HSCG40-16-Q-P45671_Specification_Pkg_Rev-1_dtd_05_January_2016.pdf

USCG 45750 (RB-M 45)

SPECIFICATION FOR UNPLANNED DRYDOCK REPAIRS

FY2016

Developed By: Alexandria M Fell

(Rev-1, 05 January 2016)

USCG 45750 (RB-M-45) UNPLANNED DRYDOCK AVAILABILITY FY2016

ii (Rev-1)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property ................................................................................. vi Consolidated List of Critical Inspection Items ........................................................................................... vii Principal Characteristics ............................................................................................................................ viii General Requirements WORK ITEM 1: General Welding, Provide WORK ITEM 2: Fendering System, Repair WORK ITEM 3: Main Diesel Engine(S) To Auragen Generator(S) And Jet Drive(S), Align WORK ITEM 4: Electrical Isolation, Perform; Auragen WORK ITEM 5: Diesel Tank(s), Refuel WORK ITEM 6: Diesel Fuel Tank, Defuel WORK ITEM 7: Marine Chemist Services, Provide WORK ITEM 8: Drydock WORK ITEM 9: Temporary Services, Provide WORK ITEM 10: Sea Trial Performance, Support, Provide WORK ITEM 11: U/W Body, Preserve (Partial – Condition B) WORK ITEM 12: Hull Plating (U/W Body), Inspect 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

1/5/2016 1 1 Removed Section 3.3: Bidding from Work Item and changed size specifications listed in Table 1: Welding Location

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 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 – as follows:

• MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

• Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

• Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws::

www.gpoaccess.gov

The Government is aware of the following internet web links where contractors may procure commercial specifications:

• American Welding Society (AWS): http://www.awspubs.com/index.php

• ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

• NFPA: http://www.nfpa.org

• SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS

Coast Guard Drawing 45 RB-M 084-002, Rev -, Docking Plan Coast Guard Drawing 45 RB-M 084-002, Rev –, Docking Plan Coast Guard Drawing 45 RB-M 110-001, Rev -, Hull Structure Coast Guard Drawing 45 RB-M 114-001, Rev -, Fendering Arrangement Coast Guard Drawing 45 RB-M 170-001, Rev -, Folding Mast Coast Guard Drawing 45 RBM 201-001, Rev -, Main Engine Arrangement Coast Guard Drawing 45 RBM 247-002, Rev -, Water Jet Propulsor Arrangement Coast Guard Drawing 45 RB-M 261-001, Rev -, Fuel Supply System Schematic Coast Guard Drawing 45 RB-M 261-001, Rev -, Fuel Supply System Schematic Coast Guard Drawing 45 RB-M 261-002, Rev -, Fuel Supply System Coast Guard Drawing 45 RB-M 261-002, Rev -, Fuel Supply System Coast Guard Drawing 45 RB-M 261-004, Rev -, Fuel Supply System Tubes Coast Guard Drawing 45 RB-M 261-005, Rev -, Fuel Supply System - Pipe Assemblies Coast Guard Drawing 45 RB-M 261-005, Rev -, Fuel Supply System – Pipe Assemblies Coast Guard Drawing 45 RB-M 261-100, Rev -, Fuel Fill and Vent Schematic Coast Guard Drawing 45 RB-M 261-101, Rev -, Fuel Fill and Vent Arrangement Coast Guard Drawing 45 RB-M 261-101, Rev -, Fuel Fill and Vent Arrangement Coast Guard Drawing 45 RBM 311-006, Rev -, APU System Coast Guard Drawing 45 RB-M 631-001, Rev -, Painting Layout http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace v (Rev-1)

COAST GUARD PUBLICATIONS

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

Manual Coast Guard Technical Publication (TP) 4934, SWBS 074, Dec 2014, Small Boat Diagrams for Hotwork Coast Guard Technical Publication (TP) 4934, SWBS 074, Sep 2014, Small Boat Diagrams for Hotwork Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and

Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures Surface Forces Logistics Center Standard Specification 8634 (SFLC Std Spec 8634), 2014, Drydocking Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), 2014, Temporary

Services

OTHER REFERENCES

ASTM International (ASTM) D3359, 2009, Standard Test Methods for Measuring Adhesion by Tape

Test ASTM International (ASTM) D4138, 2007, Standard Practices for Measurement of Dry Film Thickness of Protective Coating Systems by Destructive, Cross-Sectioning Means Commercial Item Description (CID) A-A-59316, Nov 2003, Abrasive Materials for Blasting MIL-PRF-24647, 2013, Paint System, Anticorrosive and Antifouling, Ship Hull The Society for Protective Coatings (SSPC) Surface Preparation Specification No. 1 (SSPC-SP 1), 2004, Solvent Cleaning The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 3), 2004, Power Tool Cleaning The Society for Protective Coatings (SSPC), June 1996, Paint Application Specification No. 2 (PA-2), Measurement of Dry Coating Thickness with Magnetic Gages vi (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)

2 N Repair Kit, Fender NSN: 2090-01-589-9430 or

PN: RBM-SRK

1 ea. 200.00

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

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

***Government-furnished property, which is to be supplied by either the vessel or the C4IT ServiceCenter vii (Rev-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)):

Work Item Title

3 Main Diesel Engine(S) To Auragen Generator(S) And Jet Drive(S), Align

11 U/W Body, Preserve (Partial – Condition B) viii (Rev-1)

PRINCIPAL CHARACTERISTICS

45' RB-M

PHYSICAL

Length overall 44 feet, 10.5 inches Unfixed height 20 feet 9 inches Beam, maximum 14 feet, 7.75 inches Full load draft 3 feet, 4 inches Full load displacement 36,500 pounds Max sustained speed 42.5 knots Range 250 nautical miles at 30 knots Mission limits 8 foot seas / 30 knot winds Survivability limits 12 foot seas / 50 knot winds

HULL

Hull manufacturer Marinette Marine Corp.

5086 (GRADE) Aluminum Hin- 2009

MACHINERY

Type 6, cylinder diesel engine Number of units 2, MTU's 60 series 825 hp Propulsion type 2, Rolls-royce water-jet

TANKS

1 (Rev-1)

00000_1115_FLT

REC_00000_FLT_Boats @ Commercial Facility (0914)

General Requirements

1. SCOPE

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

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

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and

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

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability.

NOTE

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

2 (Rev-1)

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

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

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

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

NOTE

Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes (provided in Chapter 6 of COMDTINST M10360.3) are strictly prohibited.

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

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

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

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

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

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

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

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

3.5.3 Regulatory notifications. The Contractor shall be responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The

3 (Rev-1)

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

3.5.4 Environmental manager. The Contractor shall appoint in writing an Environmental Manager for the project, and shall be responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager shall ensure compliance with Hazardous Waste Program requirements, including hazardous waste handling, storage, manifesting, and disposal; implement the Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas;

ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the Environmental Records binder and required documentation, including environmental permits compliance and close-out.

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

3.6 Local Policy.

3.6.1 Coast Guard turn-over preparation. The Contractor shall be aware that, upon arrival, after haul out, and prior to departing the Contractor’s facility, the Coast Guard crew shall be allowed to accomplish various tasks in preparation for the turn-over of the boat to the Contractor. The following conditions apply to this paragraph:

3.6.1.1 The Coast Guard requires a maximum of three days at the beginning of the contract, and three days at the end to accomplish various tasks.

3.6.1.2 The Contractor may commence/continue work during these time frames.

<<APM Note: Paragraph 3.6.1.3 pertains to 47’ MLB only. For all other SBPL assets delete this paragraph.>>

3.6.1.3 Coast Guard personnel will disconnect the Detroit Diesel Electronic Control (DDEC) System and any other electronic equipment, as required to avoid damage to systems arising from hotwork on the vessel during the availability.

3.6.1.4 Coast Guard personnel will remove the transducers after initial haul-out and reinstall prior to re-floating the vessel.

3.6.1.5 The Unit will contact the servicing ESD or ESU to setup removal/installation of the transducer if Unit personnel are unable to accomplish this task.

3.7 SFLC standard specification approved changes. The Contractor shall be aware that the following are approved changes to published SFLC 2014 Edition Standard Specifications and supersede published content:

3.7.1 SFLC Standard Specification 6310, Requirements for Preservation of Ship Structures.

4 (Rev-1)

3.7.1.1 SFLC Std Spec 6310, page C-2, Section C1.5.1. Change from "lead-containing paint as 0.06%" to "lead-containing paint as 0.009%".

3.7.1.2 SFLC Std Spec 6310, page 4, Section 2 References, Group- Other References. Add “The Society for Protective Coatings (SSPC) Paint Application Guide No. 11, 2008, Protecting Edges, Crevices, and Irregular Steel Surfaces by Stripe Coating”

3.7.1.3 SFLC Std Spec 6310, page Appendix C-6, add "Hempel Hempadur Multi-Strength GF 35870" with FED- STD-595 color "Black/Red" under ANTI-ABRASION COATING, ICE BREAKING CAPABLE VESSELS, <235’.

3.7.1.4 Standard Spec 6310, page Appendix A-7, Under "UNDERWATER (U/W) BODY/BOOT-TOP", Add line Column 1: Option for U/W Body and Boot-Top, Steel Hulls, <154', in Salt Water. Column 2: Blank. Column 3:

SSPC-SP 10/NACE NO. 2 using grit conforming to MIL-A-22262 / (1.5-3.5) - or - SSPC-SP WJ-2(M)/NACE WJ-2(M). Columns 4 and 5: Same as "U/W Body and Boot-Top, Aluminum Hull, High Speed (>30 knots)".

3.7.2 SFLC Standard Specification 0000 General Requirements.

3.7.2.1 SFLC Std Spec 0000, paragraph 1.3 ‘Acronyms and term definitions’, page 5, “PCL (Paint Containing Lead)” definition replaced by, “Any paint or coating containing lead in excess of 0.009 percent by weight (1.0 mg/cm2 or 90 ppm). Lead Based Paint (LBP) is an interchangeable term with PCL.”

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 mfgr.

CHECKPOINT 3 - AMBIENT CONDITIONS

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

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

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

CHECKPOINT 4 - PRE-SURFACE PREPARATION

Remove surface contaminants (soluble salts, loose rust, mud, and marine growth) with low pressure fresh water wash down (maximum 5,000 psi).

If oil and grease are present, perform solvent cleaning, as per SSPC SP-1.

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

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

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

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

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

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

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

CHECKPOINT 9 – FINAL INSPECTION

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

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

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

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

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

CHECKPOINT 10 – RECORD KEEPING

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

6 (Rev-1)

Name of QP-1/NACE Inspector Signature Cert. # Date / Time

7 (Rev-1)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

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-1)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

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-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 and 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

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils

Place Surface Profile Replica Tape Here

Reading:__________ mils Mean Mil Reading (IAW ASTM D4417-Method C) for above 15 readings: ______________

9 (Rev-1)

10 (Rev-1)

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

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 and 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 _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils Mean Mil Reading (IAW ASTM D4417-Method B) for above 10 readings (by column):

_____ mils _____ mils _____ mils _____ mils _____ mils

11 (Rev-1)

12 (Rev-1)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15

DATE TEST LOCATIONS CONDUCTIVITY

(MICROSIEMENS/CM)

13 (Rev-1)

14 (Rev-1)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

COATING MFG PRODUCT NAME BATCH # INDUCTION

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

15 (Rev-1)

07400_AKP_1114_BOAT_FLT

WORK ITEM 1: General Welding, Provide

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to provide general welding.

TABLE 1- WELDING LOCATION

LOCATION SIZE

Stbd fwd hull Renew approximately 15 sq ft of

1/4 in 5086 Aluminum hull plating

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 4934, SWBS 074, Sep 2014, Small Boat

Diagrams for Hotwork Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None

16 (Rev-1)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

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

3.2 Requirement. The Contractor shall provide general welding, including but not limited to, fabrication, brazing, inspection, plate renewal, crack repair, overlay, and associated processes on Coast Guard vessels and equipment in accordance with TP 4934 and SFLC Std Spec 0740.

3.3 Touch-up preservation, general. The Contractor shall prepare and coat all new and disturbed exterior and interior surfaces, as applicable, to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.)

4. NOTES

This section is not applicable to this work item.

17 (Rev-1)

11020_AKP_0515_45RBM

WORK ITEM 2: Fendering System, Repair

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to repair the fendering system as listed in Table 1below.

TABLE 1- FENDER REPAIR LOCATION

LOCATION TYPE OF DAMAGE SIZE

Fwd stbd hull above hull identification markings

Scrape and cracks Approximately 6 sq ft

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

N Repair Kit, Fender NSN: 2090-01-589-9430 or

PN: RBM-SRK

1 ea. 200.00

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 45 RB-M 114-001, Rev -, Fendering Arrangement

COAST GUARD PUBLICATIONS

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

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

18 (Rev-1)

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures - general. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

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

3.2 Repair. The Contractor shall repair the fender sections listed in Table 1 in accordance with the manufacturer’s instructions contained in the repair kit, Coast Guard Drawing 45 RB-M 114- 001 and SFLC Std Spec 0000.

3.3 Government-furnished property. The Contractor shall be aware that the government reserves the right to provide new fender sections when a benefit to the US Coast Guard can be obtained.

19 (Rev-1)

24000_AKP_1115_45RBM

WORK ITEM 3: Main Diesel Engine(S) To Auragen Generator(S) And Jet Drive(S), Align

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to align the Main Diesel Engine(s) (MDE) to the Auragen Generator(s) and the MDE(s) to the Jet Drive(s).

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 45 RBM 201-001, Rev -, Main Engine Arrangement Coast Guard Drawing 45 RBM 247-002, Rev -, Water Jet Propulsor Arrangement Coast Guard Drawing 45 RBM 311-006, Rev -, APU System

COAST GUARD PUBLICATIONS

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

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

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

• 3.2.1 MDE/ Auragen Generator Preliminary Alignment Check

• 3.2.2 MDE to Jet Drive Preliminary Alignment Check

• 3.2.3 Engine Mounts

20 (Rev-1)

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

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

• Primary Fuel Filter Assembly

• Marine Interface Module

NOTE

Coast Guard personnel will operate all vessel machinery and equipment.

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

CAUTION

The Coast Guard crew will complete Red Danger Tags IAW COMDTINST 9077.1 (series) and attach them to the following:

Circuit Breaker CB2, ENGINE PRIMARY, Power Panel 24 VDC

ENGINE BUS 24P2, “OFF”.

Circuit Breaker CB1, ENGINE SECONDARY, Power Panel 24 VDC

VITAL BUS 24P1, “OFF”.

Affected MDE Propulsion Raw Water Suction Valve, Lazarette, “CLOSED”.

Affected MDE Propulsion Raw Water De-Icing Valve, Lazarette, “CLOSED”.

Affected MDE Fuel Shutoff Valve, Engine Room, “CLOSED”.

Affected MDE Secondary Fuel Filter Shutoff Valve, Engine Room, "CLOSED".

3.2 Preliminary alignment checks. The Contractor shall conduct preliminary alignment checks on the Main Diesel Engine(s) (MDE) to the Auragen Generator(s) and the MDE(s) to Jet Drive(s) in accordance with SFLC Std Spec 0000, Coast Guard Drawings 45 RBM 201-001, 45 RBM 247- 002 and 45 RBM 311-004.

3.2.1 MDE to generator preliminary alignment check. The Contractor shall conduct a preliminary alignment check. Submit A CIR.

3.2.1.1 Remove the generator drive shaft.

21 (Rev-1)

3.2.1.2 Remove the three roll pins from the Overhung Load Adapter (OHLA) shaft flange, (Refer to Figure 1).

3.2.1.3 Install the MDE to generator alignment tool, (Refer to Figure 2).

• Align the generator alignment tool flange (Item 1) to the OHLA shaft (Item 2) and install.

• Slide the alignment sleeve (Item 4) onto the generator alignment pin.

• Align the MDE alignment tool flange (Item 5) to the MDE adapter (Item 6).

3.2.1.4 Check the MDE to generator alignment, (Refer to Figure 3).

CAUTION

Do not force the alignment sleeve when checking MDE-to-Generator alignment. Forcing the alignment sleeve will cause the alignment sleeve to bind, damaging the surfaces of the alignment sleeve and the alignment sleeve pins.

• Slide the alignment sleeve (Item 1) towards the MDE adapter (Item 2).

• Verify the alignment sleeve slides to the MDE alignment pin mark (Item 3) using finger force.

• Slide the alignment sleeve towards the OHLA shaft (Item 4).

NOTE

Alignment is satisfactory if the alignment sleeve slides to each alignment pin mark using finger force.

Alignment is unsatisfactory if the alignment sleeve does not slide to each alignment pin mark using finger force.

• Verify the alignment sleeve slides to the generator alignment pin mark (Item 5) using finger force.

3.2.1.5 If alignment is unsatisfactory measure the offset distance between the two alignment pins, (Refer to Figure 4).

3.2.2 MDE to jet drive preliminary alignment check. The Contractor shall conduct a preliminary alignment check. Submit A CIR.

3.2.2.1 Remove the cardan shaft.

3.2.2.2 Install the MDE to jet drive alignment tool, (Refer to Figure 5).

• Align the MDE alignment tool flange (Item 1) to the reduction gear output flange

(Item 2) and install.

• Slide the alignment sleeve (Item 4) onto the MDE alignment pin (Item 5).

• Align the jet drive alignment tool flange (Item 6) to the jet drive input flange (Item

7).

3.2.2.3 Check the MDE to jet drive alignment, (Refer to Figure 6).

22 (Rev-1)

CAUTION

Do not force the alignment sleeve when checking MDE–to-Jet drive alignment. Forcing the alignment sleeve will cause the alignment sleeve to bind, damaging the surfaces of the alignment sleeve and the alignment sleeve pins.

• Slide the alignment sleeve (Item 1) towards the MDE adapter (Item 2).

• Verify the alignment sleeve slides to the MDE alignment pin mark (Item 3) using finger force.

• Slide the alignment sleeve towards the jet drive shaft (Item 4).

NOTE

Alignment is satisfactory if the alignment sleeve slides to each alignment pin mark using finger force.

Alignment is unsatisfactory if the alignment sleeve does not slide to each alignment pin mark using finger force.

• Verify the alignment sleeve slides to the jet drive alignment pin mark (Item 5) using finger force.

3.2.2.4 If alignment is unsatisfactory measure the offset distance between the two alignment pins, (Refer to Figure 4).

3.2.2.5 Measure the distance between the reduction gear output flange (Item 1) and the jet drive input flange (Item 2), (Refer to Figure 7). Distance is satisfactory if it is 16 inches +/- 3/32 inch.

3.2.3 Engine mounts inspect. The Contractor shall inspect the MDE(s) mounts. Submit A CIR.

3.3 Alignment. The Contractor shall align the MDE, (Refer to Figure 8).

• Use the offset measured from the MDE-Generator alignment check to determine direction of adjustment.

• Remove the nuts (Item 1) that secure the MDE (Item 2) to the aft MDE mounts (Item

3).

• Loosen the lower jam nut (Item 4) on the MDE mounts.

• Clean the threads of the nuts and the MDE mount using alcohol to remove any residual sealant or anti-seize.

• Lever the MDE in the direction needed to correct misalignment, ensuring to prevent damaging any hoses or accessories.

• It may be necessary to install the Engine Lift Tool, P/N: MMRBM0956, to adjust the

MDE alignment.

• Measure distance between reduction gear output flange and jet-drive input flange.

• Distance is satisfactory if it is 16 inches +/- 3/32 inch.

• Check MDE-Generator Alignment.

• If satisfactory, apply anti-seize compound, to the threads (Item 5) of the MDE

Mounts.

• Install and tighten two forward mount top lock nuts without applying torque

23 (Rev-1) specification to secure position.

3.3.2 The Contractor shall recheck MDE-Jet Drive Alignment.

3.3.3 The Contractor shall if satisfactory, apply anti-seize compound, P/N: 37230, to the threads (Item 5) of the MDE Mounts. (Item 2)

• Install and tighten two aft mount top lock nuts without applying torque specification to secure position.

• Repeat steps for MDE/Jet Drive Alignment until correct alignment is obtained.

• Tighten the nuts to 430 ft-lbs to secure the MDE to the MDE Mount using a torque wrench, P/N: A-A-2411, Torque Multiplier, P/N: J6202A, and Socket, 1-7/16" Deep, 3/4" Dr, P/N: 07523L, while holding the upper jam nut (Item 6) stationary with a Wrench, Check Nut, 38mm, P/N: JKEM38.

• Set the torque wrench to 131 ft-lbs to yield a torque multiplier output of 430 ft-lbs.

• Apply sealing compound, P/N: 242, to the threads (7) of the MDE Mount.

• Tighten the lower jam nut against the upper jam nut using Wrench, Check Nut, 38mm, P/N: JKEM38, while holding the upper jam nut stationary with a second Wrench, Check Nut, 38mm, P/N: JKEM38.

• Tap bottom wrench once firmly with hammer in the tightening direction to ensure secure fit.

3.3.4 The Contractor shall confirm the MDE to Jet Drive alignment is satisfactory and that the MDE to Generator alignment is satisfactory. Submit a CFR.

3.4 Remove the MDE-Jet Drive alignment tool. The Contractor shall remove the alignment tool as follows:

• Remove the four bolts (Item 8) that secure the jet-drive alignment tool flange (Item

6) to the jet-drive input flange (Item 7), (Refer to Figure 1).

• Remove the jet-drive alignment tool flange from the jet-drive input flange.

• Remove the alignment sleeve (Item 4) from the MDE alignment pin (Item 5).

• Remove the four bolts (Item 3) that secure the MDE alignment tool flange (Item 1) to the reduction gear output flange (Item 2).

• Remove the MDE alignment tool flange from the reduction gear output flange.

3.4.1 Install the cardan shaft.

3.5 Remove the MDE-Generator alignment tool. The Contractor shall remove the alignment tool as follows:

• Remove the three shoulder bolts (Item 7) that secure the MDE alignment tool flange (Item 5) to the MDE adapter (Item 6).

• Remove the MDE alignment tool flange from the MDE adapter.

• Remove the alignment sleeve (Item 4) from the generator alignment tool (Item 1).

• Remove the three bolts (Item 3) that secure the generator alignment tool flange to the

OHLA shaft (Item 2).

• Remove the generator alignment tool flange from the OHLA shaft.

24 (Rev-1)

• Install the three roll pins (Item 1) to the OHLA shaft flange (Item 2), (Refer to Figure 1).

3.5.1 Install the generator drive shaft.

CAUTION

The Coast Guard crew will remove Red Danger Tags IAW COMDTINST 9077.1 (series) from the following and place in the normal operational position:

Circuit Breaker CB2, ENGINE PRIMARY, Power Panel 24 VDC

ENGINE BUS 24P2.

Circuit Breaker CB1, ENGINE SECONDARY, Power Panel 24 VDC

VITAL BUS 24P1.

Affected MDE Propulsion Raw Water Suction Valve, Lazarette.

Affected MDE Propulsion Raw Water De-Icing Valve, Lazarette.

Affected MDE Fuel Shutoff Valve, Engine Room.

Affected MDE Secondary Fuel Filter Shutoff Valve, Engine Room.

NOTE

Coast Guard personnel will operate all vessel machinery and equipment.

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

Submit a CFR.

4. NOTES

4.1 Related work items. Main Diesel Engine Mount Washers, Replace.

4.2 Tag-out. The Coast Guard crew will complete Red Danger Tags IAW COMDTINST 9077.1 (series) and attach them to the following:

• Circuit Breaker CB2, ENGINE PRIMARY, Power Panel 24 VDC ENGINE BUS

24P2, “OFF”.

• Circuit Breaker CB1, ENGINE SECONDARY, Power Panel 24 VDC VITAL BUS

24P1, “OFF”.

• Affected MDE Propulsion Raw Water Suction Valve, Lazarette, “CLOSED”.

• Affected MDE Propulsion Raw Water De-Icing Valve, Lazarette, “CLOSED”.

Affected MDE Fuel Shutoff Valve, Engine Room, “CLOSED”.

• Affected MDE Secondary Fuel Filter Shutoff Valve, Engine Room, "CLOSED".

25 (Rev-1)

4.3 Remove Tag-out. The Coast Guard crew will remove Red Danger Tags IAW COMDTINST

9077.1 (series) from the following and place in the normal operational position:

• Circuit Breaker CB2, ENGINE PRIMARY, Power Panel 24 VDC ENGINE BUS 24P2.

• Circuit Breaker CB1, ENGINE SECONDARY, Power Panel 24 VDC VITAL BUS 24P1.

• Affected MDE Propulsion Raw Water Suction Valve, Lazarette.

• Affected MDE Propulsion Raw Water De-Icing Valve, Lazarette.

• Affected MDE Fuel Shutoff Valve, Engine Room.

• Affected MDE Secondary Fuel Filter Shutoff Valve, Engine Room.

4.4 Coast Guard Personnel. Coast Guard Personnel will operate all vessel equipment and machinery.

FIGURE 1. OHLA SHAFT FLANGE ROLL PINS

26 (Rev-1)

FIGURE 2. GENERATOR ALIGNMENT TOOL

27 (Rev-1)

FIGURE 3. MDE - GENERATOR ALIGNMENT CHECK

28 (Rev-1)

FIGURE 4. MDE – GENERATOR AND JET DRIVE ALIGNMENT PIN OFFSET

MEASUREMENT

29 (Rev-1)

FIGURE 5. MDE - JET DRIVE ALIGNMENT TOOL

30 (Rev-1)

FIGURE 6. MDE - JET DRIVE ALIGNMENT CHECK

31 (Rev-1)

FIGURE 7. MDE - JET DRIVE FLANGE DISTANCE MEASUREMENT

32 (Rev-1)

FIGURE 8. MDE MOUNT

33 (Rev-1)

33000_RDW_0915_45RBM

WORK ITEM 4: Electrical Isolation, Perform; Auragen

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform electrical isolation prior to conducting any welding procedures.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 4934, SWBS 074, Dec 2014, Small Boat

Diagrams for Hotwork Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

34 (Rev-1) off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

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

WARNING

Observe safety precautions when working with electrical and electronic equipment. Failure to adhere to this warning exposes personnel to the danger of electrical shock and personal injury.

The Coast Guard crew will complete Red Danger Tags IAW COMDTINST 9077.1 (series) and attach them to the following:

AC BUS 1 240 VOLT AC SELECTION SWITCH, AC Power Island, “OFF”.

AC BUS 2 240 VOLT AC SELECTION SWITCH, AC Power Island, “OFF”.

Circuit Breaker MAIN, Power Panel 24 VDC VITAL BUS 24P1, “OFF”.

Circuit Breaker DC MAIN, Power Panel 24 VDC ENGINE BUS 24P2, “OFF”.

Circuit Breaker DC MAIN, Power Panel 24 VDC NON-VITAL BUS

24P3, “OFF”.

Deutsch Circuit Breaker 12 VDC MAIN, Power Panel 12 VDC MAIN

PANEL 12P1, “OFF”.

Place the shore tie breaker on the pier in the following position:

“OFF”.

Disconnect the shore tie cable from the boat.

Circuit Breaker CB10 INST Lights, Power Panel 24 VDC NON-Vital

BUS 24P3, “OFF”

3.2 Magnetic compass. The Contractor shall disconnect the Magnetic Compass electrically and mechanically. The recommended mechanical removal is the three screws that secure the Magnetic Compass to the Console mount, leaving the mounting bracket undisturbed. Remove the Magnetic Compass from the vessel.

35 (Rev-1)

3.3 Disconnect batteries. The Contractor shall remove the two straps that secure the cover on the Port and Starboard Battery Box.

• Remove the Port Battery Box Cover.

• Disconnect the negative battery lead from the battery terminal.

• Wrap the negative battery lead with black electrical tape.

• Disconnect the positive battery lead from the battery terminal.

• Wrap the positive battery lead with black electrical tape.

• Place the cover on the Port Battery Box.

3.4 Auxiliary machinery compartment. The Contractor shall remove the lock wire from each of the electrical connectors, taking care not to damage the electrical connector or the clip. Perform the following steps for the port and starboard side.

3.4.1 Disconnect the three electrical connectors (Refer to Figure 1), (1) from the Port Inverter Charging System/Electronic Control Unit (ICS/ECU) (2) using soft jaw pliers.

CAUTION

When removing/installing the terminal connections for the dc positive and negative cables on the ICS/ECU, use a wrench on each nut to prevent the terminal stud from rotating. Rotation of the terminal stud will damage connections internal to the ICS/ECU and render the unit inoperable.

3.4.2 Disconnect the DC Negative Cable (Refer to Figure 2), (1) from the Port ICS/ECU (2).

3.4.3 Wrap the DC Negative Cable with electrical tape.

3.4.4 Disconnect the main system ground cable, 24B HULL GROUND, from the hull connection point. The hull connection point is located just aft of the starboard battery box on a main hull stiffener.

3.5 Engine room. The Contractor shall perform the following:

• Disconnect the Port Marine Interface Module (MIM) power cable ground wire from the MIM. Disconnect the Port MIM power cable, ENG 2-5, from the MIM, (Refer to Figure 5).

• Disconnect the Starboard MIM power cable ground wire from the MIM. Disconnect the Starboard MIM power cable, ENG 1-5, from the MIM,(Refer to Figure 5).

• Disconnect the two electrical connectors, W10 (Refer to Figure 3), (1), from the Port Auragen Generator (2).

• Remove the lockwire from the electrical connector (3), GEN 2-1, taking care not to damage the electrical connector.

• Disconnect the electrical connector, GEN 2-1, from the Port Auragen Generator using soft jaw pliers, P/N: TG69.

• Disconnect the two electrical connectors, W10, from the Starboard Auragen Generator.

• Remove the lockwire from the electrical connector, GEN 1-1, taking care not to

36 (Rev-1) damage the electrical connector.

• Disconnect the electrical connector, GEN 1-1, from the Starboard Auragen Generator using soft jaw pliers, P/N: TG69.

CAUTION

Ensure welding equipment ground is attached to the hull adjacent to the weld site to prevent equipment damage.

3.6 The Contractor shall now conduct welding repairs in Work Item # 1 of this Specification package.

3.7 Reconnect. After all welding is completed on vessel, the Contractor shall reconnect the following:

3.7.1 Engine room. The Contractor shall reconnect the electrical connector, GEN 1-1 (Refer to Figure 3), (3), to the Starboard Auragen Generator (2) as follows:

3.7.1.1 Tighten the connector by hand while simultaneously pushing the cable toward the connection ( it may be…