MDE Hot Flush Spec Rev-1_041211.pdf

MAIN DIESEL ENGINE (MDE) HOT FLUSH - IDIQ

210 & 270 FOOT "A and B CLASS" MEDIUM ENDURANCE CUTTERS

SPECIFICATION FOR DOCKSIDE REPAIRS

Developed By: Tim Frownfelter

(Rev-1, 12 April 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: Main Diesel Engine (MDE), Perform Hot Flush, 210 ‘A-Class’ WORK ITEM 2: Main Diesel Engine (MDE), Perform Hot Flush, 210 ‘B’ Class WORK ITEM 3: Main Diesel Engine (MDE), Perform Hot Flush, 270 ‘A’ Class WORK ITEM 4: Main Diesel Engine (MDE), Perform Hot Flush, 270 ‘B’ Class

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

04/12/2011 1 Gen. Rqmts. Modified/expanded par. 3.2.4.3 to address pumping over water. Added par.

3.3 to address placement of contractor equipment.

1 Section 3 (Requirements) re-written to further clarify contractor responsibilities.

2 Section 3 (Requirements) re-written to further clarify contractor responsibilities 3 Section 3 (Requirements) re-written to further clarify contractor responsibilities 4 Section 3 (Requirements) re-written to further clarify contractor responsibilities

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 618 WMEC 262-1, Rev H, Arrangement - Lube Oil Coast Guard Drawing 618 WMEC 262-2, Rev G, DIAG - Lube Oil Coast Guard Drawing 618 WMEC 262-3, Rev -, Mods to Lube Oil & Associated Piping for Spinner II

Installation Coast Guard Drawing 618 WMEC 262-3, Rev -, Mods to Lube Oil & Associated Piping for Spinner II

Installation (ACTIVE) Coast Guard Drawing 618 WMEC 262-50, Rev -, MN Engine LO DIAG & Components Coast Guard Drawing 618 WMEC 262-52, Rev -, MN ENG LO Heat Exchanger Coast Guard Drawing 627 WMEC 262-1, Rev E, Arrangement of Lube Oil System Coast Guard Drawing 627 WMEC 262-2, Rev C, Diagram of Lube Oil System Coast Guard Drawing 627 WMEC 262-5, Rev -, Mods to Lube Oil & Associated Piping for Spinner II

Installation Coast Guard Drawing 627 WMEC 262-52, Rev -, Heat Exchanger – Lube Oil Cooler Coast Guard Drawing 901 WMEC 262-1, Rev H, Lube Oil Sys Diag Coast Guard Drawing 901 WMEC 262-2, Rev J, Lube Oil Service System A&D Coast Guard Drawing 905 WMEC 262-1, Rev B, Lube Oil System DIAG Coast Guard Drawing 905 WMEC 262-2, Rev D, Lube Oil Serv Sys A&D 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 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 MIL-PRF-2104, July 2004, Rev-H, Lubricating Oil, Internal Combustion Engine, Combat/Tactical

Service 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.

This section is not applicable to this package.

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)):

This section is not applicable to this package.

vii (Rev-1)

PC_210A_WMEC_0909

Principal Characteristics

210' WMEC (A Class)

PHYSICAL CHARACTERISTICS

Length Overall 210' 6" Length, Design Waterline 200' 0" Depth (main deck at side to baseline) 19' 6" Maximum Beam 34' 0" Height of Highest Projection 88' 0" Full Load Draft 4,000 lbs Height of FM Antenna Above Baseline 90' 0" Light Ship Displacement 875 long tons Full Load Displacement 1100 long tons Shore Tie Voltage Requirements 400A / 440V Frame Spacing 1' 0"

MACHINERY CHARACTERISTICS

Main Propulsion 2 Alco Model 251B Diesel Engines, 5,000 BHP total

Ship's Service Generators 2 Caterpillar Model 3406B Diesel-driven SR4. 250 KW each @ 0.8 power factor, 440V AV, 3 phase, 60 cycle

Emergency Generator Caterpillar Model D333B Diesel-Driven. Century Synchronous Model, ACR-507, 100KW

Number of Propellers 2 Number of Blades 4 Diameter 7' 6" Pitch Controllable Shaft RPM 300 Shaft Diameter 8.25"

TANK CAPACITIES

Diesel Fuel (95%) 48,375 gal Fresh Water (95%) 11, 108 gal JP-5 Fuel (95%) 4,697 gal Lube Oil (95%) 1,942 gal viii (Rev-1)

210' WMEC (B-Class)

PHYSICAL CHARACTERISTICS

Length Overall 210' 6" Length, Design Waterline 200' 0" Depth (main deck at side to baseline) 19' 6" Maximum Beam 34' 0" Height of Highest Projection 88' 0" Full Load Draft 4,000 lbs Height of FM Antenna Above Baseline 90' 0" Light Ship Displacement 875 long tons Full Load Displacement 1100 long tons Shore Tie Voltage Requirements 400A / 440V Frame Spacing 1' 0"

MACHINERY CHARACTERISTICS

Main Propulsion 2 Alco Model 251B Diesel Engines, 5,000 BHP total

Ship's Service Generators 2 Caterpillar Model 3406B Diesel-driven SR4. 250 KW each @ 0.8 power factor, 440V AV, 3 phase, 60 cycle

Emergency Generator Caterpillar Model D333B Diesel-Driven. Century Synchronous Model, ACR-507, 100KW

Number of Propellers 2 Number of Blades 4 Diameter 7' 6" Pitch Controllable Shaft RPM 300 Shaft Diameter 8.25"

TANK CAPACITIES

Diesel Fuel (95%) 48,375 gal Fresh Water (95%) 11, 108 gal JP-5 Fuel (95%) 4,697 gal Lube Oil (95%) 1,942 gal ix (Rev-1)

270' WMEC (A Class)

PHYSICAL CHARACTERISTICS

Length Overall 270' 0" Depth 33' 3" Maximum Beam 37' 9-3/8" Frame Spacing 1' 0" Full Load Draft 13.85' Full Load Displacement 1825.64 long tons Shore Tie Voltage Requirements 450 vac, 400A, 3 phase cables

HULL CHARACTERISTICS

MACHINERY CHARACTERISTICS

Number of Propellers 2

Number of Blades 4

Diameter of Propeller 9' Pitch Controllable

RPM 260

Shaft Diameter 10.55" at exit of hull

TANK CAPACITIES

x (Rev-1) xi (Rev-1)

270' WMEC (B Class)

PHYSICAL CHARACTERISTICS

Length Overall 270' 0" Depth 33' 3" Maximum Beam 38' 5/8" Frame Spacing 1' 0" Full Load Draft 13.85' Full Load Displacement 1825.64 long tons Shore Tie Voltage Requirements 450 vac, 400A, 3 phase cables

HULL CHARACTERISTICS

MACHINERY CHARACTERISTICS

Number of Propellers 2

Number of Blades 4

Diameter of Propeller 9' Pitch Controllable

RPM 260

Shaft Diameter 10.55" at exit of hull

TANK CAPACITIES

00000_0310_FLT

REC_0000_FLT_ Commercial Project @ CG 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 HW disposal. The Contractor shall be responsible for all hazardous wastes generated by work under this contract. Label and package all hazard wastes in 49 CFR-approved containers, and in accordance with all other applicable Federal, state, and local laws and regulations. In addition, comply with applicable parts of 40 CFR

1 (Rev-1)

262, applicable to handling of hazardous wastes.

3.2.1 Along with the Government, the Contractor shall be contractually considered the co-generator of all hazardous wastes; be aware that the Government will make available its facility’s EPA Generator Identification (ID) Number for manifesting of hazardous wastes.

3.2.2 The Contractor shall identify, arrange, and be responsible for the turnover of all hazardous wastes, within the confines of the Coast Guard shore facility, to the facility’s HM/HW Coordinator. Notify the ship’s HW Coordinator prior to any transfers of HW from ship to shore.

3.2.3 The Contractor shall prepare a manifest of hazardous waste to be reviewed and signed by the HM/HW Coordinator. Contact the HM/HW Coordinator for turnover of any hazardous waste; in addition, notify the COTR 24 hours prior to any waste removals, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.2.4 The Contractor shall be aware of the following:

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

3.2.4.2 Local environmental regulations at the Government facilities may be more stringent than in many jurisdictions. As with all environmental regulations, it is the Contractor's responsibility to research, prepare for, and comply with, the local and state regulations.

3.2.4.3 Coast Guard facilities do not have Facilities Response Plans (see 33 CFR 154 Subpart F). It is the Contractor’s responsibility to furnish the Facility Response Plan (FRP) when required for over-the-water liquids transfers to and from vessels. This requirement is applicable to transfers to/from vessels with an oil/fuel capacity of 250 barrels or more. In the event where liquids must be pumped over water, the contractor shall provide an oil absorbent boom around the ship and pier prior to pumping liquids to or from ship. To accommodate the additional cost of providing oil absorbent boom, a separate line item is included as an option item in the “Schedule of Supplies and Services” to be activated on an individual job basis as-needed.

3.3 Location of contractor equipment. The contractor shall be aware that the Coast Guard may have certain piers that restrict placement of contractor equipment on the pier due to weight limitations and inaccessibility. The contractor may be required to locate Conex boxes, flushing pumps, and any other large equipment away from the pier. To accommodate the additional distance from the pier, separate line items are included as options in the “Schedule of Supplies and Services” to be activated on an individual job basis as-needed. At no time shall Contractor’s Conex boxes be placed aboard the cutter.

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: ___________________________________________________________ Abrasive Manufacturer and Sieve Size: _________________________________

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)

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)

23329_MWS_1210_210_270_210’ WMEC ‘A’ Class (ALL) (1210)

IDIQ_23329_210_270 (0111)

WORK ITEM 1: Main Diesel Engine (MDE), Perform Hot Flush, 210 ‘A-Class’

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a staged hot flush of the Main Diesel Engine (MDE) lubrication oil passages onboard a WMEC 210 ‘A’ Class vessel. The engine is an ALCO 16V 251-CE diesel engine. The requirements are for one (1) engine, port or starboard, as designated.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 618 WMEC 262-1, Rev H, Arrangement - Lube Oil Coast Guard Drawing 618 WMEC 262-2, Rev G, DIAG - Lube Oil Coast Guard Drawing 618 WMEC 262-3, Rev -, Mods to Lube Oil & Associated Piping for Spinner II

Installation Coast Guard Drawing 618 WMEC 262-3, Rev -, Mods to Lube Oil & Associated Piping for Spinner II

Installation (ACTIVE) Coast Guard Drawing 618 WMEC 262-50, Rev -, MN Engine LO DIAG & Components Coast Guard Drawing 618 WMEC 262-52, Rev -, MN ENG LO Heat Exchanger

COAST GUARD PUBLICATIONS

None.

OTHER REFERENCES

MIL-PRF-2104, July 2004, Rev-H, Lubricating Oil, Internal Combustion Engine, Combat/Tactical

Service

3. REQUIREMENTS

3.1 General. The Contractor shall adhere to the following general requirements throughout the duration of all flushing stages:

3.1.1 CIR.

None.

3.1.2 Technical Representative.

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences):

Deck plates.

Piping.

Miscellaneous machinery.

Wiring and cables/cableways.

3.1.5 Flushing media. The Contractor shall use a MIL-L-2104 Grade MS-HDO 10W flushing fluid (approximately 800 gallons) conforming to MIL-PRF-2104.

NOTE

Upon completion of lube oil flushing, the flushing oil may be returned to clean containers and can be used for the next hot lube oil flush provided cleanliness of lube oil can be maintained.

3.1.6 Flushing pump. The Contractor shall use a positive displacement pump capable of 260 gallons per minute at 120 PSI.

NOTE

The Contractor should be aware that neither the cutter, nor the cutter support base, is capable of providing the 440 VAC power necessary to operate such pumping systems and that the contractor must provide a suitable 450 VAC power source

3.1.7 Jumper lines. For all lube oil relief and bypass valves, the Contractor shall install jumper lines to facilitate flushing of these valves and associated lines.

3.1.8 Filter/filtration system. The Contractor shall accomplish the following for the flushing media filters/filtration system:

3.1.8.1 Filter the flushing fluid using milspec muslin bags or filters rated at 25 microns.

3.1.8.2 Renew the muslin bags prior to the start of each flushing stage.

3.1.8.3 Renew muslin bags a minimum of every 2 hours to maintain a differential pressure increase of no more than 5 psig over the differential pressure of a clean muslin bag.

9 (Rev-1)

3.1.9 Component removal/reinstallation tracking. The Contractor shall ensure that all components removed from the engine/lube oil system are match-marked and tracked via a recorded log to ensure proper reinstallation.

Submit a CFR at the end of each flushing stage.

3.1.10 COTR notification. The Contractor shall notify the COTR at least 24 hours prior to beginning each flushing operation.

3.1.11 Pre-flush cleanliness verification. Prior to starting the staged hot flush, the Contractor shall perform the following:

3.1.11.1 Remove and dispose of engine filters.

3.1.11.2 Drain and clean engine sump and screens, filter housing(s), strainer housing(s).

3.1.11.3 Remove and clean oil strainers.

3.1.11.4 Wipe clean and oil-wet engine interior surfaces and components (e.g., crankcase, crankshaft, connecting rods, bearing caps, gears, etc.).

3.1.12 Post-flush report requirements. After each flushing stage, the contractor shall submit a detailed report to the COTR within 24 hours, to include the following at a minimum:

• Method used to obtain the particulate contamination reading.

• Method used to determine particle size.

• Final contamination level readings.

3.1.13 Flushing waste disposal. The contractor shall dispose of all fluids, materials and other waste resulting from the hot flush in accordance with all applicable Federal, state and local regulations.

3.2 Flushing particulars. Using Coast Guard drawings 618 WMEC 262-1, 618 WMEC 262-2, 618 WMEC 262- 3, 618 WMEC 262-4 (as applicable), 618 WMEC 262-50 and 618 WMEC 262-52 as guidance, the Contractor shall conduct a 4-staged flush of the engine lube oil system as described herein:

3.2.1 Flushing sequence. The Contractor shall conduct the following MDE hot oil flushes in the following sequence:

3.2.1.1 - External piping (including pre-lube);

3.2.1.2 - Internal piping;

3.2.1.3 - Combined internal and external piping (excluding pre-lube);

3.2.1.4 - In-place lube oil cooler.

3.2.2 Pre-flushing preparations. The Contractor shall perform the following prior to commencing the applicable flushing stage procedure:

• Blank off pedestal bearing oil feed lines.

• Blank off turbocharger or blower lube oil feed lines.

• Disconnect the lube oil cooler and install jumper line with valve to by-pass the cooler.

• Disconnect main bearing jumper lines and end plugs on main internal lube oil header; hand clean accessible ports and plug.

10 (Rev-1)

• Disconnect all lube oil supply lines to internal components including cam bearing, gear train, governor, and cylinder heads, as applicable.

3.2.3 External lube oil system piping flush. The Contractor shall perform the following:

3.2.3.1 Heat a quantity of clean MIL-L-2104 flushing oil, equaling 60 to 70 percent of sump capacity, to a temperature of 172° to 180° F.

3.2.3.2 Circulate the oil throughout the external lube oil circuit (excluding the prelube system at this time) in the following increments, confirming secure connections prior to each next incremental increase:

• 20 gpm;

• 125 gpm;

• 200 gpm and 120 psi.

CAUTION!

Ensure the external lube oil system valves are aligned properly to allow flushing. Do not open the dirty oil and oil replenishment lines to flushing!

NOTE

The flushing process duration begins when the oil is within and maintains the specified flushing temperature (172° to 180° F), flowrate (200 gpm) and pressure (120 psi).

3.2.3.3 Flush the external lube oil system (excluding the pre-lube system) for 12 hours.

3.2.3.4 At the end of the 12th hour, open the pre-lube system to the external lube oil system and flush for at least an additional two hours, at flushing process conditions, until a differential pressure increase of less than 5 psig higher than the differential of a clean muslin bag can be maintained for a 2-hour period.

3.2.3.5 Particle inspection. Following the additional two hours (14 hours total), collect all solid-based contaminants (see 4.2) from the muslin bags and determine the total volume of all contaminants. Submit a CFR.

NOTE

The total volume of the solid-based particles shall not exceed the volume of a U.S. quarter (25-cent piece) or contain particles greater than 1/64 inch diameter.

3.2.3.6 If the total particle volume exceeds the volume of a U.S. quarter or any particle exists greater than 1/64 inch diameter, restart the flush. Conduct an ensuing inspection of solid-based contaminants at the end of the additional flush. Submit a CFR.

NOTES

The flushing process duration begins when the oil is within and maintains the specified flushing temperature (172° to 180° F), flowrate (200 gpm) and pressure (120 psi).

The total volume of the solid-based particles shall not exceed the volume of a U.S. quarter (25-cent piece) or contain any particle greater than 1/64 inch diameter.

11 (Rev-1)

3.2.3.7 Secure the external lube oil system flushing operation, and all valves to prevent gravity flow back to the engine sump.

3.2.4 Internal lube oil system flush. The Contractor shall perform the following:

3.2.4.1 Heat a quantity of clean MIL-L-2104 flushing oil, equaling 60 to 70 percent of sump capacity, to a temperature of 172° to 180° F.

3.2.4.2 Circulate the oil throughout the internal lube oil circuit in the following increments, confirming secure connections prior to each next increment increase:

• 20 gpm;

• 125 gpm;

• 200 gpm and 120 psi.

CAUTION!

Ensure the internal lube oil system is aligned properly to allow flushing.

NOTE

The flushing process duration begins when the oil is within and maintains the specified flushing temperature (172° to 180° F), flowrate (200 gpm) and pressure (120 psi).

3.2.4.3 Flush the internal lube oil system for 2 hours, at flushing process conditions, until a differential pressure increase of less than 5 psig higher than the differential of a clean muslin bag can be maintained for a 2-hour period. Rotate the engine crankshaft through 90 degrees travel at 20 minute intervals.

NOTE

Ensure lube oil is reaching all internal oil passages by doing a visual inspection; e.g., rocker arms, camshafts, gear trains and piston skirt return passages.

3.2.4.4 Particle inspection. At the end of the two hours, collect all solid-based contaminants (see 4.2) from the muslin bags and determine the total volume of all contaminants. Submit a CFR.

NOTE

The total volume of the solid-based particles shall not exceed the volume of a U.S. quarter (25-cent piece) or contain any particle greater than 1/64-inch diameter.

3.2.4.5 If the total particle volume exceeds the volume of a U.S. quarter or any particle be greater than 1/64-inch in diameter, restart the flush until a differential pressure increase of less than 5 psig higher than the differential of a clean muslin bag can be maintained for a 2-hour period. Conduct an ensuing inspection of solid-based contaminants at the end of the additional flush. Submit a CFR.

NOTES

The flushing process duration begins when the oil is within and maintains the specified flushing temperature (172° to 180° F), flowrate (200 gpm) and pressure (120 psi).

12 (Rev-1)

The total volume of the solid-based particles shall not exceed the volume of a U.S. quarter (25-cent piece) or contain any particle greater than 1/64-inch diameter.

3.2.4.6 Secure the internal lube oil system flushing operation, and all valves to prevent gravity flow back to the engine sump.

3.2.4.7 Replace the main bearing jumper lines and replace end plugs on main internal lube oil header.

3.2.4.8 Reinstall all lube oil supply lines to internal components including cam bearing, gear train, governor, and cylinder heads.

3.2.5 Combined external and internal flush. The Contractor shall perform the following:

3.2.5.1 Heat a quantity of clean MIL-L-2104 flushing oil, equaling 60 to 70 percent of sump capacity, to a temperature of 172° to 180° F.

3.2.5.2 Circulate the oil throughout the internal and external lube oil circuit (excluding the prelube system) in the following increments, confirming secure connections prior to each next increment increase:

• 20 gpm;

• 125 gpm;

• 200 gpm and 120 psi.

CAUTION!

Ensure the internal and external lube oil systems are aligned properly to allow flushing. Do not open the dirty oil and renewal oil lines to flushing!

NOTE

The flushing process duration begins when the oil is within and maintains the specified flushing temperature (172° to 180° F), flowrate (200 gpm) and pressure (120 psi).

3.2.5.3 Flush the internal and external lube oil systems for 12 hours, at flushing process conditions, until a differential pressure increase of less than 5 psig higher than the differential of a clean muslin bag can be maintained for a 2-hour period. Rotate the engine crankshaft through 90 degrees travel at 20 minute intervals.

3.2.5.4 Particle inspection. At the end of the initial 12 hours, collect all solid-based contaminants (see 4.2) from the muslin bags and determine the total volume of all contaminants. Submit a CFR.

NOTE

The total volume of the solid-based particles shall not exceed the volume of a U.S. dime (10-cent piece) or contain any particle greater than 1/64-inch diameter.

3.2.5.5 If the total particle volume exceeds the volume of a U.S. dime or any particle greater than 1/64-inch diameter, renew the muslin bags and continue the flush (without crankshaft rotation) until a differential pressure increase of less than 5 psig higher than the differential of a clean muslin bag can be maintained for a 2-hour period. Conduct an ensuing inspection of solid-based contaminants at the end of the additional flush. Submit a

CFR.

13 (Rev-1)

NOTES

The total volume of the solid-based particles shall not exceed the volume of a U.S. dime (10-cent piece) or contain any particle greater than 1/64-inch diameter.

3.2.5.6 Secure the internal and external lube oil systems flushing operation, and all valves to prevent gravity flow back to the engine sump.

3.2.5.7 Post-internal and external flush restoration. Upon completion of engine flushing, accomplish the following:

3.2.5.7.1 Drain flushing oil from sump, piping, filter and strainer housings, place flushing oil in clean containers.

NOTES

Every effort shall be made to remove MIL-L-2104 from the lube oil system, to including removal of oil sump screens and wiping the sump clean with lint free rags. This will ensure a satisfactory test for viscosity, which will eliminate the need to change oil after a few hours of engine operation.

Careful use of clean low pressure air (100 psi or less) may be used to blow flushing lube oil back to the engine sump through the filter and strainer housings.

3.2.5.7.2 Clean and inspect lube oil sump using lint-free rags. Clean and inspect internal lube oil pump suction piping from the suction bell mouth or strainer to the pump inlet.

3.2.5.7.3 Restore lube oil system to original configuration in preparation for engine run.

3.2.5.7.4 Clean lube oil filter housing and install 10 new Contractor-provided lube oil filters 10 filters, PN Alco A910113.

3.2.5.7.5 Clean and inspect system lube oil strainer and housing; install system strainer baskets; install muslin bags in system strainer baskets if configuration permits.

CAUTION!

Thorough inspection of the engine through the air boxes and engine blowers (where applicable) is necessary to avoid the damage of hydraulic lock.

Ensure all temporary modifications to lube oil piping, resulting from flush operation have been reconfigured to the original installation. Ensure lockwire on all main bearing jumper lines and lube oil gallery end plugs have been reinstalled.

Ensure blank flanges to turbocharger(s)/blowers and main bearings (if installed) are removed.

Ensure strainer and filter bypass valves are properly set.

3.2.5.7.6 Refill MDE with new contractor provided lube oil with MIL-L-9000H, 9250 lube oil.

NOTE

14 (Rev-1)

Contractor should be aware that approx 330 gallons of oil will be needed and that a viscosity reading must be completed by the COTR prior to filling the lube oil system.

3.2.6 Lube oil cooler flushing. The contractor shall perform the following steps for flushing the lube oil cooler and accomplish three flushes total: twice in the normal direction of flow, and once in the opposite direction to occur between the two normal-direction flushes.

3.2.6.1 Drain the contents of the lube oil cooler into a suitable container and dispose of in accordance with all local, state and Federal laws and regulations.

3.2.6.2 Ensure lube oil cooler drain valves are shut.

3.2.6.3 Ensure a suitable air vent is installed and properly plugged.

3.2.6.4 Disconnect the lube oil inlet and outlet piping, clean and install blanks.

3.2.6.5 Connect the flushing module to the lube oil cooler to facilitate flow in the same direction as normal flow.

3.2.6.6 Heat a quantity of clean MIL-L-2104 flushing oil, equaling 60 to 70 percent of sump capacity, to a temperature of 172° to 180° F.

3.2.6.7 Circulate the oil throughout the lube oil cooler in the following increments, confirming secure connections prior to each next increment increase, and periodically bleed the air from the lube oil cooler to ensure all air is removed:

• 20 gpm;

• 125 gpm;

• 200 gpm and 120 psi.

CAUTION!

Ensure the lube oil cooler system is aligned properly to allow flushing.

NOTE

The flushing process duration begins when the oil is within and maintains the specified flushing temperature (172° to 180° F), flowrate (200 gpm) and pressure (120 psi).

3.2.6.8 Flush the lube oil cooler for 4 hours in the direction of normal flow.

NOTES

Lightly strike the lube oil cooler and end bells with a rubber mallet periodically to dislodge any trapped contaminants.

Every 30 minutes, open the vent/drain valves (as applicable) to ensure removal of contaminates; drain into a suitable container.

3.2.6.9 Repeat 3.2.6.6 through 3.2.6.8 one time except with flow in the direction opposite of normal flow for only two hours.

15 (Rev-1)

3.2.6.10 Repeat 3.2.6.6 through 3.2.6.8 one final time with flow in the direction of normal flow for only two hours.

3.2.6.11 Particle inspection. At the end of final flush (third), collect all solid-based contaminants (see 4.2) from the muslin bags and determine the total volume of all contaminants. Submit a CFR.

NOTE

The total volume of the solid-based particles shall not exceed the volume of a U.S. dime (10-cent piece) or contain any particle greater than 1/64-inch diameter.

3.2.6.12 If the total particle volume exceeds the volume of a U.S. dime or any particle is greater than 1/64-inch diameter, renew the muslin bags and continue the flushing sequence until a differential pressure increase of less than 5 psig higher than the differential of a clean muslin bag can be maintained for a 2-hour period. Conduct an ensuing inspection of solid-based contaminants at the end of the additional flush. Submit a CFR.

NOTES

The total volume of the solid-based particles shall not exceed the volume of a U.S. dime (10-cent piece) or contain any particle greater than 1/64-inch diameter.

3.2.6.13 Lube oil cooler restoration.

3.2.6.13.1 Drain all flushing oil from the lube oil cooler into a suitable container.

3.2.6.13.2 Restore the lube oil cooler and all associated piping/lines to original cooler configuration.

3.3 Engine run after flushing completion. In the presence of the Coast Guard Inspector, the Contractor shall thoroughly test and prove the MDE to be in satisfactory operating condition (see 4.1 (Equipment operation)).

CAUTION!

Prior to running the engine, ensure all lines disturbed throughout the flushing process are reattached correctly and are secure. Also verify the engine oil quantity is adequate prior to pre-lubing and starting the engine.

Monitor the differential pressure across the lube oil strainers and filters during engine operation. Ensure the differential pressure does not exceed bypass valves set point. If the strainer or filter requires repeated cleaning to maintain proper differential pressure, the entire flushing procedure shall be repeated.

3.3.1 After 15 minutes of no-load operation, sample and test lube oil for viscosity.

3.3.2 At the discretion of the Engineer Officer and/or COTR, continue to run engine at no load and increase engine speed from idle to full speed over a 15 minute period and in accordance with the ships Engineering Operating Procedures.

CAUTION!

Monitor the differential pressure across the strainer and filter during engine operation. Ensure the differential pressure does not exceed bypass valves set point. If the strainer or filter requires repeated cleaning to maintain proper differential pressure, the entire flushing procedure shall be repeated.

3.3.3 Continue to run the engine at no-load full speed for an additional 15 minutes.

16 (Rev-1)

17 (Rev-1)

3.3.4 Stop the engine and check the lube oil strainer.

CAUTION!

If the strainer contains solid contaminants larger than 1/64 inch or volume of solid contaminants is larger than a dime, repeat the final flush procedures until an acceptable criteria is obtained.

3.4 Inspector witnessing and approval. The Contractor shall ensure that the Coast Guard Inspector is present during all flushing oil sampling and inspection. The Contractor’s final sampling and inspection shall be approved in writing by the COTR and Coast Guard Inspector.

4. NOTES

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

4.2 Solid-based contaminants. Solid-based contaminants are defined as particles which cannot be crushed between the thumbnail and finger.

23329_MWS_1210_210_270_210’ WMEC ‘B’ Class (ALL) (1210)

IDIQ_23329_210_270 (0111)

WORK ITEM 2: Main Diesel Engine (MDE), Perform Hot Flush, 210 ‘B–Class’

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a staged hot flush of the Main Diesel Engine (MDE) lubrication oil passages onboard a WMEC 210 ‘B’ Class vessel. The engine is an ALCO 16V 251-B diesel engine. The requirements are for one (1) engine, port or starboard, as designated.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 627 WMEC 262-1, Rev E, Arrangement of Lube Oil System Coast Guard Drawing 627 WMEC 262-2, Rev C, Diagram of Lube Oil System Coast Guard Drawing 627 WMEC 262-5, Rev -, Mods to Lube Oil & Associated Piping for Spinner II

Installation Coast Guard Drawing 627 WMEC 262-52, Rev -, Heat Exchanger – Lube Oil Cooler

COAST GUARD PUBLICATIONS

None.

OTHER REFERENCES

MIL-PRF-2104, July 2004, Rev-H, Lubricating Oil, Internal Combustion Engine, Combat/Tactical

Service

3. REQUIREMENTS

3.1 General. The Contractor shall adhere to the following general requirements throughout the duration of all flushing stages:

3.1.1 CIR.

None.

3.1.2 Technical Representative.

18 (Rev-1)

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences):

Deck plates.

Piping.

Miscellaneous machinery.

Wiring and cables/cableways.

3.1.5 Flushing media. The Contractor shall use a MIL-L-2104 Grade MS-HDO 10W flushing fluid (approximately 800 gallons) conforming to MIL-PRF-2104.

NOTE

Upon completion of lube oil flushing, the flushing oil may be returned to clean containers and can be used for the next hot lube oil flush provided cleanliness of lube oil can be maintained.

3.1.6 Flushing pump. The Contractor shall use a positive displacement pump capable of 260 gallons per minute at 120 PSI.

NOTE

The Contractor should be aware that neither the cutter, nor the cutter support base, is capable of providing the 440 VAC power necessary to operate such pumping systems and that the contractor must provide a suitable 450 VAC power source

3.1.7 Jumper lines. For all lube oil relief and bypass valves, the Contractor shall install jumper lines to facilitate flushing of these valves and associated lines.

3.1.8 Filter/filtration system. The Contractor shall accomplish the following for the flushing media filters/filtration system:

3.1.8.1 Filter the flushing fluid using milspec muslin bags or filters rated at 25 microns.

3.1.8.2 Renew the muslin bags prior to the start of each flushing stage.

3.1.8.3 Renew muslin bags a minimum of every 2 hours to maintain a differential pressure increase of no more than 5 psig over the differential pressure of a clean muslin bag.

3.1.9 Component removal/reinstallation tracking. The Contractor shall ensure that all components removed from the engine/lube oil system are match-marked and tracked via a recorded log to ensure proper reinstallation.

Submit a CFR at the end of each flushing stage.

19 (Rev-1)

3.1.10 COTR notification. The Contractor shall notify the COTR at least 24 hours prior to beginning each flushing operation.

3.1.11 Pre-flush cleanliness verification. Prior to starting the staged hot flush, the Contractor shall perform the following:

3.1.11.1 Remove and dispose of engine filters.

3.1.11.2 Drain and clean engine sump and screens, filter housing(s), strainer housing(s).

3.1.11.3 Remove and clean oil strainers.

3.1.11.4 Wipe clean and oil-wet engine interior surfaces and components (e.g., crankcase, crankshaft, connecting rods, bearing caps, gears, etc.).

3.1.12 Post-flush report requirements. After each flushing stage, the Contractor shall submit a detailed report to the COTR within 24 hours, to include the following at a minimum:

• Method used to obtain the particulate contamination reading.

• Method used to determine particle size.

• Final contamination level readings.

3.1.13 Flushing waste disposal. The contractor shall dispose of all fluids, materials and other waste resulting from the hot flush in accordance with all applicable Federal, state and local regulations.

3.2 Flushing particulars. Using Coast Guard drawings 627 WMEC 262-1, 627 WMEC 262-2, 627 WMEC 262- 5, and 627 WMEC 262-52 as guidance, the Contractor shall conduct a 4-staged flush of the engine lube oil system as described herein:

3.2.1 Flushing sequence. The Contractor shall conduct the following MDE hot oil flushes in the following sequence:

3.2.1.1 - External piping (including pre-lube);

3.2.1.2 - Internal piping;

3.2.1.3 - Combined internal and external piping (excluding pre-lube);

3.2.1.4 - In-place lube oil cooler.

3.2.2 Pre-flushing preparations. The Contractor shall perform the following prior to commencing the applicable flushing stage procedure:

• Blank off pedestal bearing oil feed lines.

• Blank off turbocharger or blower lube oil feed lines.

• Disconnect the lube oil cooler and install jumper line with valve to by-pass the cooler.

• Disconnect main bearing jumper lines and end plugs on main internal lube oil header; hand clean accessible ports and plug.

• Disconnect all lube oil supply lines to internal components including cam bearing, gear train, governor, and cylinder heads, as applicable.

20 (Rev-1)

3.2.3 External lube oil system piping flush.