BLUE_SHARK_(WPB_87)_DSSPEC_REV1.pdf

USCGC BLUE SHARK (WPB 87360)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2017

Developed By: James E Beechey

(Rev 1, 11 January 2017)

USCGC BLUE SHARK (WPB-87) DOCKSIDE AVAILABILITY FY2017

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 Engines, Starboard, Renew WORK ITEM 2: Temporary Services, Provide - Cutter WORK ITEM 3: Window(s), Renew WORK ITEM 4: Interior Deck (Epoxy) Covering System(s), Reseal WORK ITEM 5: Main Diesel Engine Assembly, Perform W-5 Maintenance iii (Rev-1)

REVISIONS RECORD

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

DATE REV# WORK

ITEM#

CHANGES MADE

1/11/2017 1 3 Added required windows for renewal as GFE

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

iv (Rev-1)

CONSOLIDATED LIST OF REFERENCES

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

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

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

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

www.gpoaccess.gov

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

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

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

• NFPA: http://www.nfpa.org

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

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 167-001, Rev H, Schedule of Doors, Manholes, Windows and Hatches Coast Guard Drawing 87 WPB 182-001, Rev C, Main Engine and Generator Foundations Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft Details Coast Guard Drawing 87 WPB 634-001, Rev C, Deck Coverings & Details

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, Jun 2006, Coatings and Colors

Manual 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) 4533A, Mar 2003, MAIN DIESEL ENGINE - MAINTENANCE

MANUAL - MODEL 8V396TE94

Coast Guard Technical Publication (TP) 4573, Coolant Heating System, 17 March 2003 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.

Coast Guard Technical Publication (TP) 7025, May 2007, MAIN DIESEL ENGINE - FLUIDS &

LUBRICANTS SPECIFICATIONS

http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace v (Rev-1)

MTU Main Diesel Engine Installation Memo, 7 October 2010 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General

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

Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures Surface Forces Logistics Center Standard Specification 6341 (SFLC Std Spec 6341), 2014, Install Interior

Deck Covering Systems Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), 2014, Temporary

Services

OTHER REFERENCES

Installation of MTU Electronic Systems E 530 606/06E MTU 8V 396 TE.4 Maintenance Manual M020046/21E MTU 8V 396 TE94 Description and Operation Manual M011511/00E MTU 8V 396 TE94 Parts Catalog M033971/00DE, Order #771903 MTU 8V396 TE.4 Tolerances & Wear Limits List M070026/00E MTU Customer Connecting System CCS for ECS 396, E 531 415/00EMTU Electrical Start Device SUE-

ES for ECS 396, E 531 482/00E MTU Customer Connecting System CCS for ECS 396, E 531 416/00E MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED MTU Engine Management System Typ ECS 396/S Version E & F with ETB 4E/ETB 4F Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E MTU Exhaust Turbocharger ZR140 M040052/10E MTU Fluids and Lubricants Specification A001061/35E MTU Junction Box CCS-ECS 396E Illustrated Parts Catalog E 535 151/01ED MTU Local Operating Panel for ECS E 531 301/01E MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED MTU Monitoring & Control Unit Documentation E 535 164/00ED MTU Service Information 396-99/0562B Electric Governor Actuator with Oil Drain MTU Solenoid Actuator, Description, Assembly Instructions M040082/10E MTU Tool List M004021/20DE 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)

1 Y Main Diesel Engine 12-348-2440 1 250,000.00 1 N Soft Patch Kit 01-601-2062/87CPBSPK 1 3,000.00 1 N *Alignment Kit N/A 1 set 3,000.00 1 N Clamp, synchro (8”

V-clamp), DeAngelo Marine

01-568-6899 2 23.60

1 N Clamp, synchro (8” Turbo V-clamp)

01-593-2913 2 137.02

1 N Clamp, synchro (12” V-band clamp)

01-590-8152 2 28.34

3 N DWG 87 WPB 167-

001, item #5 Port

NSN 21-914-8548 PN

72109-1262P

1 2,455.00

3 N DWG 87 WPB 167-

001 item # 5 Stbd

NSN 21-921-0245 PN

72109-1262/S

1 2471.00

3 N DWG 87 WPB 167-

001 item #7 Stbd

NSN 21-914-9450 PN

72106-1259

1 2586.00

5 Y Cylinder Head 12-345-1076 8 $5000 5 Y “A” Bank

Turbocharger 12-347-2009 1 $11500

5 Y “B” Bank Turbocharger

12-347-2010 1 $12,000

5 Y Sea Water Pump 12-344-4810 1 $9800 5 Y Jacket Water Pump 12-344-4606 1 $6500 5 Y Starter 12-156-2556 1 $3000 5 Y **Charge Air Cooler 12-344-4608 1 $20,000 5 Y **Injector with retainer 12-341-9988 8 $700

5 N **Cylinder Liner 12-361-3855 8 $800 5 N **Piston 12-362-8999 8 $3600 5 N/A Engine Acceptance

Test Record

N/A 1/MDE N/A

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

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

***Government-furnished property, which is to be supplied by either the vessel or the C4IT ServiceCenter vii (Rev-1)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

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

Work Item Title

This section is not applicable to this package.

viii (Rev-1)

PRINCIPAL CHARACTERISTICS

87' WPB

PHYSICAL

Length overall 87' Length between perpendiculars 81' 7" Depth 10' 11" Maximum beam 19.4' Draft, mean to design waterline 5' 9" Height of highest projection 50.2' Full load displacement 93.5 long tons Minimum operating displacement 83.9 long tons Displacement, light ship 77.9 long tons Framing Longitudinal Bulkheads Four watertight bulkheads located below the Main Deck Anchor 40 lb Fortress with 480 ft. 3 strand 5/8" dia. Line stayset

HULL

Hull/main weatherdeck material ABS Grade AH 36 Superstructure 5086 Aluminum

MACHINERY

Main propulsion Two MTU 8V396TE94, sequential turbo-charged diesels Reduction gears Two ZF Type BW 255 Propulsion shaft Two AQUAMET 22, 101.6mm Shaft diameter 4" Shaft seal Two John Crane mechanical seals Shaft bearing, intermediate Thordon Elastomeric Bearing Shaft bearing, aft Thordon Elastomeric Bearing Number of propellers 2 Number of blades 5 Diameter of propeller 1040mm Pitch 1230 mm fixed Shaft RPM 828 Rudders Two 316L Stainless Steel Ship's service generators Two Man Model D08241F01 diesel with Stanford 60KW Generator

TANK CAPACITIES

3-9-1-f (fuel oil) 1402 gal 3-9-2-f (fuel oil) 1402 gal 3-12-2-f (waste oil) 86 gal 3-12-1-f (oily water) 86 gal 3-7-0-q (sewage collection) 352 gal 3-7-1-q (grey water) 52 gal 3-12-1-w (fresh water) 200 gal 3-12-2-w (fresh water) 200 gal

1 (Rev-1)

00000_0316_FLT

REC_00000_FLT_Commercial Project @ CG Facility (1212)

General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed by commercial contractors at a Coast Guard facility for Coast Guard vessels.

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

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

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

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

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

OTHER REFERENCES

None

3. REQUIREMENTS

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

NOTE

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

2 (Rev-1)

3.2 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

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

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

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

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

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

NOTE

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

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

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

3.5.1 USCG facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, during the performance of this availability. Contractor shall plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor shall comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.1.1 USCG Generator status. The activity Generator Status for the Coast Guard Facility is _________ (Status will be provided to contractor upon award of contract).

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

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

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

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

3 (Rev-1)

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

3.5.3 Regulatory notifications. The Contractor shall be responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The Contractor shall submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications shall be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

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

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

3.5.5 HW disposal. Contractor shall comply with SFLC Std Spec 0000 Appendix B, Requirements For Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.5.6 Additional Requirements. The Contractor shall be aware of the following:

3.5.6.1 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 COR or KO-approval.

3.5.6.2 Local environmental regulations at the Government facilities may be more stringent. As with all environmental regulations, the Contractor shall prepare for and comply with local and state regulations.

3.5.6.3 Coast Guard facilities do not maintain Facilities Response Plans (FRPs) per 33 CFR 154. Contractor shall furnish the FRP when required for over-the-water liquids transfers to and from vessels, and is required for oil/fuel transfers to/from vessels for 250 barrels (10,500 gallons) or more.

3.6 Local Policy. None.

3.7 SFLC standard specification approved changes. The Contractor shall be aware that the following are approved

4 (Rev-1) changes to published SFLC 2014 Edition Standard Specifications and supersede published content:

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

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

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

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

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

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

3.7.2 SFLC Standard Specification 0000 General Requirements.

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

3.7.2.2 Change Std Spec 0000 paragraph 3.2.4.2.3(QP 1 inspector or tech rep duties) bullet, “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph

3.1.19 of SFLC Std Spec 6310 (Critical drying time requirements)).” to “Determine when applied coats have sufficiently cured for overcoating or for system service resumption (see paragraph 3.1.17 of SFLC Std Spec 6310 (Critical drying time requirements)).”

4. NOTES

4.1 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 6310 to be completed and submitted during preservation of “critical-coated surfaces”, are provided at the end of this document.

4.2 USCG Facilities. Commercially contracted crane service must comply with all local USCG Facility crane operations requirements.

5 (Rev-1)

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

VESSEL NAME HULL # WORK ITEM # WORK ITEM TITLE

LOCATION OF WORK (INCL. FRAME #’S) AREA (SQFT)

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

Ensure all coatings are in compliance with SFLC Std Spec 6310, Appendix C.

CHECKPOINT 2 - PAINT STORAGE

Ensure all coatings are kept at a temperature of 65 to 85°F at all times, unless otherwise specified by the coating mfgr.

CHECKPOINT 3 - AMBIENT CONDITIONS

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

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

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

CHECKPOINT 4 - PRE-SURFACE PREPARATION

Remove surface contaminants (soluble salts, loose rust, mud, and marine growth) with low pressure fresh water wash down (maximum 5,000 psi). If oil and grease are present, perform solvent cleaning, as per SSPC SP-1.

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

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

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

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

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

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

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

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

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

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

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

CHECKPOINT 9 – FINAL INSPECTION

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

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

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

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

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

CHECKPOINT 10 – RECORD KEEPING

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

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

6 (Rev-1)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

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

DATE

TIME

ACTIVITY (SURFACE

PREPARATION, PRIMER COAT,

BARRIER COAT, TOP COAT,

ETC…)

LOCATION (FRAME &

DECK, RELATION TO

EQUIPMENT, ETC.)

TEMPERATURE % REL.

HUMID-

ITY

DEW

PT.

SURFACE AMBIENT ΔT

| DP -

SURFACE |

7 (Rev-1)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area) Brush-blasting (non-metallic substrate)

ABRASIVE MANUFACTURER: ABRASIVE SIEVE SIZE:

Place surface profile replica tapes in the spaces provided below, to serve as permanent QA record. Maintain a separate log for each location. When an area is divided into separate sections, maintain a separate log for each section.

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Place Surface Profile Replica Tape Here

Reading (mils): Reading (mils): Reading (mils):

MEAN MIL READING (IAW ASTM D4417-METHOD C) FOR ABOVE 15 READINGS:

8 (Rev-1)

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area) Brush-blasting (non-metallic substrate)

ABRASIVE MANUFACTURER: ABRASIVE SIEVE SIZE:

Record measurements taken in the spaces provided below, to serve as permanent QA record. Maintain separate log for each location. When an area is divided into separate sections, maintain a separate log for each section.

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Mean Reading (mils)

Mean Reading (mils) IAW ASTM DD4417).

9 (Rev-1)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY Measurements IAW SSPC-GUIDE 15.

DATE TEST LOCATIONS CONDUCTIVITY (MICROSIEMENS/CM)

10 (Rev-1)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

COATING MFG PRODUCT NAME BATCH

INDUCTION

TIME

COATING SYSTEM SEQUENCE

(PRIMER/TOUCHUP/3RD COAT, ETC.)

Dry Film Thickness (DFT) Measurements IAW SSPC-PA 2.

SPOT 1 2 3 4 5 AVERAGE

VALUE

*BASE METAL READING

(BMR) Required, If Magnetic Pull-Off (Type I/Banana) Gauge Is Used.

LOCATION (FRAME REFERENCE):

SPOT 1 2 3 4 5 OVERALL AVG. DFT ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE ADJUSTMENTS AFTER ADJUSTMENTS

AVG.

1 AVG. BMR DEVIATION

1 AVG. BMR DEVIATION

APPLICATION METHOD (AIRLESS, CONVENTIONAL SPRAY,

ROLLED)

AVERAGE DFT

11 (Rev-1)

23000_MWS_0712_87WPB

WORK ITEM 1: Main Diesel Engines, Starboard, Renew

1. SCOPE

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

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PART NO. QTY ESTIMATED COST

($/UNIT)

Y Main Diesel Engine NSN: 12-348-2440 1 250,000.00 N Soft Patch Kit 01-601-2062/87CPBSPK 1 3,000.00 N *Alignment Kit N/A 1 set 3,000.00

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

01-568-6899 2 23.60

N Clamp, synchro (8” Turbo V-clamp)

01-593-2913 2 137.02

N Clamp, synchro (12” V-band clamp)

01-590-8152 2 28.34

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 C, Main Engine and Generator Foundations

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, 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) 4533A, Mar 2003, MAIN DIESEL ENGINE -

MAINTENANCE MANUAL - MODEL 8V396TE94

12 (Rev-1)

Coast Guard Technical Publication (TP) 7025, May 2007, 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 Alignment personnel qualification. The Contractor shall ensure that the shaft alignment is performed under the direct supervision of personnel experienced in and regularly engaged in shaft and engine alignment. Personnel performing alignment work shall be familiar with manufacturer's installation techniques, be able to assist with proper bearing and shaft alignment, be able to analyze shaft and bearing clearances, and be able to ensure compliance with engine/reduction gear manufacturer's installation standards. Personnel engaged in the supervision of the alignment work shall possess a résumé of demonstrated experience with engine and reduction gear systems. Submit a copy of the supervisor’s résumé and any applicable references to the COTR at the Arrival Conference.

3.1.4 Refer to TP-4531, TP-4532, TP-4533, TP-7025, TP-4593C for all work herein.

3.1.5 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.

NOTE

Determine the “port” or “stbd” configuration of each new GFP engine. If two “port” GFP engines or two “stbd” GFP engines are received, then include that determination in the CFR below. One of the engines shall be converted to either the port or stbd configuration via contract mod.

3.2 Renew stbd MDE. The Contractor shall renew the stbd MDE assembly. 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

13 (Rev-1) 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. Determine if a GFP engine must be converted to “stbd” engine. 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.

• 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 crate. Turn over crated engine 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 filled to normal operating levels, a minimum of three-quarters capacity.

• All major equipment and machinery weighing over 1,000 pounds (450 kilograms) are either installed or simulated by equivalent weights appropriately located.

14 (Rev-1)

• The Contractor shall ensure that divers are on standby in order to seal stern tube from hull side of stern tube in the event of water ingress from malfunctioning emergency inflatable shaft seal during alignment procedure.

3.5 Engine assembly alignment. The Contractor shall align the stbd engine/reduction-gear to the prop shaft. Refer to Coast Guard Drawings 87 WPB 182-001, 87 WPB 243-001, and Engine/Gearbox Plant Alignment Instructions (USCG CPB Project MTU-FA 771903). Measure and record final coupling hub alignment readings. Submit CFR.

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

3.7 Operational test. The Contractor shall demonstrate proper operation of all disturbed assemblies and components. During sea trials verify no unusual noise, vibrations, binding, etc.

Correct all discrepancies. Submit a CFR.

4. NOTES

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

15 (Rev-1)

86350_1114_FLT

REC_86350_FLT_87 WPB (ALL) (1213)

WORK ITEM 2: Temporary Services, Provide - Cutter

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to provide temporary services to the Cutter, during the performance of this availability.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 8635 (SFLC Std Spec 8635), 2014, Temporary Services

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area

16 (Rev-1) against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

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

3.2 Temporary service particulars. The Contractor shall provide the below listed temporary services, in accordance with SFLC Std Spec 8635.

TABLE 1 - SERVICE SELECTION

*SUB-

PARAGRAPH TITLE Y/N

3.3.1 Office space Y

3.3.2 Telephone & Data Service as required by section 2 (references) Y

3.3.3 Parking Y

3.3.4 Duty section berthing: _1_ male, _1_ female. Duty section berthing shall be provided for The entire duration of the availability, during disruption of berthing areas.

Y

3.3.5 Electrical power (including all requirements in associated sub-paragraphs) Y

3.3.6 Hull grounding straps (not applicable when cutter is waterborne) Y

3.3.7 Compressed air (including all requirements in associated sub-paragraphs) Y

3.3.8 Hazardous material/hazardous waste disposal (see Tables 2 and 3 below) Y

3.3.9 Heavy lift equipment: {_5_day(s)/or __ hour(s)} Y

3.3.10 Water supply Y

3.3.10.1 Potable water: unlimited gallons per day, at 35 psig Y

3.3.10.2 Hot-circulating water Y

3.3.10.3 Cooling water Y

3.3.10.4 Firemain system (including all requirements in associated sub-paragraphs) Y

3.3.11 Steam (including all requirements in associated sub-paragraphs) N

3.3.12 Refuse disposal Y

3.3.13 Sewage and grey water disposal (including all requirements in associated sub-paragraphs) Y

3.3.14 Storage – General (including all requirements in associated sub-paragraphs): Y

3.3.14 Dry stores. Y

3.3.14 Paint and flammable stores. Y

3.3.14 Refrigerated stores. Y

3.3.15 Small boat storage (including all requirements in associated sub-paragraphs) Y *Each sub-paragraph number relates directly to the identical sub-paragraph number in SFLC Std Spec 8635.

TABLE 2 - HAZARDOUS WASTE DISPOSAL – LIQUIDS (GALLONS)

PAINT THINNERS ENGINE COOLANT BILGE WATER

0 5 50

TABLE 3 - HAZARDOUS WASTE DISPOSAL – SOLIDS

OILY

FILTERS

OILY RAGS

(LBS)

EMPTY 1-GAL

CONTAINER*

EMPTY 5-GAL

CONTAINER*

EMPTY 55-GAL

CONTAINER*

20 10 10 3 2

17 (Rev-1)

*Previously housed hazardous materials.

3.2 Extended temporary services. If the performance period of the contract is extended by the KO, the contractor shall continue to provide all temporary services as specified herein for the extension period.

4. NOTES

This section is not applicable to this work item.

18 (Rev-1)

16701_MWS_0315_87WPB

WORK ITEM 3: Window(s), Renew

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to renew window(s) as designated in table 1.3

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PART NO. QTY ESTIMATED COST

($/UNIT)

N DWG 87 WPB 167-001,

item #5 Port

NSN 21-914-8548 PN 72109-

1262P 1 $2,455.00

N DWG 87 WPB 167-001

item # 5 Stbd

NSN 21-921-0245 PN 72109-

1262/S 1 $2471.00

N DWG 87 WPB 167-001

item #7 Stbd

NSN 21-914-9450 PN 72106-

1 $2586.00

1.3 Windows for renewal.

WINDOW/PORTLIGHT SUBSTRATE

MATERIAL

LOCATION

USCG DWG 87 WPB -167-001, ITEM #5 Port Alum Bridge USCG DWG 87 WPB -167-001, ITEM #5 Stbd Alum Bridge USCG DWG 87 WPB -167-001, ITEM #7 Stbd Alum Bridge

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 167-001, Rev H, Schedule of Doors, Manholes, Windows and Hatches

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

19 (Rev-1)

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

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures.

Not applicable.

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

• Bulkheads.

• Furniture.

• Inclinometer.

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

3.2 Window(s) renewal. The Contractor shall renew the window(s) as designated while using Coast Guard Drawing 87 WPB 167-001 as guidance.

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

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

3.5 Operational test – post renewal(s). After completion of work, the Contractor shall, in the presence of the Coast Guard Inspector, thoroughly test and prove all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

20 (Rev-1)

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

21 (Rev-1)

S16_004_63402_MWS_0616_87WPB

WORK ITEM 4: Interior Deck (Epoxy) Covering System(s), Reseal

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to reseal the designated epoxy deck covering system.

1.2 Government-furnished property.

None.

1.3 Deck covering location and details.

LOCATION COVERING DESCRIPTION INTERFERENCES

PASSAGE (2-5-0-L)

Area: ~40 sqft Aluminum Joiner Deck

Epoxy Flake System Bulkheads, bilge access covers

HEAD (2-5-2-L)

Area: ~12 sqft

Aluminum Joiner Deck

Epoxy Flake System Bulkheads, deck drains

MESS DECK &

GALLEY (2-9-2-Q, 2-9-

1-Q) Aluminum Joiner Deck

Area: ~175 sqft

Epoxy Flake System Bilge access covers, mess deck furniture, galley equipment, bulkheads, deck drains

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 634-001, Rev C, Deck Coverings & Details

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 6341 (SFLC Std Spec 6341), 2014, Install Interior Deck Covering Systems

OTHER REFERENCES

None

22 (Rev-1)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not applicable.

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

3.1.4 Interferences. The Contractor shall handle all interferences (listed above in 1.3) in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.2 Resealing particulars. The Contractor shall reseal the designated deck covering system in the designated space as follows, using Coast Guard Drawing 87 WPB 634-001 and SFLC Std Spec 6341 as guidance:

3.2.1 Cosmetic Polymeric Epoxy Resin resealing. Accomplish the following and refer to Coast Guard Drawing 87 WPB 634-001:

3.2.1.1 Thoroughly clean deck covering surfaces with a suitable cleaning detergent conforming to MIL-D-16791, and hot water.

3.2.1.2 Rinse, clean, and dry the deck surfaces until no residue is visible.

3.2.1.3 Lightly sand with No. 60 sandpaper, or mechanically sand the surfaces, to remove the existing sealer coat; avoid damaging the color coating. Vacuum thoroughly to remove dust.

3.2.1.4 Thoroughly seal the deck covering system with a minimum of two coats of a suitable sealer, in accordance with the deck covering system manufacturer’s recommendations. Allow sealer to cure for the amount of time recommended by the manufacturer. Keep traffic off deck until sealer is cured.

3.2.2 Epoxy flake system resealing. The contractor shall reseal the deck areas specified. Sand down the existing deck covering to the color layer to remove all discolorations and damage.

Reapply color coat to obtain uniform color. Reapply sealers. Renew piece(s) 7 of Coast Guard Drawing 87 WPB 634-001 (slip resistant treads) where disturbed.

23 (Rev-1)

CAUTION!

Epoxy flake system is resealed over delicate joiner deck. Do not damage joiner deck during removal of top layer of existing deck material.

To minimize impact on cutter weight & moment, do not add excessive deck covering material, beyond what was removed. Make new deck covering thickness as close a practicable original, pre-resealed thickness.

NOTE

The sealing process is complete when the deck has a uniform appearance; i.e., when the surface film is continuous and free of blotchy areas.

24 (Rev-1)

23001_MWS_0315_87WPB

WORK ITEM 5: Main Diesel Engine Assembly, Perform W-5 Maintenance

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a W-5 overhaul of the port main diesel engines (MDE).

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y Cylinder Head NSN: 12-345-1076 8 $5000 Y “A” Bank Turbocharger NSN: 12-347-2009 1 $11500 Y “B” Bank Turbocharger NSN: 12-347-2010 1 $12,000 Y Sea Water Pump NSN: 12-344-4810 1 $9800 Y Jacket Water Pump NSN: 12-344-4606 1 $6500 Y Starter NSN: 12-156-2556 1 $3000 Y **Charge Air Cooler NSN: 12-344-4608 1 $20,000 Y **Injector with retainer NSN: 12-341-9988 1 $700 N **Cylinder Liner NSN: 12-361-3855 1 $800 N **Piston NSN: 12-362-8999 1 $3600

N/A Engine Acceptance Test Record

N/A 1/MDE N/A

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

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 4573, Coolant Heating System, 17 March 2003 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

OTHER REFERENCES

MTU 8V 396 TE.4 Maintenance Manual M020046/21E MTU 8V 396 TE94 Description and Operation Manual M011511/00E

25 (Rev-1)

MTU 8V 396 TE94 Parts Catalog M033971/00DE, Order #771903 MTU 8V396 TE.4 Tolerances & Wear Limits List M070026/00E MTU Tool List M004021/20DE MTU Exhaust Turbocharger ZR140 M040052/10E MTU Solenoid Actuator, Description, Assembly Instructions M040082/10E MTU Service Information 396-99/0562B Electric Governor Actuator with Oil Drain MTU Fluids and Lubricants Specification A001061/35E MTU Engine Management System Typ ECS 396/S Version E & F with ETB 4E/ETB 4F

Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E MTU Customer Connecting System CCS for ECS 396, E 531 416/00E MTU Customer Connecting System CCS for ECS 396, E 531 415/00EMTU Electrical Start

Device SUE-ES for ECS 396, E 531 482/00E MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED MTU Junction Box CCS-ECS 396E Illustrated Parts Catalog E 535 151/01ED MTU Local Operating Panel for ECS E 531 301/01E MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED MTU Monitoring & Control Unit Documentation E 535 164/00ED Installation of MTU Electronic Systems E 530 606/06E ANSI/NCSL Z540 3 2006.08.03, Requirements for the Calibration of Measuring and Test

Equipment ANSI/ASQC Q90003-1994, dtd 18 July 94, Inspection System

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall, for disassembly and repair work, provide an on-site technical representative certified by MTU to the 396 CM2 level and have a minimum of five years experience working on MTU marine propulsion engines over the last ten years. The technical representative shall advise on the latest manufacturer's information, dimensions, and clearances associated with the system, conduct proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly,…