Specs Rev1 - OSPREY.pdf

USCGC OSPREY (WPB 87307)

87 FOOT COASTAL PATROL BOAT (USCG)

SPECIFICATION FOR DOCKSIDE REPAIRS

Developed By: Jennifer Smith, MKC

(Rev-1, 23 November 2010)

USCGC OSPREY (WPB-87) DOCKSIDE AVAILABILITY 2011

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: Hull Plating (U/W Body) Diver’s Inspection WORK ITEM 2: Tanks (Potable Water), Clean and Inspect WORK ITEM 3: Main Diesel Engine Assembly, Port and Stbd , Renew WORK ITEM 4: Engine Exhaust Pipes , Renew (EC 087-B-043) WORK ITEM 5: Electrical Power Distribution System, Thermographic Inspection WORK ITEM 6: Critical Electric Meters , Pressure Gauges , Thermometers , Tachometers , Test and Calibrate WORK ITEM 7: HVAC System, Repair WORK ITEM 8: Decks – Exterior (Main Deck), Preserve WORK ITEM 9: Superstructure, Preserve “100%” WORK ITEM 10: Temporary Services, Provide WORK ITEM 11: Forward RHIB Notch Skid Pad With Studs, Install (EC 087-A-038) WORK ITEM 12: Ventilation Systems , Commercial Cleaning WORK ITEM 13: Deck Covering (Wet/Dry), Seal

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

DATE REV# WORK

ITEM#

CHANGES MADE

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

iii (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 or 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 87 WPB 085-010, Rev D, Docking Plan Coast Guard Drawing 87 WPB 111-001, Rev D, Shell Expansion Coast Guard Drawing 87 WPB 161-001, Rev C, Skeg Construction Coast Guard Drawing 87 WPB 182-001, Rev A, Main Engine and Generator Foundations Coast Guard Drawing 87 WPB 185-001, Rev AA, Auxiliary Foundation Booklet Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details Coast Guard Drawing 87 WPB 259-001, Rev C, Engine Exhaust Piping Coast Guard Drawing 87 WPB 514-001, Rev L, HVAC Duct and Piping Systems Coast Guard Drawing 87 WPB 562-001, Rev A, Rudder Details Coast Guard Drawing 87 WPB 583-001, Rev N, RHIB Deployment Structure Coast Guard Drawing 87 WPB 601-001, Rev G, Outboard Profile and General Arrangement Coast Guard Drawing 87 WPB 631-001, Rev M, Ships Painting Schedule Coast Guard Drawing 87 WPB 634-001, Rev C, Deck Coverings & Detail

COAST GUARD PUBLICATIONS

Bollinger Shipyard, USCG CPB Project MTU-FA 771903, 07 Feb 2000, Engine/Gearbox Plant Alignment Instructions 8V396 TE94/Flange mounted BW 255 Coast Guard Commandant Instruction (COMDTINST) M10360.3, Change 1, Jun 2006, Coatings and Color Manual Coast Guard Technical Publication (TP) 453 5B, Mar 2003 , MAIN DIESEL ENGINE - FLUIDS &

LUBRICANTS SPECIFICATIONS

Coast Guard Technical Publication (TP) 4531 , Mar 2003 , MAIN DIESEL ENGINE - DESCRIPTION &

OPERATION MANUAL - MODEL 8V396TE94

iv (Rev-1) 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

Coast Guard Technical Publication (TP) 4532 , Mar 2003 , MAIN DIESEL ENGINE - PARTS CATALOG -

MODEL 8V396TE94

Coast Guard Technical Publication (TP) 4533 , Mar 2003 , MAIN DIESEL ENGINE - MAINTENANCE

MANUAL - MODEL 8V396TE94

Coast Guard Technical Publication (TP) 4562, 15 FEB 2005, Heating, Ventilation , and Air Conditioning (HVAC) Sytem 87 WPB Class Vessels Coast Guard Technical Publication (TP) 4593C , Feb 2002, SWBS 243, Manufacturer's Instruction Book, 87' WPB Propulsion Shaft Seals, John Crane Type F.S.E.

MTU Main Diesel Engine Installation Memo, 7 October 2010 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 5100 (SFLC Std Spec 5100), Jan 2009, Clean Shipboard Ventilation Systems Surface Forces Logistics Center Standard Specification 6341 (SFLC Std Spec 6341), Jan 2009, Install Interior Deck Covering Systems Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), Jan 2009, Provide Temporary Services

OTHER REFERENCES

American National Standards Institute/American Water Works Association (ANSI/AWWA) C652, 2002, Disinfection of Water-Storage Facilities American National Standards Institute/NSF International (ANSI/NSF) 61, 2008, Drinking Water System Components - Health Effects American Society of Mechanical Engineers (ASME) B16.34, 2004, Valves-Flanged, Threaded, and Welding ANSI/NCSL Z540-1-1994, American National Standard for Calibration-General Requirements ASTM International (ASTM) F992, 2006, Standard Specification for Valve Label Plates Code of Federal Regulations (CFR) Title 29, Part 1910, Subpart T, 2007, Commercial Diving Operations Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation Federal Standard (FED-STD) 595, 2008, Colors Used In Government Procurement Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) SP-61, 2003 Edition, Pressure Testing Of Steel Valves Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) SP-67, 2002 Edition, Butterfly Valves Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) SP-72, 1999 Edition, Ball Valves with Flanged or Butt-Welding Ends for General Service Manufacturers' Standardization Society of the Valve and Fittings Industry (MSS) SP-80, 2008 Edition, Bronze Gate, Globe, Angle and Check Valves MIL-D-16791, Jan 1993, Detergents, General Purpose (Liquid, Nonionic) MIL-D-3134, Sep 1989, Deck Covering Materials MIL-PRF-24613, Dec 1990, Deck Covering Materials, Interior, Cosmetic Polymeric MIL-PRF-24667, Jun 2005, Coating system, Non-Skid, for Roll or Spray Application QPL-24667, May 2006, Qualified Product List of Products Qualified under Performance Specification v (Rev-1) 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)

3 Yes Engine 2815-12-348-2440 2 200,000.00 No Soft Patch Kit 87CPBSPK 1 3,000.00 No *Alignment Kit N/A 1 set 3,000.00

4 No Port Mufflers 9804841 2 5,800.00 No Stbd Mufflers 980465 2 5,800.00

No ISO Kit 100# Left 2.5” Bar A97-083800 13 250.00

No ISO Kit 100# Right 2.5” Bar A97-083900 13 250.00

No Turbo Outlet Riser Stbd 321 B99-041502 2 1500.00

No Turbo Outlet Riser Port 321 B99-041501 2 1500.00

No Clamp V-Band Tube 8” 024-007000 12 100.00 No Silkolene Sealant Tube 042-023000 7 120.00

No Clamp V-Band MTU 225mm 024-001200 4 300.00

No Elbow Muffler outlet Stbd 321 B99-041602 1 2000.00

No Elbow Muffler outlet Port 321 B99-041601 1 2000.00

No Clamp V-Band Tube 12” 024-009000 6 300.00

No Flange Marmon Female 12” 321 B99-043104 4 350.00

No Bellows Unit 12” 321 B99-042600 4 1400.00

No Bellows Unit Turbo 12” 321 B99-041400 4 1300.00

No Marmon Flg male 321SS B98-042903 4 200.00 No Adaptor Dual 8D to 12D B08-13100 2 3400.00 No Concentric Ring Port CG Dwg 87WPB259-001 1 2000.00 No Concentric Ring Stbd CG Dwg 87WPB259-001 1 2000.00

No Exhaust Lagging (Supplied by cutter) n/a Complete set 10,000.00

7 No Cooling Coil DX-TR-3-440-600-18R-10-V1- CU/AL 1 ea $10,000.00

8 No Slip Resistant Sheets N/A 1 KT 5,000.00

11 No **Forward Skid Pad 1 ea $300.00 *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

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_STD, paragraph

3.2.6.5 (Inspection report particulars)):

Work Item Title

This section is not applicable to this package.

vii (Rev-1)

Principal Characteristics

87' WPB

PHYSICAL CHARACTERISTICS

Length Overall 87' Length between Perpendiculars 81' 7" Depth 10' 11" Maximum Beam 19.4' Draft, Mean to Design Waterline 5' 9" Height of Highest Projection 50.2' Full Load Displacement 93.5 long tons Minimum Operating Displacement 83.9 long tons Displacement, Light Ship 77.9 long tons Framing Longitudinal Bulkheads Four watertight bulkheads located below the Main Deck Anchor 40 lb Fortress with 480 ft. 3 strand 5/8" dia. Line stayset

HULL CHARACTERISTICS

Hull/Main Weatherdeck Material BS-4360, GR 43A Steel Superstructure 5086 Aluminum

MACHINERY CHARACTERISTICS

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

Reduction Gears Two ZF Type BW 255 Propulsion Shaft Two AQUAMET 22, 101.6mm Shaft Diameter 4" Shaft Seal Two John Crane mechanical seals Shaft Bearing, Intermediate Thordon Elastomeric Bearing Shaft Bearing, Aft Thordon Elastomeric Bearing Number of Propellers 2 Number of Blades 5 Diameter of Propeller 1040mm Pitch 1230 mm fixed Shaft RPM 828 Rudders Two 316L Stainless Steel Ship's Service Generators Two Man Model D08241F01 diesel with Stanford

60KW Generator

TANK CAPACITIES

3-9-1-F (Fuel Oil) 1402 gal 3-9-2-F (Fuel Oil) 1402 gal 3-12-2-F (Waste Oil) 86 gal 3-12-1-F (Oily Water) 86 gal 3-7-0-Q (Sewage Collection) 352 gal 3-7-1-Q (Grey Water) 52 gal 3-12-1-W (Fresh Water) 200 gal 3-12-2-W (Fresh Water) 200 gal viii (Rev-1) ix (Rev-1)

00000_0310_FLT

REC_0000_FLT_ Commercial Project @ Contractor’ Facility (1209)

General Requirements

1. SCOPE

1.1 Intent. This item describes the general requirements to be followed by the Contractor while conducting this availability.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and

Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety

Administration, Department Of Transportation

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 also to all other work subsequently authorized by changes, modifications, or extensions to the contract.

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

3.3 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI

1 (Rev-1) in accordance with SFLC Std Spec 0740.

3.4 HW disposal. The Contractor is considered as the generator of all contract-generated hazardous wastes and shall use its facility’s EPA generator ID number for management, transportation, and disposal of said hazardous wastes. Ensure the following:

3.4.1 Contractor’s hazardous waste handlers shall comply with applicable requirements of 40 CFR 262.

3.4.2 All contract generated hazardous wastes shall be packaged in 49 CFR-compliant containers.

3.4.3 The designated wastes shall be disposed of at a state or Federally-approved and permitted HW TSDF.

3.4.4 Name of destination TSDF shall be submitted to the KO at the Arrival Conference.

4. NOTES

4.1 Access to COMDTINST M10360.3. The COMDTINST M10360.3 may be accessed at the following URL address: http://www.uscg.mil/directives/cim.asp

4.2 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 0000 to be completed and submitted during preservation of “critical-coated surfaces”, are provided at the end of this document.

2 (Rev-1) http://www.uscg.mil/directives/cim.asp

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________ Specific Area Being Preserved: ___________________________________________________________

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

Ensure all coatings are in compliance with COMDTINST M10360.3, 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 manufacturer(s).

CHECKPOINT 3 - AMBIENT CONDITIONS

Ensure surface and surrounding temperatures are each between 50 and 90°F for water-based 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 manufacturer(s).

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.

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure cleanliness of prepared surface is as per specification (i.e.: SSPC SP-12, SP-11, SP-10…).

Verify surface anchor profile (1.5-3.5 mils for abrasive-blasted steel surfaces; 1.0 mil (minimum) for power-tool cleaned surfaces; 1.0-1.5 mils for abrasive-blasted aluminum surfaces); and 1.5 –2.5 for surfaces to be coated w/single coat of inorganic zinc). Conduct 5 sets of 3 readings for the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area.

Measure soluble salt conductivity (5 measurements per 1000 sqft) – maximum threshold: 70 microsiemens/cm for non-submerged surfaces and 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.

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

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

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

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

CHECKPOINT 10 – RECORD KEEPING

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

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

3 (Rev-1)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________

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

DATE &

TIME

ENTER ACTIVITY

(Surface preparation, primer coat, barrier coat, top coat, etc…)

LOCATION

TEMPERATURE

% REL.

HUMIDITY

SIGNATURE

OF

INSPECTOR DEW

POINT SURFACE AMBIENT ΔT

DP - Surface

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

4 (Rev-1)

QA-3 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG)

Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________ Location of Surface Profile Measurements: ___________________________________________________________

SURFACE PREPARATION METHOD PROFILE

(mils)

Min Max Avg.

SSPC-SP-10/NACE No. 2 SSPC-SP-12/NACE No. 5

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 separate log for each area/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

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

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

5 (Rev-1)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________

Location of Work (including frame numbers): _______________________________________ Area (square feet): ____________

DATE TEST LOCATIONS CONDUCTIVITY

(microsiemens/cm)

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

6 (Rev-1)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence) Vessel Name: _______________________ Hull Number: ______________ CLIN No.: _____________ Work Item Title: ________________________________________________

Coating Manufacturer: ___________________Product Name: _______________________Batch Number: ____________ Induction Time: _______________________________________________________________ Coating System Sequence (Indicate Whether: Primer, Touch-Up Primer, Barrier Coat, 3rd Coat…): __________________

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-Of (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: __________________________________________________________

Name of QP-1 or NACE-Certified Inspector: __________________________________________ Cert. No.: ____________ Signature of Inspector: _______________________________________ Date:_______________ Time: _________

7 (Rev-1)

8 (Rev-1)

11000_UWDIVER_0310_FLT

REC_11000_UWDIVER_FLT_87’ WPB- ALL (0110)

WORK ITEM 1: Hull Plating (U/W Body) Diver’s Inspection

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to conduct inspection of the vessel’s U/W body, while the vessel is moored pier side. Affected surfaces or components include, but are not limited to the following:

• U/W hull plating.

• U/W body coating system.

• Transducer(s)/sonar dome.

• Shaft(s).

• Propellers.

• Rudder(s).

• Sea chest(s) and strainer(s).

• Miscellaneous appendages (examples: bilge keels, rope guards, and fairwaters…).

• Hull and sea chest zinc anodes.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 085-010, Rev D, Docking Plan Coast Guard Drawing 87 WPB 111-001, Rev D, Shell Expansion Coast Guard Drawing 87 WPB 161-001, Rev C, Skeg Construction Coast Guard Drawing 87 WPB 562-001, Rev A, Rudder Details

COAST GUARD PUBLICATIONS

None.

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1910, Subpart T, 2007, Commercial Diving Operations http://www.access.gpo.gov/nara/cfr/cfr-table-search.html#http://www.access.gpo.gov/nara/cfr/cfr-table-search.html#page1

3. REQUIREMENTS

3.1 General. The Contractor shall, in accordance with 29 CFR 1910.401-440, provide a certified diver and a tender team, as well as necessary support personnel and equipment, to accomplish the tasks specified herein.

WARNING!

Mixed gas diving and live boating are not permitted!

3.1.1 Provide the Coast Guard Inspector 24 hours advance notice of when the diver inspection will occur. Before diving procedures are commenced, meet with the COTR and the Coast Guard Inspector, to discuss diving safety requirements and the securing of cutter machinery, as applicable.

NOTE

At Contractor’s request, Ship’s force will secure and tag out the cathodic protection system, main engines, steering gear, generator set, A/C unit, fire pumps, and all other machinery which may cause a hazard while a diver is in the water.

3.1.2 Ensure the Coast Guard Inspector has capability for maintaining continuous two-way communication with diving personnel at all times, during the performance of the this work item.

3.2 Pre-diving clearance. The Contractor shall ensure that the diving team shall obtain clearance from the Officer-of-the-Deck before beginning diving operations.

3.3 Inspection requirements - general. The Contractor shall survey the entire U/W body of the vessel, to inspect for abnormal conditions or situations, which may include, but not be limited to the below-listed. Use the drawings listed in Section (References) for guidance.

• Hull plating and appendage damages.

• Coating system defects or failures.

• Welding corrosion and erosion.

• Deformation in appendages.

3.3.1 Hull plating.

3.3.1.1 Inspect the exterior condition of the hull for presence of marine growth, deformation, and any evidence of major corrosion or electrolytic action.

3.3.1.2 Inspect for deformation along the stem and keel areas, condition of butt-welded seams, doubler plates, lap seams, and any signs of damaged plating or unusual waviness in the plating.

9 (Rev-1)

3.3.2 Coating system inspection.

3.3.2.1 Inspect the condition of the U/W body coating system, for signs of the following:

• Peeling.

• Blistering.

• Abrasion.

3.3.2.2 Use the guidelines provided in Table I (Paint Deterioration Ratings (PDR) for Antifouling/Anticorrosion (AF/AC) Paint System) and Table II (Fouling Ratings (FR) In Order of Increasing Severity) to assist in proper documentation of the coating system degradation and fouling rate, respectively.

TABLE 1 - PAINT DETERIORATION RATINGS (PDR) FOR

ANTIFOULING/ANTICORROSION (AF/AC) PAINT SYSTEM

PAINT

DETERIORATION

RATING (PDR)

DESCRIPTION

10 AF paint intact, red in color or with mottled pattern of light green and red.

20 AF paint missing from edges, corners, seams welds, river or boll head to expose AC paint.

30 AF paint missing from slightly curved or flat areas to expose AC paint.

40 AF paint missing from intact blisters to expose AC paint.

50 AF blisters ruptured to expose intact AC paint.

60 AF/AC paint missing or peeling to expose steel substrate, no corrosion present.

70 AF/AC paint removed from edges, corners, seams, welds, river or bolt heads to expose steel substrate with corrosion present.

80 Ruptured AF/AC blisters on slightly curved or flat surfaces with corrosion stains present.

90 Area corrosion of steel substrate with no AF/AC paint cover due to peeling or abrasion damage.

100 Area corrosion showing visible surface evidence of pitting, scaling, and roughening or steel substrate.

10 (Rev-1)

TABLE II - FOULING RATINGS (FR) IN ORDER OF INCREASING SEVERITY

TYPE FOULING

RATING

(FR)

DESCRIPTION

Soft 0 A clean, foul-free surface; red and/or black AF paint or a bare metal surface.

Soft 10 Light shades of red and green (incipient slime). Bare metal and painted surfaces are visible beneath the fouling.

Soft 20 Slime as dark green patches with yellow or brown colored areas(advanced slime). Bare metal and painted surfaces may by obscured by the fouling.

Soft 30 Grass as filaments up to 3 inches (76 mm) in length, projections up to 1/4 inch (6.4 mm) in height; or a flat network of filaments, green, yellow, or brown in color; or soft non-calcareous fouling such as sea cucumbers, sea grapes, or sea squirts projecting up to 1/4 inch (6.4 mm) in height. The fouling can not be easily wiped off by hand.

Hard 40 Calcareous fouling in the form of tubeworms less than ¼ inch in diameter or height.

Hard 50 Calcareous fouling in the form of barnacles less than ¼ inch in diameter or height.

Hard 60 Combination of tubeworms barnacles, less than ¼ inch (6.4 mm) in diameter or height.

Hard 70 Combination of tubeworms and barnacles, greater than ¼ inch in diameter or height.

Hard 80 Tubeworms closely packed together and growing upright away from surface. Barnacles growing one on top of another, ¼ inch or less in height. Calcareous shells appear clean or white in color.

Hard 90 Dense growth of tubeworms with barnacles, ¼ inch or greater in height;

Calcareous shells brown in color (oysters and mussels); or with slime or grass overlay.

Composite 100 All forms of fouling present, Soft and Hard, particularly soft sedentary animals without calcareous covering (tunicates) growing over various forms of hard growth.

3.3.3 Sea chests and other hull penetrations

• Inspect all sea chests and other hull penetrations for signs of any obstructions/marine growth in the openings that might prevent proper suction and discharge of water.

• Inspect for bare metal areas (surrounding penetrations) and for bare metal pitting.

• Inspect for general appearance, loose, damaged, or missing grates, loose or missing fasteners, condition of sea strainers and lockwire on bolt.

11 (Rev-1)

3.3.4 Propeller and shaft associated components.

3.3.4.1 Inspect the condition of the propeller shafts, struts, fairwaters, and rope guards. Note any loose or missing fairwater or rope guard fasteners.

3.3.4.2 Inspect propellers for corrosion, pitting, erosion, fouling, cracks, dings, curls, and nicks by side and blade.

3.3.4.3 Inspect the condition of the struts, keel drain plugs, rudders, rudder stocks, and rudder bearings, including any damage, pitting on leading and trailing edges of the rudder, and the presence of drain plugs..

3.3.5 Transducers. Inspect the general condition of the fathometer transducer. Record condition of rubber coating and amount of marine growth present. Note in the inspection report any cuts, gouges, or other surface defects found.

3.3.6 Cathodic protection system. Visually inspection of all zinc anodes, check the soundness of mounting strap and stud welds, missing fasteners, and percentage of remaining material.

3.4 Inspection documentation. The Contractor shall document the hull survey as follows:

3.4.1 Written report.

3.4.1.1 Note and record the U/W body coating system fouling rating on the attached “Pre-Clean Bio-fouling Inspection Data” Form.

3.4.1.2 Note all inspection findings and observations, as applicable, on attached observations on the following attached inspection data forms, as applicable, on the attached :”Diver Hull Inspection Data” Form.

3.4.1.3 In addition to completing the ”Diver Hull Inspection Data” Form, do the following, as applicable:

• Document condition of running gear on attached “Running Gear Inspection Data” Form for each shaft.

• Document propeller condition on attached “Propeller Inspection Data” Form for each propeller.

• Document condition of rudders on attached “Port and Starboard Rudder Data Inspection” Form.

3.4.2 Audio-video report. In addition to the written documentations specified above, produce an audio-video report, with narration, of all inspected surfaces. Place linear measuring devices, as applicable, in the field of view when videotaping hull damages, to provide scale for these damages.

3.4.3 Documentation submission. Within 24 hours after the completion of the diver inspection, do the following:

3.4.3.1 Submit a CFR indicating the amount of recommended U/W body surface cleaning, if any.

3.4.3.2 Submit both, the written and audio-video reports to the COTR.

3.4.3.2.1 Ensure that all video equipment have the following characteristics/functions:

• Remote video/sound recorder.

• Suitability for underwater use.

• Auto-focus and auto-exposure.

• Color pictures.

• Two-way communication devices, to allow for communication and recording of communications between

12 (Rev-1) the diver operating the video camera and the Person-in-Charge, COTR, and Coast Guard Inspector.

• Audio/visual cables long enough to transmit the video picture and two-way communications to the recorder and monitor.

• Online video monitor large enough, to allow the Person-in-Charge, the COTR, and the Coast Guard

Inspector to observe the video picture.

• Sufficient lighting to ensure a quality color video picture and depth of field.

• A yardstick or other suitable linear measuring device with clear measurement marks which can be read from the monitor.

3.4.3.2 .2 Closely monitor the video and sound quality during the survey, to ensure that the pictures on the monitor and the communication sounds remain of high quality. When either video or audio quality deteriorates, ensure that the survey is temporarily halted, until all problems have been corrected.

4. NOTES

4.1 Unit responsibilities. The ship's force will tag-out and secure the following:

• All propulsion machinery and shafting, including auxiliary propulsion machinery and steering machinery whenever the diver is in the water.

• All underwater body transducers, including the sonar equipment, for the duration of the underwater inspection operation.

• All active cathodic protection equipment for the duration of the underwater inspection operation.

• Each sea suction while the diver is inspecting the sea suction's sea chest strainer.

4.2 Mailing of video record. Upon receipt, the COTR will forward the second copy of the underwater video inspection record to the Engineering Section of the Product Line Division to which the vessel is assigned.

13 (Rev-1)

PRE-CLEAN BIOFOULING INSPECTION DATA

VESSEL NAME: HULL TYPE /

NUMBER LOCATION (CITY) DATE (mm/dd/yy)

PRODUCT LINE: INSPECTING ACTIVITY VISIBILITY (ft)

LOCATION OF LAST DRYDOCKING UNDOCKING DATE

LOCATION OF LAST PAINTING DATE

PAINT

TYPE: ANTIFOULING: ANTICORROSION:

DATE OF THE LAST WATERBORNE FULL HULL CLEANING DATE OF THE LAST WATERBORNE INTERIM CLEANING

UNDERWATER PHOTOGRAPHS TAKEN □ YES □ NO VIDEO TAKEN □ YES □ NO

COMPONENTS ( CHECK IF: )

N/A NOT INSPECTED

( PERCENTAGES MUST ADD UP TO 100 )

FOULING RATING FOULING RATING FOULING RATING

PROPELLER Centerline FR- % FR- % FR- %

Port Outboard FR- % FR- % FR- %

Port Inboard FR- % FR- % FR- %

Starboard Inboard FR- % FR- % FR- %

Starboard Outboard FR- % FR- % FR- %

SHAFT Centerline FR- % FR- % FR- %

Port Outboard FR- % FR- % FR- %

Port Inboard FR- % FR- % FR- %

Starboard Inboard FR- % FR- % FR- %

Starboard Outboard FR- % FR- % FR- %

RUDDER Centerline FR- % FR- % FR- %

Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

SONAR DOME Port Side FR- % FR- % FR- %

Starboard Side FR- % FR- % FR- %

SEA CHEST Typical FR- % FR- % FR- %

BOW Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

SIDES Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

BOTTOM Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

STERN Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

TRANSOM Port FR- % FR- % FR- %

Starboard FR- % FR- % FR- %

Signature (Ship’s Engineer):_______________________________________________________ Signature (Diving Supervisor):______________________________________________________

14 (Rev-1)

DIVER HULL INSPECTION DATA

VESSEL NAME: HULL TYPE / NUMBER LOCATION (CITY) DATE (mm/dd/yy) PRODUCT LINE: INSPECTING ACTIVITY VISIBILITY (ft)

LOCATION OF LAST DRYDOCKING UNDOCKING DATE

LOCATION OF LAST PAINTING DATE

PAINT

TYPE: ANTIFOULING: ANTICORROSION:

DATE OF THE LAST WATERBORNE FULL HULL CLEANING DATE OF THE LAST WATERBORNE INTERIM CLEANING

UNDERWATER PHOTOGRAPHS TAKEN □ YES □ NO UNDERWATER COLOR VIDEO TAKEN □ YES □ NO

UNDERWATER WORK ACCOMPLISHED THIS DATE

□ FULL CLEAN □POLISH □MULTI-BRUSH □INSPECT □PAINT

□INTERIM □HYDRO □HAND-HELD □REPAIR □OTHER__________________________________

1. HULL COATING SYSTEM (PDR___________)

a. ANTIFOULING PAINT

PERCENTAGE REMAINING________________ PERCENT REJUVENATION________________

IS THE A/F □ HARD □ SOFT

PERCENTAGE __________ PEELING __________ LOCALIZED or __________ GENER L A __________ BLISTERING __________ LOCALIZED or __________ GENERA L __________ ABRASION __________ LOCALIZED or __________ GENERAL

CONDITION SUMMARY [ IF PAINT DAMAGE IS LOCALIZED, GIVE LOCATION(s) ]

b) ANTICORROSION PAINT

PERCENTAGE REMAINING _______________

PERCENTAGE __________ PEELING __________ LOCALIZED or __________ GENER L A __________ BLISTERING __________ LOCALIZED or __________ GENERA L __________ ABRASION __________ LOCALIZED or __________ GENERAL

CONDITION SUMMARY [ IF PAINT DAMAGE IS LOCALIZED, GIVE LOCATION(s) ] c)

DOCKING BLOCK AREAS (PDR _________)

AVERAGE PERCENTAGE OF BLOCK AREAS PAINTED ____________________ %

BARE METAL PITTING ____________________ % __________________ IN. DIAMETER ____________________ IN. DEEP

CONDITION SUMMARY [ IF PAINT DAMAGE IS LOCALIZED, GIVE LOCATION(s) ]

15 (Rev-1)

DIVER HULL INSPECTION DATA (CONTINUED)

2 CATHODIC PROTECTION SYSTEM .

SACRIFICIAL ANODES (ZINCS) a.

AVERAGE PERCENTAGES OF ANODES REMANING ____________________ %

ANODES ARE: □ UNIFORMLY WASTED □ WASTAGE GREATEST IN FOLLOWING AREAS:

ANODES ARE : □ WELDED □ BOLTED □ BOTH

NUMBER AND LOCATION OF ANY ANODES MISSING OR INACTIVE:

MISSING___________________________________________________

INACTIVE__________________________________________________

b IMPRESSED CURRENT .

□ DAMAGE NOTED ON ATTACHED DRAWING (Port/Stbd) (FRAME ____________________ )

□ WIRES LOOSE, BROKEN, OR MISSING (Port/Stbd) (FRAME ____________________ )

□ CAPASTIC SHIELD DAMAGE (Port/Stbd) (FRAME ____________________ )

□ INSULATORS LOOSE OR DAMAGED (Port/Stbd) (FRAME ____________________ )

□ OTHER (Port/Stbd) (FRAME ____________________ )

3. GENERAL HULL DAMAGE (HULL PLATING, BILGE KEELS, etc.):

4. HULL PENETRATIONS (PDR _________)

_______________ % CLOGGED WITH MARINE GROWTH (POST CLEAN)

_______________ % BARE METAL (AREA SURROUNDING PENETRATION)

_______________ % BARE METAL PITTING

AVERAGE PIT SIZE: _______________ in. DIAMETER, _______________ in. DEPTH

CONDITION SUMMARY: ___________________________________________________

16 (Rev-1)

DIVER HULL INSPECTION DATA (CONTINUED)

5. SONAR DOME

□ NO VISIBLE DAMAGE □ DAMAGE NOTED ON ATTACHED DRAWING □ CUTS □ LAYER SEPARATION □ WIRE PILES

E POSED X

6. PROPULSION SHAFTING

VISIBLE BARE METAL □ YES □ NO RUST BLEEDING □ YES □ NO PITTING □ YES □ NO

CONDITION SUMMARY (TYPE OF DAMAGE, LOCATION AND SIZE):

7 STRUTS AND BEARING HOUSING .

PERCENT BARE METAL: STARBOARD PORT

MAIN _________________________ % ___________________ %

INTERMEDIATE _________________________ % ___________________ %

PDR _________________________ ___________________

CONDITION OF STRUT LEADING AND TRAILING EDGES: ______________________________________

CONDITION OF ROPE GUARDS:

CONDITION OF FAIRWATERS: ___________________________________________________

8 RUDDER .

□ NO DAMAGE □ DAMAGE SHOWN ON ATTACHED DRAWINGS

STARBOARD PORT

PERCENT BARE METAL % %

PDR

ACCESS PLATES INTACT? □ YES □ NO □ YES □ NO

WAS RUDDER SOUNDED? □ YES □ NO □ YES □ NO

ANY SIGNS OF

FLOODING? □ YES □ NO □ YES □ NO

ANY SIGNS OF

DROPPING? □ YES □ NO □ YES □ NO

CONDITION SUMMARY:

9. PROPELLERS

□ NO DAMAGE □ DAMAGE SHOWN ON ATTACHED DRAWINGS

PROP #1: NICKS __________ CURLS __________ CRACKS – LARGEST CRACK LENGTH __________ in.

PROP #2: NICKS __________ CURLS __________ CRACKS – LARGEST CRACK LENGTH __________ in.

PROP #3: NICKS __________ CURLS __________ CRACKS – LARGEST CRACK LENGTH __________ in.

PROP #4: NICKS __________ CURLS __________ CRACKS – LARGEST CRACK LENGTH __________ in.

PROPELLERS NUMBERED STARBOARD TO PORT.

Diving Supervisor: ___________________________________________ Ship’s Engineer: _________________________________

17 (Rev-1)

18 (Rev-1)

19 (Rev-1)

20 (Rev-1)

21 (Rev-1)

12314_DLA_0209_FLT

REC_12314_FLT/87’ WPB (ALL) (0310)

WORK ITEM 2: Tanks (Potable Water), Clean and Inspect

1.1 Intent. This work item describes the requirements for the Contractor to clean and inspect the following tank(s):

TYPE OF

TANK LOCATION CAPACITY - 95%

(gallons)

LOW SUCTION

(gallons) Potable Water Vestibule, Frames 13-15 Port 205 6 Potable Water Vestibule, Frames 13-15 Stbd 205 6

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 601-001, Rev G, Outboard Profile and General Arrangement

COAST GUARD PUBLICATIONS

None.

OTHER REFERENCES

American National Standards Institute/NSF International (ANSI/NSF) 61, 2008, Drinking Water System

Components - Health Effects American National Standards Institute/American Water Works Association (ANSI/AWWA) C652, 2002, Disinfection of Water-Storage Facilities

3. REQUIREMENTS

3.1 General. The Contractor shall refer to Coast Guard Drawing 87 WPB 601-001 for guidance. The Contractor shall notify the Dockmaster prior to filling or draining the potable water tank(s), when this item is being executed in a drydock availability. The Contractor shall accomplish the following for the tank(s) designated in paragraph 1.1 (Intent):

3.1.1 Operational test - initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of all designated tank TLIs, to demonstrate existing operational condition.

Submit a CFR.

3.1.2 Tank content removal. Remove and dispose of all fluids and/or residues in accordance with all applicable Federal, state, and local regulations.

3.1.3 Tank cleaning. Remove tank cover(s); clean tank interior surfaces free of all foreign materials, such as sediment or sludge. Remove all persistent residues, taking care not to damage the tank coating system. Remove cleaning media and residues continuously from the tank during the washing process. Remove any residual wash media and wipe up residual moisture with clean lint-free cloths. Collect, contain, and dispose of all wash media, residues, and cleaning materials in accordance with all Federal, state, and local regulations.

3.1.4 Inspection. Visually inspect all tank interior surfaces, including, but not limited to bulkheads, floor and overhead plating, structural members, manhole cover surfaces, fasteners and gasket seating surfaces. Submit a CFR including the following, as applicable:

• Tank structural condition.

• Inaccessible areas, if any.

• Tank level indicator (TLI) and/or float switch condition (if applicable).

• Suction and discharge piping condition.

• Fastener material and condition (correct fastener material is stainless steel).

NOTE

Ensure that no one enters the tanks once disinfection is completed.

3.2 Tank closing. The Contractor shall ensure that the tank(s) remain open for approximately 24 hours after completion of the tasks specified above. Notify the COTR at least 24 hours prior to closing the tank(s). After satisfactory inspection by the Coast Guard Inspector, and completion of all authorized repairs, close tank manhole cover(s) with new gasket material conforming to ANSI/NSF 61. Renew all stud cotton grommets (as applicable) upon reinstallation of manhole cover(s).

3.3 Tank disinfecting. After all other work involving the potable water system and tank closing have been completed, the Contractor shall disinfect and treat the affected potable water tank(s) and associated disturbed piping and components, as necessary, to meet or exceed the requirements of AWWA C652. After tank disinfecting; remove and dispose of all treated water in accordance with all Federal, state and local regulations.

3.4 Operational test – post repairs. After completion of work, the Contractor shall witness an operational test (by Coast Guard personnel) of all designated tank TLIs to prove satisfactory operating condition. Submit a CFR.

4. NOTES

This section is not applicable to this work item.

22 (Rev-1)

23 (Rev-1)

23000_JLW_1010_87WPB

WORK ITEM 3: Main Diesel Engine Assembly, Port and Stbd , Renew

1.1 Intent. This work item describes the requirements for the Contractor to renew the port and stbd main diesel engines (MDE).

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PART NO. QTY ESTIMATED COST

($/UNIT)

Yes Engine 2815-12-348-2440 2 200,000.00 No Soft Patch Kit 87CPBSPK 1 3,000.00 No *Alignment Kit N/A 1 set 3,000.00

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details

Coast Guard Drawing 87 WPB 182-001, Rev A, Main Engine and Generator Foundations

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Jan 2009, Welding and Allied Processes

MTU Main Diesel Engine Installation Memo, 7 October 2010

Bollinger Shipyard, USCG CPB Project MTU-FA 771903, 07 Feb 2000, Engine/Gearbox Plant Alignment Instructions 8V396 TE94/Flange mounted BW 255

Coast Guard Technical Publication (TP) 4531, Mar 2003, MAIN DIESEL ENGINE -

DESCRIPTION & OPERATION MANUAL - MODEL 8V396TE94

Coast Guard Technical Publication (TP) 4532, Mar 2003, MAIN DIESEL ENGINE - PARTS

CATALOG - MODEL 8V396TE94

Coast Guard Technical Publication (TP) 4533, Mar 2003 , MAIN DIESEL ENGINE -

MAINTENANCE MANUAL - MODEL 8V396TE94

Coast Guard Technical Publication (TP) 4535B, Mar 2003, MAIN DIESEL ENGINE - FLUIDS

& LUBRICANTS SPECIFICATIONS

Coast Guard Technical Publication (TP) 4593C, Feb 2002, SWBS 243, Manufacturer's Instruction Book, 87' WPB Propulsion Shaft Seals, John Crane Type F.S.E.

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General. The Contractor shall:

3.1.1 Technical Representative Services for grooming, commissioning, etc. Provide an on-site technical representative certified by MTU to the M2 Level and that has accumulated marine MTU repair/overhaul experience in 5 of the last 10 years; experience in installing/commissioning MTU marine engines preferred. The technical representative shall advise on manufacturer's information, procedures, software, control systems, dimensions, and clearances associated with the system, conduct proper repair methods, and ensure compliance with manufacturer's procedures and standards during installation of the marine propulsion diesel engine.

3.1.2 For dock and sea trials, provide an on-site qualified technical representative certified by MTU to the E3 Level.

3.1.3 Refer to TP-4531, TP-4532, TP-4533, TP-4535B, TP-4593C.

3.1.4 Tag-outs and isolation. Ensure all affected systems are properly tagged out and low voltage systems in way of repairs have been isolated and secured.

3.2 Renew port and stbd MDEs. The Contractor shall renew the port and stbd MDE assemblies. Use Government-furnished material listed in paragraph 1.2 above. Refer to MTU Main Diesel Engine Installation Memo (for info only). Close valves, drain, and disconnect the engine fluid systems. Dispose of removed fluids in accordance with all applicable Federal, state, and local regulations. Remove all engine support components to facilitate safe removal of the engine. Retain all removed components for reinstallation. Renew all disturbed fasteners. Visually inspect the engine bed and foundation for deformation and rust. Submit a CFR. Prepare and package the F condition engine for shipment. Drain all fluids from the engine before packaging. Remove all electrical connections, and seal off sockets with a suitable adhesive tape. All screwed connections must be sealed with plastic or metal blanking caps. All flanged connections must be fitted with suitable wooden blanks, sealed in position with waterproof adhesive tape. Cover all openings to atmosphere with waterproof paper sealed with waterproof adhesive tape. Blank exhaust pipes and any other orifices over 3 inches in diameter with wooden flanges, sealed with adhesive tape. Re-use crates from A-condition engines. In addition:

• Remove MIM & EDM from ECS UNI & place in F engine's X-10 box.

• Ensure MIM and EDM are packaged in Static Proof bags or equivalent when stored in the X10 box.

• Crankshaft locking device (provided on "A" condition engine) is returned with the F.

• Serial Number on crate is changed to reflect serial number of "F" condition engine.

24 (Rev-1)

• Condition Code on crate changed to F.

• Ensure F engine is protected from weather if left outside.

• Install shipping blanks from A engine (turbos, water inlets/outlets, etc) on F engine.

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

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

• “NO OIL OR WATER, DO NOT TURN!”.

• “ENGINE REMOVED FROM SERVICE – Date__________”.

3.2.2 Notify the COTR at least 24 hours prior to closing shipping crates. Turn over crated engines to the PA as an MTI item.

3.3 After the completion of all work, reinstall access soft patches with new gasket and new fasteners. Reinstall all interferences removed to accomplish this work. An approved sealant may be used in addition to the new gasket to ensure there are no water leaks. Renew all removed fluids (e.g. lube oil, jacket water, etc.)

3.4 Alignment preparation. Prior to engine alignment, the Contractor shall ensure the following conditions are met for at least 24 hours before the alignment check:

• Cutter fuel and water…