 (Rev-1)

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).

9 (Rev-1)

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)

10 (Rev-1)

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.

1 AVG. BMR DEVIATION

1 AVG. BMR DEVIATION

APPLICATION METHOD (AIRLESS,

CONVENTIONAL SPRAY, ROLLED)

AVERAGE DFT

11 (Rev-1)

23010_MWS_0421_87WPB

WORK ITEM 1: Main Diesel Engines (MDEs), Port and Starboard - Reinstall

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to reinstall both MDEs upon completion of all MDE foundation work.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

N Soft Patch Kit

NSN: 8040-01-601-2062

PN: 87SPK CPB-1 PATCH

2 ea.

Y *Alignment Kit N/A 1 set

N Clamp, synchro (8” V-clamp), DeAngelo Marine

NSN: 5340-01-568-6899

PN: 024-007000

4 ea.

N Clamp, Turbo Adaptor

NSN: 5340-01-593-2913

PN: 024-001200

4 ea.

N Clamp, synchro (12” V-band clamp)

NSN: 5340-01-590-8152

PN: 024-009000

4 ea.

N Nut, plain, hexagon NSN: 5310-01-F17-5302 32 ea.

N Washer, flat NSN: 5310-01-F17-4971 64 ea.

N Screw, cap, hexagon head NSN: 5305-01-F17-4972 32 ea.

N Sealant, Silkolene NSN: 8030-01-593-2919 2 ea.

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

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 131-001, Rev J, Deck Construction Plan

Coast Guard Drawing 87 WPB 182-001, Rev C, Main Engine & Generator Foundations

Coast Guadr Drawing 87 WPB 201-001, Rev G, Machinery Arrangement

Coast Guard Drawing 87 WPB 243-003, Rev -, Propulsion Shaft Details

Coast Guard Drawing 87 WPB 635-001, Rev C, Linings and Insulation Plan & Details

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 4500, SWBS 233, Sept 2017, Engine Change-Out Guide

– Waterborne Main Diesel

Coast Guard Technical Publication (TP) 4533,SWBS 233, Apr 2016 Main Diesel Engine -

Maintenance Manual - Model 8V396TE94

12 (Rev-1)

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

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

NOTE TO USERS:

3.1.2 Tech Rep. The Contractor must provide the services of a Certified W-6 Technical Representative to accomplish the following on site:

Advise on manufacturer's information, procedures, software, control systems, dimensions, and clearances associated with the system.

Conduct proper repair methods

Ensure compliance with manufacturer's procedures and standards during reinstallation and commissioning of the main diesel engines.

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

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

3.1.2.3 The Contractor shall notify COR at least two weeks prior to the expected date of sea trials so technical representative support services can be arranged.

3.1.2.4 The Contractor shall ensure that the MDE/reduction gear-to-propeller shaft alignment is performed under the direct supervision of personnel experienced in and regularly engaged in shaft and engine alignment. Personnel performing alignment work shall be familiar with manufacturer's installation techniques and be able to ensure compliance with engine/reduction gear manufacturer's installation standards. Personnel engaged in the supervision of the alignment work shall possess a résumé of demonstrated experience with engine and reduction gear systems.

3.1.2.4.1 Submit a copy of supervisor résumés and any applicable references to the COR at the Arrival

Conference.

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance

13 (Rev-1) with SFLC Std Spec 0000, (Vessel component, space, and equipment protection).

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

Engine foundation.

Piping.

Electrical wiring.

Valves.

Soft patch.

Insulation.

Exhaust and exhaust hangers.

Electronic equipment.

3.2 General. Using the references listed in Section 2 above, the Contractor must accomplish the following:

3.2.1 MDEs reinstallation.

3.2.1.1 Upon completion of all foundation work, remove all protective measures and coverings from the

MDEs and reinstall each MDE on their respective foundation.

NOTE

The Contractor must renew all disturbed fasteners when reinstalling removed components.

3.2.1.2 Connect all fluid, exhaust and electrical systems to the engine using all Government-furnished property listed under paragraph 1.2 as applicable. Furnish and fill all emptied engine fluids with the appropriate fluids in accordance with the technical publications.

NOTE

Ensure all exhaust system interfaces are resealed using the Government-furnished sealant.

3.2.1.3 Place the MDEs in operational condition in accordance with all tech rep pre-arrival requirements.

3.2.2 Alignment checks preparation. The Contractor must ensure the following conditions are met for at least 24 hours before the alignment checks on both MDEs:

Cutter fuel and water filled to normal operating levels, a minimum of three-quarters capacity.

All major equipment and machinery weighing over 500 pounds are either installed or simulated by equivalent weights appropriately located.

Arrangements made for divers to be on standby during alignment operations. Divers shall be used to plug the stern tube to prevent water ingress in the event of a malfunctioning emergency shaft seal.

All exhaust components reinstalled and engine fluids at proper capacity for both main diesel engines.

14 (Rev-1)

3.2.3 Initial coupling alignment checks. Prior to final setting of MDE/reduction gear mounts to the foundations, while using Coast Guard Drawings 87 WPB 182-001, 87 WPB 243-003, and Coast Guard

Technical Publication (TP) 4500, Enclosure 3, as guidance, the Contractor must measure the alignment between the MDEs/reduction gears and propulsion shafts. Record the initial coupling alignment readings on the form beneath 4.2 and submit as part of a CFR with any recommendation(s) necessary to achieve satisfactory alignment.

3.2.4 Alignment. If a Change Request has been authorized, the Contractor must align the affected

MDE(s)/reduction gear(s) to its respective propeller shaft(s).

3.2.5 MDE/reduction gear mounting. After achieving proper alignment for each MDE/reduction gear assembly to the propeller shaft, the Contractor must securely mount the MDE/reduction gear to the foundation.

NOTES

1. Chock resin mounting is required when the space between the foundation rail top and MDE/reduction gear mount foot bottom is 1/2” or greater. If a gap of 1/2” or greater is unattainable, submit a CFR.

2. When chocking the MDE/reduction gear assemblies in place, the

Contractor must abide by all chocking compound manufacturer’s instructions.

NOTES TO USERS:

1. DIN 931 Grade 10.9 bolts require higher torque to apply the proper tension to hold the bolts which may be adverse to maintaining alignment. DIN 931

Grade 8.8 bolts require lesser torque to maintain the holding tension

(clamping force) while remaining within allowable static loading and reducing risk to alignment. If Grade 8.8 bolts are desired, have the bolts be DIN 931

Grade 8.8 and Contractor-furnished. Per calculations, Grade 10.9 bolts will require a torque of 325 ft-lbs to achieve adequate bolt tension and exceeds allowable static stresses per ABS requirements. Grade 8.8 bolts require a torque of 233 ft-lbs to achieve adequate bolt tension.

2. While a locking method for the foundation mounting bolts is not shown in any documentation, a double-nut or a locking nut (or washer) is strongly advised. If a double nut is chosen, ensure the KTR procures the mounting bolts with adequate length to accept two nuts per bolt. Add a requirement to have the Contractor furnish the appropriate fasteners.

3.2.6 Final coupling alignment checks. After mounting the MDEs/reduction gears, while using Coast

Guard Drawings 87 WPB 182-001, 87 WPB 243-003, and Coast Guard Technical Publication (TP) 4500, Enclosure 3, as guidance, the Contractor must verify the alignment between the MDEs/reduction gears and propulsion shafts. Measure and record final coupling alignment readings on the form beneath 4.2 and submit as part of a CFR.

3.3 Soft patch renewal. After the completion of all work, the Contractor must renew the access soft patch seals using the Government-furnished kits.

3.4 Water hose test. The Contractor must inspect and perform a water hose test of all affected boundaries in accordance with SFLC Std Spec 0740, Appendix C. Submit a CFR.

15 (Rev-1)

3.5 Touch-up preservation, general. The Contractor must prepare and coat all new and disturbed exterior and interior surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.6 Operational test. The Contractor must demonstrate proper operation of all disturbed assemblies and components. During sea trials verify no unusual noise, vibrations, binding, etc. Submit a CFR.

3.7 Insulation renewal. Using Coast Guard Drawing 87 WPB 635-001, the Contractor must renew thermal bulkhead and/or overhead insulation, as applicable, that is removed/disturbed during the performance of this work item in accordance with SFLC Std Spec 0000.

4. NOTES

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

4.2 Alignment form.

16 (Rev-1)

HUB ALIGNMENT MEASUREMENT FORM

Vessel Name and Hull Number: _______________________

Circle each as appropriate: PORT / STARBOARD , INITIAL / FINAL

***ALL

MEASUREMENTS

IN INCHES

SHAFT INITIAL

POSITION

SHAFT

ROTATED

90°

SHAFT

ROTATED

180°

SHAFT

ROTATED

270°

Gap (.250” or larger required)

Parallel A

Parallel B

Parallel C

Parallel D

Angular A

Angular B

Angular C

Angular D

Inspection facility: ____________________ Date and time:_____________________

Inspector signature: _______________________________________________________________

17 (Rev-1)

S_18210_MWS_0421_SWIT

WORK ITEM 2: Foundations, Both Main Diesel Engines (MDEs), Repair

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to weld repair and drill new

MDE/reduction gear assembly mount holes on both MDE foundations.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 182-001, Rev C, Main Engine & Generator Foundations

Coast Guard Drawing 87 WPB 201-001, Rev G, Machinery Arrangement

COAST GUARD PUBLICATIONS

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

ASTM F10531053M – 94, Standard Guide for Steel Hull Construction Tolerances (Metric)

3. REQUIREMENTS

3.1 General.

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

None.

3.1.2 Tech Rep.

18 (Rev-1)

Not applicable.

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

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.2 MDE foundation repairs. Using the references listed in Section 2 above, the Contractor must weld fill both MDEs existing foundation holes and newly drill 16 MDE/reduction gear foundation holes for both

MDE/reduction assemblies (16 per engine, 32 holes, total).

WARNING!

Prior to drilling the foundation holes, the EXACT hole locations to be drilled must be established and accounted for via engine/reduction alignment to the propeller shaft for each MDE assembly. It is absolutely imperative for the

Contractor to accurately account for the new hole positions such that the established alignment is maintained and repeatable upon drilling completion and final reinstallation of both MDE assemblies.

3.2.1 Accurately survey and record the locations of the new foundation holes to be drilled for MDE assembly reinstallation for both MDEs. Submit a CFR.

3.2.2 Using Coast Guard Drawing 87 WPB 182-001 and ASTM F1053 as guidance, weld repair the existing foundation holes on both MDE foundations.

CAUTION!

Newly-welded surfaces must be fair to adjacent surfaces within tolerances specified by ASTM F1053.

3.2.4 In the presence of the Coast Guard Inspector, mark the positions of the new holes to be drilled.

3.2.5 Measure the distance between the foundation top and underside of each MDE/reduction gear mount.

Submit a CFR for approval.

NOTE TO USERS: If the gap between the foundation tops and mount bottoms are 1/2” or greater, the MDE(s)/reduction gear(s) should be chocked into place. Each hole should be per 182-001, Gen Note 15 +6mm (minimum), +10mm max. If the gap is <1/2”, then shims should be used and the holes drilled per Gen Note 15 as written – unless twisted foundation tops are suspected.

3.2.6 Upon approval of the CFR submitted under 3.2.5, drill the new foundation holes as directed by the

Coast Guard Inspector.

3.3 Touch-up preservation. The Contractor must prepare and coat all new and disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, (Touch-ups and minor coating repairs.)

19 (Rev-1)

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.3 Operational test, post repairs. After completion of work and in the presence of the Coast Guard

Inspector, the Contractor must thoroughly test and demonstrate the equipment listed below to be in satisfactory operating condition. Submit a CFR.

4. NOTES

This section is not applicable to this work item.