6.2.5 Commandant Instruction

Commandant United States Coast Guard

2100 Second Street SW Washington, DC 20593-0001 Staff Symbol: G-SEN-1 Phone: (202) 267-2951

COMDTINST M9000.6E

October 21, 2004

COMMANDANT INSTRUCTION M9000.6E

Subj: NAVAL ENGINEERING MANUAL

1. PURPOSE. This Manual promulgates Coast Guard Naval Engineering policy and selected procedures.

2. ACTION. Area and district commanders, commanders of maintenance and logistics commands, commanding officers of headquarters units, assistant commandants for directorates, Chief Counsel, and special staff at Headquarters shall comply with the provisions of this Manual. Internet release authorized.

3. DIRECTIVES AFFECTED. Naval Engineering Manual, COMDTINST M9000.6D is canceled.

4. SUMMARY OF CHANGES. This Notice incorporates all changes to previous editions of the Naval Engineering Manual and the following significant new changes:

a. Chapter 001:

Changed information in Section B “CHANGE PROCESS” to reflect new NEM change process.

b. Chapter 041:

This chapter was re-worded to define the CCB process. Updated List of Standard Boats.

c. Chapter 042:

Changed Sect A. “Hierarchy of Guidance” for Naval Engineering publications and directives. Providing new guidance for referenced specification usage.

DISTRIBUTION – SDL No. 142 a b c d e f g h i j k l m n o p q r s t u v w x y z

A 3 3 3 3 4 3 1 1 1 1 2 1 1 1 1 1 1 B 11* 20* 5 10 1 5 1 1 6 4 1 1 1 3 C 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 5 2 D 1 1 1 1 1* 1 1 1 1 1 E 1 F G 1 H NON-STANDARD DISTRIBUTION: *B:b Area TACLET Engineering staff (1 each)*B:c MLCs (6 extra); D:l SWOSCOLCOM, ATG Mayport, ATG Norfolk, ATG San Diego, ATG Pearl Harbor, TAFT Roosevelt Roads only

COMDTINST 9000.6E

d. Chapter 076:

New Chapter Added

e. Chapter 077:

Removed Industrial Hygiene Manual COMDTINST M6260.9 (series) as reference.

f. Chapter 079:

Corrected misspelled words in section D “Weight” and Section E “Damage Control Organization.” Updated Table 079-1 “Table Of Damage Control Organization.”

Removed all references to 133’ and 213’ cutters.

g. Chapter 080:

Updated Integrated Logistics Support Requirements.

h. Chapter 081:

Introduces Lead MLC for Cutter Classes. Changed Sect G.1.c Provides MLC direction for use of cutter class Standard Support Level (SSL) allocated each Fiscal Year.

Distributing SSL funds to be strictly used to address the maintenance needs for specific platforms within the class, or otherwise gain concurrence from operational commanders.

Removed all references to 133’ and 213’. Section F. redefines management of the Engineering Change process to include new scoring and resource allocation methodology to ensure highest priority needs are consistently acted on.

i. Chapter 083:

Added Supply Policy and Procedures Manual (SPPM), COMDTINST M4400.19 (series) as a reference in section C “APPROPRIATIONS.”

j. Chapter 085:

Rewrote Section D. Para 3 MANAGEMENT OF ENGINEERING DRAWINGS FOR COAST GUARD PLATFORMS: to incorporate referencing NE-TIMS.

k. Chapter 086

Updated ELC Technical Information Management Branch (O2T) to (O5T) in all references.

l. Chapter 088:

New definition of Maintenance Augmentation Teams (MAT)

m. Chapter 090:

Removed 090 G.; ADDITIONAL RECORDS: Added Oil History Log (Cutters only);

Degaussing Folder; Record of tank inspections; and Zinc Log. Removed Machinery Allowance Book; and Stability and Loading Booklet.

n. Chapter 233:

Modified tables 233-1 and 233-3. Updated Diesel Engine Maintenance Program

o. Chapter 262:

Changed address for submitting oil samples to the Navy Lab in Norfolk, Va. Changed wording to address new procedure in section C, “Lubricating Oil Testing and Analysis Procedures.”

p. Chapter 505:

Aligned verbiage to incorporate NSTM definitions.

q. Chapter 540:

Section A.3.a “Authorized Gasoline Containers” revised.

r. Chapter 541:

Updated new fuel requirements.

s. Chapter 555:

Removed Sections F.10 & G.1.b. Section G, definitions for Clothing/Battle Dress and Repair Party Firefighting Ensemble (FFE). Updated Section F.4 b. to include 2 other classes of vessels authorized Halon 1301. Updated Section H.4, Hose Replacement Schedule.

t. Chapter 570:

Aligned verbiage to incorporate NSTM definitions.

u. Chapter 573:

Changed Section C. PADEYES, CHOCKS, CLEATS AND BITTS. To: ATON

WEIGHTHANDLING FITTINGS.

v. Chapter 583:

Table 583-1 NOTES: Note 6 Changed to “Weight does not include 2000 pound cargo.”

w. Chapter 589:

Changed the format of the entire chapter.

x. Chapter 593:

Section E.3, contents completely revised

y. Chapter 634:

Made changes to Table 6341-1, “AUTHORIZED DECK COVERING MATERIAL”.

5. REQUESTS FOR CHANGES. Recommendations for improvements to this Manual should be submitted in accordance with chapter 001.

6. ENVIRONMENTAL ASPECT AND IMPACT CONSIDERATIONS. Environmental considerations were examined in the development of this Manual and have been determined not to be applicable.

7. FORMS AND REPORTS AVAILABILITY. Machinery History Card, CG-2929, SN 7530-

00-F01-2260; Operating Record Main Engines, CG-3186, SN 7530-00-F01-3000; Operating Record-Main Propulsion, CG-3186A, SN 7530-01-GF2-5750; Watch Quarter and Station Bill, CG-3485, SN 7530-00-F01-4340; and Request for Directives, CG-4428, SN 7530-00- F02-0620 may be ordered from Engineering Logistics Center (ELC) Baltimore. Ship’s Maintenance Action Form, OPNAV4790/2K, and Ship’s Maintenance Action Automated, OPNAV 4790/2Q can be found at http://forms.daps.dla.mil/. All other forms called for in this Manual are available in USCG Electronic Forms on SWSIII or on the Internet at http://www.uscg.mil/ccs/cit/cim/forms1/welcome.htm or the Intranet at http://cgweb.uscg.mil/g-c/g-ccs/g-cit/g-cim/forms1/main.asp.

ERROLL BROWN /s/ Assistant Commandant For Systems http://forms.daps.dla.mil/ http://www.uscg.mil/ccs/cit/cim/forms1/welcome.htm http://cgweb.uscg.mil/g-c/g-ccs/g-cit/g-cim/forms1/main.asp

Naval Engineering Manual

COMDTINST M9000.6E

Table of Contents

Chapter Section Title Page

001 INTRODUCTION

A Purpose 001-1 B Change Process 001-1 C Distribution 001-2 D Ordering 001-2 E Forms and Reports 001-2

041 ENGINEERING CHANGES

A General 041-1 B Engineering Changes Throughout the Lifecycle 041-2 C Definitions 041-3 D Engineering Change Process 041-4 E Engineering Change Administration 041-9 E Testing of Commercial Products 041-11

042 SPECIFICATIONS AND STANDARDS

A Hierarchy of Guidance 042-1 B Referenced Specifications 042-2 C Applicability of U.S. Navy GENSPECS 042-2 D Exceptions 042-2 E Naval Ships Technical Manuals (NSTM) 042-2 F Limited Rights Information 042-3

044 MACHINERY SPACE WATCH REQUIREMENTS

A General 044-1 B Inspections of Operating Machinery 044-1 C Unattended Main Propulsion Machinery Spaces 044-1

074 WELDING

A Grounding of Welding Machines 074-1 B Welding on Board Cutters and Boats 074-1 C Deployment Repairs 074-1 i

076 Reliability and Maintainability

A General 076-1 B Definitions 076-1 C Reliability and the Impact on Acquisitions 076-2 D Reliability Information 076-2 E Failure Reporting and Corrective Action Systems 076-3 F Reliability Centered Maintenance (RCM) 076-4 G Condition-Based Maintenance 076-7 H Quality Control 076-9 I Quality Assurance 076-10 J Risk Management 076-10

077 SAFETY

A General 077-1 B Gas Free Engineering/Confined Space Entry 077-1 C Walk in Refrigerator Alarm and Safety Systems 077-2 D Installed and Portable Eductors 077-3 E Mandatory Safety and Occupational Health Briefing 077-3 F Electrical Safety Program 077-4 G Equipment Tag-Out Procedures 077-4 H Use Of Diesel Fuel As A Solvent 077-5 I Gasoline 077-5 J Hydraulic Fluid 077-5 K Spray Shields and Protective Covers 077-6 L Self Contained Ionization Smoke Detectors 077-7 M Safety Precautions and Operating Instructions 077-7 N Safety Precautions for Gasoline Powered Boats 077-7 O Heat Stress 077-9 P Hearing Conservation 077-9 Q Repairing And Removing Asbestos 077-9 R Spray Painting Inside Ships 077-9 S Ordnance and Ammunition 077-9 ii

079 STABILITY AND DAMAGE CONTROL

A Stability Information 079-1 B Flooding Casualty Control Software (FCCS) 079-2 C Stability Requirements 079-2 D Weight 079-3 E Damage Control Organization 079-3 F DC Books, DC Diagrams and 079-6 Compartment Check Off Lists (CCOL's) G Material Conditions Of Readiness and 079-17 Damage Control Classifications H Compartmentation and Deck Numbering 079-17 System I Watertight Integrity Tests and 079-21 Inspections J Engineering Casualty Control Manual 079-21

080 INTEGRATED LOGISTICS AND SUPPORT REQUIREMENTS

A Integrated Logistics Support (ILS) 080-1 B Integrated Logistic Support Plan (ILSP) 080-1 C Integrated Logistic Support Management Team (ILSMT) 080-1 D Cutter Support Review (CSR)/Equipment Support 080-1 Review (ESR)

081 MAINTENANCE OF CUTTERS AND BOATS

A General 081-1 B Reliability Centered Maintenance (RCM) 081-1 C Levels of Maintenance 081-1 D Lead MLC Designations 081-2 E Types of Maintenance 081-2 F Management 081-4 G Maintenance and Financial Program 081-6 H Cutter and Boat Funding Accounts and Responsibilities 081-8 I Naval Engineering Re-Capitalization (AFC-45) 081-9 J AFC-30 Cutter Financial Programs 081-10 K AFC-42 Electronic Financial Programs 081-11 L Configuration Management Concerns 081-11 M Maintenance and Financial Program 081-11 N Maintenance Days 081-12 iii

083 SUPPLY SUPPORT

A General 083-1 B Responsibility 083-1 C Appropriations 083-1

085 COAST GUARD NAVAL ENGINEERING DRAWINGS

A Introduction 085-1 B Definitions 085-1 C General 085-4 D Management of Engineering 085-4 Drawings for Coast Guard Platforms E Drawing Distribution 085-6 F Selected Record and Non-selected 085-7 Record Engineering Drawings G Drawing Title Blocks and Numbering System 085-9 H Electronic (AutoCad) File Labeling Convention 085-11 I New Drawing Preparation 085-12 J Drawing Revisions 085-12 K Revision Procedures for Special Situations 085-14 L Superceding a Drawing 085-15 M Canceling a Drawing 085-16 N Technical Publication Drawings 085-16

086 TECHNICAL PUBLICATIONS

A Naval Engineering Technical Publications. ELC (05T) 086-1 B Naval Engineering Job Aids 086-2

088 PERSONNEL

A Naval Engineering Shore-Based Support Teams 088-1 B Force Management 088-2 C Engineer Officer In Training (EOIT) Program 088-3 D Naval Engineering Postgraduate (PG) 088-3 and Advanced Training (NET) Programs E Duties of Shore Unit Engineering Personnel 088-3 iv

090 INSPECTIONS, RECORDS, REPORTS, AND TESTS

A General 090-1 B General Inspections and Tests 090-1 C Hull History, Machinery History, 090-2 Resistance Test Records, And Current Ship's Maintenance Projects (CSMP) D Engineering Department Records and Accounts 090-5 E Reports 090-10 F Naval Engineering Cutter Materiel Assessment 090-13 G Additional Records 090-13 H Relief of the Engineer Officer or Engineer Petty Officer 090-14 I Maintenance of Boat Record Files 090-14 J Procedures For Lists of Top Ten 090-15 Maintenance Problems

091 SURVEYS OF CUTTERS AND BOATS

A Service Life 091-1 B Ship Structure and Machinery 091-1 Evaluation Board (SSMEB) C Boards of Survey for Boats 091-6

094 FULL POWER TRIALS

A Full Power Trials for Cutters 094-1 B Full Power Trial for Standard Boats 094-1

097 STABILITY TESTS

A General 097-1 B Stability Test Frequency And Schedule 097-1 C Test Personnel 097-1 D Stability Test Reports; Review and Approval 097-2 E Stability Test Procedures 097-2

110 BOAT STRUCTURE

A General 110-1 v

233 INTERNAL COMBUSTION ENGINES

A Diesel Engine Maintenance Program Overhaul Guidance 233-1 B Diesel Engine Maintenance Program 233-8 Performance Monitoring C Performance Tests of Shipboard and 233-16 Shore-Based Gasoline and Diesel Boat Engines D Marking Boat Instrument Panel Gauges 233-17 E Diesel Engine Crankweb Deflection Requirements 233-18

235 ELECTRIC PROPULSION

A Propulsion Dielectric Absorption Tests 235-1 B In-Place Cleaning of Direct Current 235-1 Propulsion Motors and Generators C High-Potential Test 235-2

243 PROPULSION SHAFTING

A General 243-1

244 PROPULSION BEARINGS

A Bearing Stave Material 244-1 B Bearing Sleeves 244-1 C Cutlass Bearings 244-1 D Bearing Clearance Criteria 244-1

245 PROPELLERS

A Propellers for Boats 245-1

254 CONDENSERS AND HEAT EXCHANGERS

A Zinc Anodes in Condensers and Heat Exchangers 254-1 B Installation and Maintenance Requirements 254-2

262 LUBRICATING OILS

A General 262-1 B Diesel Engine Lubricating Oil Policy 262-1 C Lubricating Oil Testing and Analysis Procedures 262-4 D Two-Stroke Cycle Gasoline Engine 262-32 Lubricating Oil vi

300 ELECTRIC PLANT (GENERAL)

A Shore Electric Power Facilities 300-1

475 DEGAUSSING

A Degaussing Installations 475-1

505 FLEXIBLE HOSE PROGRAM

A General 505-1 B Hose Classification 505-1 C Hose Log 505-2 D Hose Replacement Schedule 505-3 E Hose Shelf Life 505-3 F Hose Service Life 505-4 G Hose PMS and Inspections 505-4 H Hydrostatic Testing 505-5 I Hose Selection 505-5 J Expansion Joints (Flex Joints) 505-6 K Hose and Flexible Joint Tags 505-7

517 AUXILIARY BOILERS AND FORCED CIRCULATION

STEAM GENERATORS

A Feedwater Treatment 517-1 B Feedwater Testing 517-2 C Supplemental Requirements for All 517-4 Boilers and Steam Generators

530 POTABLE WATER SYSTEMS

A Potable Water Systems 530-1 B Treatment of Evaporator Feedwater 530-1 C Chemical Cleaning of Evaporators 530-1 D Joint Sealing Compounds 530-1

540 GASOLINE, HANDLING AND STOWAGE

A Gasoline, Gasoline Equipment, and Stowage 540-1 vii

541 FUEL SYSTEM, CUTTERS AND BOATS

A Fueling Evolutions 541-1 B Authorized Fuels for Cutters and Boats 541-1 C Onboard Fuel Management 541-7 D Fuel Request/Logreqs 541-12 E Reporting Fuel Problems 541-12 F General Questions 541-13

542 FUEL SYSTEM, SHIPBOARD AVIATION

A Shipboard JP-5 Aviation Fuel Handling 542-1 B Maintenance of Equipment 542-1

550 COMPRESSED GAS CYLINDERS

A General 550-1 B Hydrostatic Testing Intervals 550-1 C Identification Marks 550-2 D Test Facilities 550-2 E Use of Non-Shatterable Cylinders 550-2

551 COMPRESSED AIR SYSTEMS

A Compressed Air Plants and Systems 551-1 B Moisture Separators and Air Oilers 551-1

555 FIREFIGHTING

A Firefighting Equipment and Procedures 555-1 B Firefighting Organization 555-1 C Maintenance 555-1 D Authorized Equipment 555-1 E Firefighting Agents 555-1 F Firefighting Equipment and Installation 555-2 G Protective Equipment 555-6 H Flexible Hose in Firefighting Service 555-9

556 HYDRAULIC EQUIPMENT

A General 556-1 B Inspection and Maintenance 556-1 C Hydraulic Hose Renewal 556-1 D General Requirements for Cleaning and 556-1 Flushing Hydraulic Systems viii

570 GENERAL DUTY AND REPLENISHMENT WEIGHT

HANDLING SYSTEMS

A General 570-1 B General Design Requirements 570-3 C Charts 570-6 D Label Plates 570-6 E Inspection and Testing 570-6

571 REPLENISHMENT-AT-SEA (RAS) SYSTEMS

A Testing and Inspection of RAS Fittings 571-1 B Frequency 571-1 C Method of Inspection 571-1 D Load Test Records 571-1

573 CARGO HANDLING SYSTEMS

A Booms and Frames 573-1 B Chain Stoppers 573-7 C ATON Weight Handling Fittings 573-9

581 ANCHOR(S) AND ANCHOR CHAIN MAINTENANCE

A General 581-1 B Periodicity 581-1

583 LIFE RAFTS, LIFE FLOATS,

AND BOAT HOISTING EQUIPMENT

A Inflatable Life Rafts and Life Floats 583-1 B Tests and Inspection of Boat Hoisting Equipment 583-1

588 HELICOPTER HANDLING

A Helicopter Deck Tie-Down-Fitting Testing 588-1

589 CRANES

A General 589-1 B Crane Inspections 589-2 C Crane Tests 589-5 D Safety 589-8 ix

591 OCEANOGRAPHIC RESEARCH EQUIPMENT

A General 591-1 B Standard Loads 591-1 C Weight Handling System Structural 591-1 Design and Test Policy D Dynamic Test Loading 591-2 E Science Wires 591-2

593 ENVIRONMENTAL POLLUTION CONTROL SYSTEMS

A General 593-1 B Shipboard Regulations 593-1 C Contract Provisions 593-1 D Polychlorinated Biphenyls (PCBs) 593-1 E Incinerators 593-2

613 RIGGING

A Wire Rope 613-1 B Wire Rope Fittings 613-10 C Sheaves 613-11

630 PRESERVATIVES AND COVERINGS

A Paint 630-1 B Cathodic Protection 630-1

634 DECK COVERINGS

A General 634-1 B Authorized Materials 634-1

635 THERMAL INSULATION

A General 635-1 B Asbestos Policy 635-1

640 LIVING AND BERTHING SPACES

A Habitability Improvement of Cutters 640-1 B Habitability Improvements That Require 640-1 Engineering Changes x

670 STOWAGE, HANDLING, AND DISPOSAL OF

HAZARDOUS MATERIALS

A General Policy 670-1 B Inventory 670-1 C Stowage 670-1 D Handling 670-1 E Disposal 670-1 F Electronic Records 670-2

700 ORDNANCE, GENERAL

A General 700-1 B Coast Guard Module Test and Repair 700-1 (MTR) Program C NESU Held Navy Ordnance Support Equipment 700-1

834 COMPUTER PROGRAMS

A Computer Programs For Engineering Use 834-1 B Installation & Utilization Requirements 834-1 C Distribution of Software 834-2

997 DOCKING INSTRUCTIONS FOR CUTTERS AND BOATS

A Cutters 997-1 B Boats 997-2 xi

TABLES

Table Title Page

TABLE 041-1 List of Standard Boats 041-1 TABLE 079-1 Table of DC Organization 079-6 TABLE 079-2 CCOL Format 079-13 TABLE 079-3 Table of Required Bills 079-29 TABLE 081-1 Lead MLC for Cutter Classes 081-2 TABLE 081-2 Maintenance Days 081-14 TABLE 085-1 Drawing Revision and Signature Authority 085-6 TABLE 091-1 Sheets of Form CG-3496 091-4 TABLE 091-2 SSMEB Schedule & Remaining Service Life 091-12 TABLE 233-1 Engine Application Table 233-3 TABLE 233-2 Available Overhaul Kits 233-6 TABLE 233-3 Engine Pressure & Temperature Chart 233-18 TABLE 245-1 Table of Propellers for Boats 245-2 TABLE 262-1 Approved Engine Oil Exceptions Table 262-1 TABLE 262-2 Wear Metal Threshold Limits 262-21 TABLE 262-3 Oil Trend Analysis Decision Making Guide 262-24 TABLE 262-4 Oil Physical Test Criteria 262-25 TABLE 262-5 Significance of Wear Metals & Source 262-26 TABLE 262-6 Standard Lab Recommendation Codes for 262-27 Spectrometric Analysis TABLE 475-1 Degaussing Coils 475-2 TABLE 573-1 Inspection & Overhaul Frequency for 573-11 Booms & Frames TABLE 573-2 SWL/Dynamic Test Weights Booms & Frames 573-13 TABLE 573-3 Science Frame Ratings & Test Requirements 573-14 TABLE 583-1 Weights for Testing Davits/Lifting Gear 583-4 TABLE 589-1 Inspection & Overhaul Frequency for Cranes 589-11 TABLE 589-2 SWL/Dynamic Test Weights for Cranes 589-12 TABLE 589-3 SWL/Dynamic Test Weights for 589-15 225’ WLB & 175’ WLM Cranes TABLE 634-1 Authorized Deck Covering Material 634-1 xii

FIGURES

Figure Title Page

FIGURE 041-1 Platform Engineering Change Process 041-13 FIGURE 041-2 System Engineering Change Process (HM&E) 041-14 FIGURE 041-4 Engineering Change Request (page 1) 041-15 FIGURE 041-5 Engineering Change Request (page 2) 041-16 FIGURE 081-1 Vessel Logistics System Maintenance Management 081-5 FIGURE 090-1 Sample EO/EPO Relieving Letter 090-17 FIGURE 090-2 Sample CO/OINC Forwarding Letter 090-19 FIGURE 090-3 Top Ten List 090-19 FIGURE 090-4 New Item Support Form 090-21 FIGURE 090-5 EO/EPO Relief Checklist (Afloat) 090-22 FIGURE 090-6 EO/EPO Relief Checklist (Ashore) 090-27 FIGURE 262-1 DD Form 2026 262-15 FIGURE 262-2 Wear Metal Concentration Vs Constant 262-19 Oil Replenishment FIGURE 262-3 Wear Metal Concentration Vs Periodic 262-19 Oil Addition and Oil Change FIGURE 262-4 Example of Equipment History 262-22 xiii xiv

APPENDICES

Appendix Title Page

APPENDIX A COAST GUARD CUTTER STABILITY TEST PROCEDURES

A Stability Test Procedure A-1 B Preparation for Testing A-1 C Conduct of Test A-8 D Test Results A-15

APPENDIX B CUTTER AND BOAT INTERIOR PAINTING SYSTEM

A Vessel Coating System - Interior B-1

APPENDIX C NAVAL ENGINEERING MANUAL FORMS LIST

A Forms List C-1

APPENDIX FIGURES

Figure Title Page

FIGURE A-1 Double Bottom Tank Sounding A-4 FIGURE A-2 Sketch of Mooring A-6 FIGURE A-3 Line Arrangement A-7 FIGURE A-4 Satisfactory Pendulum Arrangement A-11 FIGURE A-5 Tangent Plot A-14 FIGURE B-1 Coating System by Compartment B-3 FIGURE C-1 Naval Engineering Manual Forms List C-1

CHAPTER 001. INTRODUCTION

A. PURPOSE. The Naval Engineering Manual (NEM), COMDTINST M9000.6 E, is published to promulgate Coast Guard Naval Engineering policy and selected procedures.

Area commanders, unit commanding officers, and officers-in-charge responsible for the operation, maintenance, repair, and alteration of HM&E systems on cutters and standard boats shall comply with the guidance provided in this Manual. In addition, Weapons officers and Weapons petty officers responsible to their respective commands for maintenance, repair, and alteration of Navy-owned ordnance systems shall also comply with the guidance provided in this Manual.

1. The NEM includes certain technical information not readily available in other reference documents. When adequate information is available from another source, this Manual references the appropriate source. Such information will not be duplicated in this Manual.

2. The NEM contains detail only to the extent necessary to clearly establish information reporting requirements and/or define testing, maintenance, repair, and engineering change procedures not sufficiently explained elsewhere. It shall be the responsibility of the Area Commander/Maintenance and Logistics Commander to develop and promulgate the detailed procedures necessary to execute this policy.

3. The indexing format for the NEM generally conforms with the Ship Work Breakdown Structure (SWBS), NAVSEA 0900-LP-039-9010, as used in the Naval Ships Technical Manual (NSTM).

B. CHANGE PROCESS. To ensure this Manual remains up-to-date, coincides with current practices, and continues to meet program needs, future change proposals shall be forwarded as specified in the following paragraphs.

1. Change proposals may be originated at any organizational level. Proposals shall be submitted via web-enabled form located on the Office of Naval Engineering (G-SEN) website at http://cgweb.comdt.uscg.mil/g-sen/resources/nem.htm.

2. The web form requests the following information: change originator’s name / rate / rank, unit, phone number, e-mail, NEM chapter reference, section title, proposed new text, background / reason for change and suggested references (if any). When the change proposal is submitted, the web form will display a confirmation page with instructions and point of contact for following-up. The proposal will then be e-mailed automatically to the NEM Manager at G-SEN-1.

3. Upon receipt, the G-SEN-1 NEM Manager will initiate the following action:

a. Immediately contact the change proposal originator to confirm receipt of the submission.

001-1 http://cgweb.comdt.uscg.mil/g-sen/resources/nem.htm

b. Conduct a thorough investigation of the proposal to justify the need, identify possible conflicts with other directives and publications, and assess the affects of implementation.

c. Forward the proposal to the appropriate NEM Chapter Owner who is the point of contact for technical review.

4. Upon receipt, the NEM Chapter Owner will:

a. Immediately contact the change proposal originator to confirm receipt of the submission

b. Conduct a technical review of the change proposal. The Chapter Owner is responsible for ensuring that all interested parties (including MLC’s) are provided an opportunity to review the change proposal and provide concur/non-concur input.

c. Contact the change proposal originator to discuss the proposal and background. If the change is not approved, the Chapter Owner will notify the originator via e-mail with an explanation for the disapproval.

d. Approved changes will be forwarded to the G-SEN-1 NEM Manager for inclusion in the next revision.

5. G-SEN is the final approving authority and has overall responsibility for the Naval Engineering Manual.

a. All approved changes are immediately entered into the electronic version of the next NEM revision.

b. In December of each year the new revision of the NEM, including all changes submitted throughout the previous year, will be routed for sequential clearance to the Assistant Commandant for final approval.

c. Upon obtaining Assistant Commandant approval, the revision will be submitted to CG-612 for annual publishing to the online USCG Directives System. The most recent revision of the NEM is available online at http://cgweb.uscg.mil/g-c/g-ccs/g-cit/g-cim/directives/cgcim.html.

d. As hard copy printing and distribution of the NEM is a significant budget item, the revision will be sent to the printer for hard copy printing and distribution every other year at the beginning of even numbered years (ie: 2006, 2008 etc…).

The G-SEN-1 NEM Manager is responsible for ensuring that funding is requested and obtained for printing and distribution in the appropriate years.

C. DISTRIBUTION. Commandant (G-SEN) shall determine distribution of this Manual.

Requests for changes to the distribution should be submitted on "Request for Allowance

001-2 http://cgweb.uscg.mil/g-c/g-ccs/g-cit/g-cim/directives/cgcim.html http://cgweb.uscg.mil/g-c/g-ccs/g-cit/g-cim/directives/cgcim.html

001-3

Change" (Form CG-5323), addressed to Commandant (G-CIM), via the chain of command.

D. ORDERING. The Directives Publication and Reports Index (DPRI), COMDTNOTE 5600 provides guidance for ordering M9000.6E and its associated changes. Form CG- 4428, Request For Directives, shall be completed and forwarded to the appropriate stockpoint.

E. FORMS AND REPORTS. Machinery History Card, CG-2929, SN 7530-00-F01-2260;

Operating Record Main Engines, CG-3186, SN 7530-00-F01-3000; Operating Record- Main Propulsion, CG-3186A, SN 7530-01-GF2-5750; Watch Quarter and Station Bill, CG-3485, SN 7530-00-F01-4340; and Request for Directives, CG-4428, SN 7530-00- F02-0620 may be ordered from Engineering Logistics Center (ELC) Baltimore. Ship’s Maintenance Action Form, OPNAV4790/2K, and Ship’s Maintenance Action Automated, OPNAV 4790/2Q can be found at http://forms.daps.dla.mil/. All other forms called for in this Manual are available in USCG Electronic Forms on SWSIII or on the Internet at http://www.uscg.mil/ccs/cit/cim/forms1/welcome.htm or the Intranet at http://cgweb.uscg.mil/g-c/g-ccs/g-cit/g-cim/forms1/main.asp.

http://forms.daps.dla.mil/ http://www.uscg.mil/ccs/cit/cim/forms1/welcome.htm http://cgweb.uscg.mil/g-c/g-ccs/g-cit/g-cim/forms1/main.asp

CHAPTER 041. ENGINEERING CHANGES

A. GENERAL.

1. Scope. This chapter defines and promulgates processes to request, develop, and implement Engineering Changes. The Engineering Change process is used by the Coast Guard to field new equipments and systems as a control element in support of Configuration Management. Engineering Changes to electronic equipment under the authority of the Command, Control, Communications, and Computers Directorate (CG-6) shall follow the procedures outlined in the Electronics Manual, COMDTINST M10550.25 (series). Electronic Engineering Changes that impact HM&E equipment (i.e. power load, arrangements, weight, etc.) shall also follow the Engineering Change process outlined in this chapter. Engineering Changes to Navy-owned ordnance equipment (ORDALTs) are promulgated by the Naval Sea System Command and are not within the scope of this chapter. Ordnance Manual, COMDTINST M8000.2 (series), Chapter 4, contains policy and procedures regarding ORDALTs. This chapter complies with, but does not specifically address the Coast Guard Configuration Management guidelines outlined in Commandant Instruction 4130 (series). Naval Engineers shall be aware of these instructions prior to taking any significant role in the Engineering Change process.

2. Intent of Engineering Changes. Changes to cutters and boats which initially seem to be minor and simple, often accumulate to negatively impact system capability and operational availability. Additionally, it must be realized that the resources used to accomplish Engineering Changes typically reduce funding available for maintenance.

Many change requests have merit, but a lack of a clear, positive benefit to cost ratio across a cutter or boat class may prevent approval. In addition, limited funding may cause delays in Engineering Change execution.

All HM&E Engineering Change Requests (ECR)s will be reviewed using an Engineering Change Needs Analysis process maintained by the ELC. This analysis will determine if the ECR is necessary to meet operational requirements, address a safety or environmental issue, or provides enough cost benefit over the system’s life cycle to justify the expense of an Engineering Change. If an ECR does not warrant an Engineering Change it will be disapproved by the ELC or CCB and returned to the originator with the rationale for disapproval.

3. Applicability. The procedures set forth in this section apply to all cutters, standard boats, and Port Security Units. Standard boats are listed in Table 041-1. The respective District Commander must approve changes to nonstandard boats. The authority to change barges is delegated to the MLCs who shall administer Barge Engineering Changes.

Table 041-1: List of Standard Boats 14’ CB-S Cutter Boat, Small 18’ CB-M Cutter Boat, Medium

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22’ CB-L Cutter Boat, Large 24' CB-OTH Cutter Boat, Over-the-Horizon 25’ TPSB Transportable Port Security Boat 25' RB-S Response Boat, Small (includes Response Boat, Homeland

Security) 26’ MSB Motor Surf Boat, MK V 30’ SPC (SURF) Special Purpose Craft, Surf Rescue Boat 41’ UTB Utility Boat 44’ MLB Motor Lifeboat 45' RB-M Response Boat, Medium 47’ MLB Motor Lifeboat 49’ BUSL Buoy Boat, Stern Loading 52' SPC (HWX) Special Purpose Craft (Heavy Weather Surfboat) 55’ ANB Aids to Navigation Boat

B. ENGINEERING CHANGES THROUGHOUT THE LIFECYCLE. There are two distinct, but integrated periods to Engineering Changes throughout the lifecycle of an asset: Acquisition and Sustainment.

1. Acquisition Engineering Changes. This period covers the time between acquisition inception to the time the last asset has been delivered and the warranty period is completed. During this time, the Engineering Change process is managed by the Acquisition Program office. The Program Manager for the acquisition will be the Configuration Manager, having final approval/disapproval authority for all Engineering Changes. The ELC will be a member of the Configuration Control Board and may be a voting member depending upon each individual project’s Configuration Management Plan. As a member of the CCB, the ELC will provide technical advice, including recommendation for approval/disapproval, to the Program Manager. During this period, the Acquisition Program office will normally fund Engineering Changes, with exceptions being coordinated with G-SEN.

2. Sustainment Engineering Changes. This period covers the time between acquisition completion and decommissioning. G-O is the Configuration Manager during this period, having final approval/disapproval authority for all Platform Engineering Changes. ELC has authority to approve/disapprove System Engineering Changes.

Systems Management and Engineering Facilities (SMEFs) have authority to approve/disapprove electronic System Engineering Changes.

3. Multi-user ECP Automated Review System (MEARS). MEARS is an on-line Engineering Change process that is currently in the testing phase. This Engineering Change system, if accepted, would be used during both the Acquisition and Sustainment phases of an assets lifecycle. An implementation decision will be made after a test period is completed. The plan is for MEARS to not alter the established Engineering Change approval processes. It will just move the process on-line, improving process efficiency.

4. Detailed descriptions of processes, roles, and responsibilities for Sustainment Engineering Changes are covered in the following sections of this chapter. Detailed

041-2 descriptions for Acquisition Engineering Changes are located in the Major Systems Acquisition Manual (COMDINST M4150.2 series), Coast Guard Configuration Management guidelines (COMDINST 4130 series), and program specific plans (Configuration Management Plan and Configuration Control Board charter).

C. DEFINITIONS. Engineering Changes fall into two categories: Platform and System.

1. Platform Engineering Change. A modification to a cutter or standard boat that meets one of the following criteria:

a. Changes to cutter or standard boat class mission characteristics/capability.

b. Changes in weight or moment that significantly affect intact or damaged stability.

Although each case is unique due to different limiting factors (e.g., hull strength, damaged stability, etc.), changes that create more than a 0. 001-foot change in KG or add/delete more than 1/20 of 1% of the full load displacement (i.e. 112 lbs. per 100 tons of displacement), require a Platform Engineering Change. If in doubt about the effect of the intended weight change, request technical advice from the ELC platform manager or MLC Type Desk.

c. Changes to the hull structure, space allocations, watertight integrity, or compartmentation.

d. For standard boats, changes to outfitting requirements specified on approved Allowance Equipage Lists (AEL) and additions of new outfitting items that would be required to be placed on an AEL.

2. System Engineering Change. An Engineering Change that does not meet the criteria of a Platform Engineering Change and meets one of the following criteria:

a. A change to any system, part, component, or subassembly that is documented on an Allowance Parts List (APL).

b. A change to an approved system software, fluid, or paint system. Such changes will usually be to improve reliability, maintainability, or operational efficiency of the system or equipment.

c. Forms, fit or functional change to a closure or fitting.

(1) Form. Form is defined by the quantitative and qualitative descriptions of material features, such as composition, dimensions, size, weight, finishes, and the respective tolerances. Any change affecting the weight, balance, or inertia; shape, size, dimensions, mass, and/or other visual parameters, which uniquely characterize an item, affect the form.

(2) Fit. Fit is the ability of an item to physically interface or interconnect with or become an integral part of another item. A change that would affect interface connectivity affects fit.

(3) Function. Function is the operations or actions that an item is designed and required to perform. Performance parameters include operational requirements such as range, speed, lethality, reliability, maintainability, 041-3 survivability, or safety, including operational and logistics parameters and their respective tolerances. Any change affecting intended performance affects function.

d. Damage control classification change.

3. Prototype. A full-scale installation to evaluate the usefulness and effectiveness of an Engineering Change and/or to develop or modify installation specifications.

D. ENGINEERING CHANGE PROCESS. All Engineering Changes shall be initiated through the submission of an Engineering Change Request (ECR). ECRs may originate at any organizational level. Figures 041-1 and 041-2 are process flow chart depictions of the Engineering Change process. The process is completed in four phases: Concept, Validation, Development, and Deployment. These phases are described in detail below.

1. Concept Phase. All ECRs must be submitted using CG Form 5682, ENGINEERING CHANGE REQUEST (see Figure 041-3). Instructions are included on page two of the form. The form may be submitted electronically or on paper. The originator is encouraged to provide as much amplifying detail as possible to assist with the proper evaluation of the request.

Note: Configuration Change Forms (4790/CK) shall not be used as a tool to request Engineering Changes, but should only be used to notify the ELC of the completion of an authorized Engineering Change that affects the cutter/boat’s configuration.

a. Field Units and Area/District Staffs. Group units shall submit ECRs to the servicing MLC (v or t) via the Group and District Commander. Other field units shall submit ECRs to the servicing MLC (v or t) with an information copy to the operational commander. In either case, the originator shall send an information copy to the ELC (01) to ensure proper tracking of the request.

b. MLCs. MLCs shall evaluate each ECR from the perspective of requirements and impact on current operations. MLCs shall endorse the requirements and comment specifically on the system need, safety, program/capability need, and risk. MLCs shall also recommend a source of funding and a classification (see paragraph E.4).

MLCs shall endorse the request with approval or disapproval on the ECR form within 45 days of receipt. If approved, the request shall be forward to the ELC

(01) for further development. If disapproved, the request shall be returned to the originator with an explanation for disapproval, and an informational copy shall be sent to the ELC (01). For HM&E ECRs that have initial funding projected to be AFC-45 (see E.1), the MLCs shall add approved ECRs to the World of Work (WOW) or to a waiting list pending assignment to the WOW. For more information on the WOW see Ch 080 C.2.

c. Headquarters Unit/Level Organizations. Although most ECRs are generated through the MLCs, the G-O facility managers, G-A, CG-6, ELC, Systems Maintenance Engineering Facilities (SMEF), Boat Standardization Teams, and other Headquarters unit/level organizations may also submit ECRs. These

041-4 units/organizations shall complete the appropriate sections of the ECR Form. All ECRs shall be forwarded to the ELC (01).

d. Engineering Logistics Center. The ELC shall review and categorize all ECRs to determine the appropriate development and approval process. Upon receipt of the ECR, the ELC shall start a case file and begin tracking the case in the DARTS database. ECRs categorized as Platform Engineering Changes shall be forwarded to G-SEN & G-O for Headquarters Configuration Control Board (CCB) review and approval. ECRs categorized as System Engineering Changes to electronic equipment managed by a SMEF shall be forwarded to the appropriate SMEF for review, development, and approval (see Electronics Engineering Manual COMDTINST 10550.25 (series)). All other ECRs shall be retained at the ELC for review, development, and approval. All ECRs received by the ELC shall have this initial disposition completed within 60 days of receipt.

2. Validation, Development, and Deployment Phases. The process used for these phases is dependent upon the category assigned to the ECR. These phases are described below for each category of ECR.

a. Platform Engineering Change. (Figure 041-1)

(1) Validation Phase. During this phase, the ECR is validated against engineering, operational, and resource requirements. The CCB will provide conceptual approval/disapproval for the ECR. Although the CCB may provide conceptual approval, ECP development may be delayed for funding determination. ECRs without funding support shall not be developed further.

(a) G-SEN. G-SEN manages the validation of Platform Engineering Changes at Headquarters from an engineering perspective. G-SEN shall also coordinate with the G-O facility manager and CG-6 to validate the ECRs from the perspective of requirements and impact on future operations.

(b) G-O. G-O manages the validation of Platform Engineering Changes at Headquarters from a requirements and operations perspective.

(c) CCB. The CCB shall review the ECR and provide initial approval/disapproval within 30 days of receipt. The conceptual approval provided in this phase is for the ECR to move forward and be fully developed. This does not provide final approval authority to implement the Engineering Change. If the ECR is disapproved, the CCB shall return the request to the originator with an explanation for disapproval, and an information copy shall be sent to the ELC (01). For conceptually approved HM&E ECRs that will be funded out of AFC-45 money, the CCB shall forward the ECR to the NEMLWG for funding approval. For all other conceptually approved HM&E ECRs, the CCB shall forward the request to the ELC for further development. Conceptually approved electronic ECRs shall be forwarded to the appropriate SMEF for technical development. Only ECRs with identified funding sources shall be fully developed.

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(d) NEMLWG. The NEMLWG shall receive all conceptually approved HM&E ECRs that will be funded through AFC-45 funds from the CCB.

The NEMWLG shall approve funding for ECP development and deployment based on WOW prioritization (see Ch 080 C.2). ECRs with identified funding shall be forwarded to the ELC for development.

(2) Development Phase. During this phase, the Platform Engineering Change request is prepared for implementation from the perspective of configuration management, life cycle logistics support, and installation. The ELC or SMEF is primarily responsible for this phase.

(a) SMEF. Appropriate SMEFs shall develop electronic system ECRs, forwarded from the CCB. During development, considerations for life cycle logistics support and installation requirements shall be made. Upon completion of the technical package, the SMEF shall forward the package to the ELC for final logistical development. The technical package shall be forwarded to the ELC in the standard Engineering Change format (see paragraph (d) below).

(b) ELC. The ELC shall develop HM&E ECRs from a technical, configuration management, life cycle logistics support, and installation perspective. The ELC shall also finish development of electronic ECRs after initial development by the appropriate SMEF. The ELC shall forward complete Engineering Change packages to the CCB for final approval.

(c) CCB Concurrent Clearance. All members of the CCB shall review the final Platform Engineering Change package in concurrent clearance and provide their recommendation to the Configuration Manager (CCB Chair).

CG-6 and SMEFs are included for electronic Engineering Changes. After receiving the recommendation of the CCB the Configuration Manager shall approve or disapprove the Engineering Change. If there are no future modifications to the Engineering Change, this approval provides final authority to proceed with implementation of the change. The Configuration Manager shall forward the Engineering Change to the ELC for deployment.

(d) A fully developed Platform Engineering Change (CGHQ 3379) is comprised of a cover sheet and sufficient information to directly accomplish the Engineering Change, or to support development of a contract specification. This information shall be formatted into the following 21 areas, which reflect the general Engineering Change description, installation specifications, and the ILS elements.

Purpose Background References Material Required Equipment Removals/Relocation/Disposal Equipment Installations

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Quality Control/Quality Assurance Safety Stability Impact Funding Requirements and Sources Supply Support (including packaging, handling, and storage) Special Tools/Test Equipment Technical Information

Manuals Drawings

Computer Resources Maintenance Training and other manpower and personal issues Documentation Reprocurement Data Repair Program

(3) Deployment Phase. During this phase, the actual Engineering Change is installed on applicable units. Once a finalized EC is distributed to the cutter or boat, they shall follow the guidance contained on the Engineering Change form and schedule completion with their applicable NESU or Group when funded from the source directed by the EC. Completion of the EC is mandatory and shall be completed within the period defined on the EC.

NESUs and Groups will ensure timely completion of ECs on cutters and boats during their regular platform visits. Deviations from the specifications developed for the change will only be authorized by the Configuration Manager.

(a) ELC. After receiving final approval authority from the Configuration Manager, the ELC shall sign the Platform Engineering Change and distribute it to appropriate commands. If additional development is required during this phase and this development leads to changes in cost or scope approved by the CCB or significant support or operational parameters change the ELC shall return the Engineering Change to the CCB for further review.

(b) Field Units. After completion of an Engineering Change, installing units shall fill out the completion section of the Engineering Change authorization form and submit two copies, one to their servicing MLC and one to the ELC. In addition, installing units shall complete a Configuration Change Form (4790/CK) and submit it to the ELC.

b. System Engineering Change. (Figure 041-2)

(1) Validation Phase. The ELC or SMEF manages this phase of the process.

System Engineering Change requests shall be reviewed from the perspective of technical feasibility. Disapproved System Engineering Change requests shall be returned to the originator with an explanation of the reason for the disapproval. SMEFs shall send the ELC (01) an info copy of all ECR disapproval notices.

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NOTE: If necessary, the ELC/SMEF shall consult with Headquarters and/or MLCs to determine the proper funding requirements of the ECR.

ECRs without funding support shall not be developed further.

(2) Development Phase. The ELC or SMEF shall develop all approved System Engineering Change requests that have identified funding sources. These ECs shall be developed and formatted in the same way as Platform Engineering Changes. System Engineering Changes developed by a SMEF will have a concurrent clearance review limited to the MLCs (v/t) and the ELC. System Engineering Changes developed by the ELC shall have a concurrent clearance review limited to the MLCs (v).

(3) Deployment Phase. Once concurrent clearance feedback issues are resolved, the ELC or SMEF shall sign the System Engineering Change and distribute it to appropriate commands. Once a finalized EC is distributed to the cutter or boat, they shall follow the guidance contained on the Engineering Change form and schedule completion with their applicable NESU or Group when funded from the source directed by the EC. Completion of the EC is mandatory and shall be completed within the period defined on the EC.

NESUs and Groups will ensure timely completion of ECs on cutters and boats during their regular platform visits. Deviations from the specifications developed for the change will only be authorized by the ELC. Field units shall complete a Configuration Change Form and forward to the ELC. In addition, field units shall fill out the completion section of the Engineering Change and submit it to their servicing MLC and the ELC.

3. Prototypes. The Engineering Logistics Center (ELC) shall be the sole Engineering Change prototype approving authority. Figures 041-1 and 041-2 depicts where prototypes fit into the Engineering Change process. Requests for prototypes should be incorporated into the Engineering Change request. Unsuccessful prototypes shall be removed after completion of the evaluation period. The removal shall be funded by the organization that funded the installation.

a. ELC. Prototypes shall not be approved prior to CCB approval for Platform level Engineering Changes. Upon receipt of the prototype request, the ELC shall evaluate the technical impact of the request and, if appropriate and after consultation with the originator, issue a prototype authorization letter. Prototype authorization letters shall typically be issued to the UTB Systems Center for UTBs and to the National Motor Lifeboat School (NMLBS) for MLBs. Prototype authorization letters for other boat and cutter classes will typically be issued to the MLC or SMEF. The letter shall include a Prototype Evaluation Plan (PEP), developed by the ELC, or SMEF for electronic systems. Completed Prototype Evaluation Plans for Platform Engineering Changes shall be forwarded to the Configuration Manager for review.

b. Field Units. The Prototype Evaluation Plan shall be completed by the unit on which the prototype was installed and returned to the ELC with a copy to other activities involved in the prototype (i.e. SMEF, MLC, etc.). Because prototypes

041-8 are often an integral part of the Engineering Change development process, it is critical that the Prototype Evaluation Plan be completed and returned.

c. CCB. For Platform Engineering Changes, the CCB shall review completed Prototype Evaluation Plans and provide a recommendation to the Configuration Manager for full implementation of the Engineering Change. The Configuration Manager provides the final approval or disapproval over full implementation of the Engineering Change.

4. Emergency Procedures. Circumstances requiring immediate action to meet emergency operational commitments or recently discovered safety hazards may preclude use of the normal ECR process. In these cases, the MLC or HQ unit shall submit the ECR (CG Form 5682) and Configuration Change Form (4790/CK) by message, e-mail, or express mail to ELC (01). Cost data shall be provided to the extent that it is available without holding up the resolution of the emergency situation.

The approval decision shall be made within three working days of receipt. This abbreviated procedure shall only be used to meet vital operation commitments or resolve immediate safety or health threats. Regardless of the urgency of the Engineering Change, the full development of the ECR must eventually be accomplished as outlined above.

E. ENGINEERING CHANGE ADMINISTRATION.

1. Funding. Funding for Engineering Changes will be determined through the ECR process as outlined in this chapter. It is anticipated that funding will come from one of three major sources as outlined below:

Funding Source Low Cost

Medium Cost

High Cost

Unit AFC 30 X

MLC AFC 4X X

Program Manager (3X/4X/AC&I) X

a. Low Cost. Low cost engineering changes are those changes which have a total cost (including design, material, life cycle cost, logistic support and installation) less than or equal to the MLC established AFC 30 CSMP funding threshold for the particular cutter class.

b. Medium Cost. Medium cost engineering changes are those changes which have a total cost (including design, material, life cycle cost, logistic support and installation) greater than the MLC established AFC 30 CSMP funding threshold but not to exceed 5% of the affected cutter class annual AFC 45 Standard Support Level (SSL).

c. High Cost. High cost engineering changes are those changes that have a total cost (including design, material, life cycle cost, logistic support and installation)

041-9 greater than 5% of the affected cutter class annual AFC 45 standard support level (SSL). AC&I threshold levels are listed in the Financial Resource Management Manual (FRMM), COMDTINST M7100.3 (Series).

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