MLCPACINST M9000_6E.pdf

NAVAL ENGINEERING DIVISION

MAINTENANCE AND LOGISTICS COMMAND PACIFIC

NAVAL ENGINEERING

ORGANIZATION AND OPERATING

PROCEDURES MANUAL

MLCPACINST M9000.6E

April 2007

MAINTENANCE AND LOGISTICS COMMAND PACIFIC

ORGANIZATION AND OPERATING PROCEDURES

NAVAL ENGINEERING DIVISION

TABLE OF CONTENTS

TITLE PAGE

Letter of Promulgation i Record of Corrections iv

Table of Contents v

Chapter 001 INTRODUCTION 001-1 001.A Scope 001-1 001.B Changes 001-1

001.C Distribution 001-1

Chapter 002 ORGANIZATION 002-1 002.A Mission and Vision Statements 002-1 002.B Organizational Relationships/ Responsibilities 002-1 002.C Services and Functions 002-5 002.D Routine Correspondence 002-6 002.E Continuous Change Process 002-7

Chapter 036 MAINTENANCE PHILOSOPHY

AND DEFINITIONS 036-1

036.A Background 036-1 036.B Maintenance Philosophy 036-1 036.C Outputs of a Streamlined RCM Philosophy 036-1 036.D Other Maintenance Definitions 036-3

Chapter 037 MAINTENANCE RESPONSIBILITIES 037-1 037.A General 037-1 037.B COMDT Naval Engineering 037-1 037.C Engineering Logistics Center (ELC) 037-1 037.D MLC Pacific Naval Engineering Division 037-1 037.E Naval Engineering Support Units (NESU) 037-2 037.F Unit Commanding Officers and Officers-in-Charge 037-3 037 G Operational Commanders 037-3 037 H Sector / Group Commanders 037-3

Chapter 038 MAINTENANCE POLICY AND PLANNING 038-1 038.A Maintenance Policy 038-1

038.B Maintenance Planning 038-2

Chapter 039 MAINTENANCE PROGRAMS AND

INITIATIVES 039-1

039.A General 039-1 039.B Coast Guard Machinery Assessment Program 039-1

(CGMAP)

039.C ELC Sponsored Fuel Testing Program 039-5 039.D Condition Based Dry Docking (CBD) Program 039-6 039 E Buoy Handling System (BHS) Assessment Program 039-9 039 F NESU Non-MAT Chartered Customer Support Program 039-12 039.G Tank & Void Inspection & Maintenance 039-12 039.H Flexible Hose & Expansion Joint Maintenance Program 039-15 039.I Support Contract Initiative 039-17 039 J Gauge & Meter Calibration Program 039-22 039.K Diesel Engine Assessment and Overhaul Program 039-22

Chapter 040 KEY MAINTENANCE PROCESSES 040-1 040.A General 040-1 040.B Executing the Acquisition Team (A-Team) Process 040-1 040.C Updating and Distributing Cutter Long Range Maintenance Plans (LRMP) 040-1 040.D Updating and Distributing the Naval Engineering Project Listing (NEPL) 040-2 040.E Updating the Class Maintenance Plan (CCMP) 040-3 040.F Processing and Responding to Casualty Reports (CASREPs) 040-4 040.G Processing and Managing Current Ship’s Maintenance Projects (CSMPs) 040-5 040.H Processing and Managing Engineering Change Requests (ECRs) 040-6 040.I Processing and Managing Engineering Changes (ECs) 040-6 040.J Requesting NESU Maintenance Augmentation Team (MAT) Assistance 040-7 040.K Requesting Work from MLCPAC ISC Industrial Support Activities 040-8 040.L Requesting Work from U.S. Navy or Other Government Agency Sources 040-9

Chapter 041 ENGINEERING CHANGE REQUESTS 041-1 041.A General 041-1 041.B ECR Initiation and Submission 041-1 041.C Process 041-2 041.D Actions 041-4

041.E Engineering Change Completion Tracking 041-4

Chapter 042 PLANNING AVAILABILITIES 042-1 042.A General 042-1 042.B Definitions 042-1 042.C Long Range Availability Planning 042-4 042.D Unplanned Availabilities 042-6 042.E A-Team Process 042-6 042.F Worklist Development 042-7 042.G Acquisition Strategy and Funding 042-8 042.H Specification Development 042-11 042.I Solicitation and Award 042-11 042.J Other Important Planning Considerations 042-11

Chapter 043 CONDUCTING AVAILABILITIES 043-1 043.A General 043-1 043.B Responsibilities 043-1 043.C Award Message 043-3 043.D Pre-Arrival Conference 043-3 043.E Pre-Arrival Safety Briefing 043-4 043.F Arrival Conference 043-4 043.G Safety Measures 043-5 043.H Security Measures 043-6 043.I Inspections 043-7 043.J Testing of Work 043-9 043.K Drydocking /Haul Outs 043-10 043.L Contractor/ Cutter Relations 043-11 043.M Contract Administration 043-12 043.N Management of Availability Growth 043-20 043.O Homeport Travel 043-23 043.P Completion Procedures 043-24 043.Q 3rd A-Team Meeting 043-27

Chapter 076 RELIABILITY & MAINTAINABILITY 076-1 076 A General 076-1 076 B Reliability Centered Maintenance (RCM) 076-1 076 C Condition-Based Maintenance (CBM) 076-2 076 D Class Maintenance Plans (CMP) and Planned Maintenance System (PMS) Feedback 076-3 076 E Reliability Centered Maintenance Working Group & Conferences 076-6 076 F CG Maintenance Effectiveness Review (CGMER) 076-7 076 G Root Cause Failure Analysis 076-8

Chapter 077 SAFETY 077-1 077.A General 077-1 077.B Diving Operations 077-1

077.C Safety Precautions for Sewage and Wastewater Systems 077-1

Chapter 079 STABILITY AND DAMAGE CONTROL 079-1 079.A Engineering Casualty Control Manual 079-1 079 B Ballasting and Deballasting 079-1

Chapter 080 FINANCIAL PROGRAMS 080-1 080.A AFC-45 Cutter Financial Program 080-1 080.B AFC-30 Cutter Financial Program 080-3 080.C AFC-30 & 45 Boat Financial Program 080-5 080 D AFC 42 Financial Program 080-5 080.E AFC-77 WAGB Financial Program 080-6 080 F AFC-77 Navy Type Navy Owned (NTNO) Systems Financial Program 080-6

Chapter 082 MLCP(v) GAUGE AND METER CALIBRATION 082-1 082.A Purpose, Description and Responsibilities 082-1 082.B Policy and Implementation 082-4

Chapter 083 LOGISTICS SUPPORT 083-1 083.A General 083-1 083.B HM & E Support for Cutters 083-1 083.C LOGREQ Support 083-2 083.D Fuel Support 083-2 083.E Logistics Support for Deployed Area Cutters 083-2 083.F Ordnance Supply Support 083-2 083.G GFE/GFM Staging for Availabilities 083-3

Chapter 085 ENGINEERING DRAWINGS 085-1 085.A General 085-1 085.B Drawings 085-1 085.C Drawing Revisions 085-1 085.D Drawing Indexes 085-3

Chapter 088 MLCP(v) SHORE-BASED SUPPORT TEAMS 088-1 088.A Maintenance Augmentation Teams (MAT) 088-1 088.B Advanced Ship System, Instruction and Support Team (ASSIST) 088-3 088.C CMplus Assistance Team 088-4 088.D Major Incident Response Team (MIRT) 088-4 088.E Acquisition Teams (A-Teams) 088-5

Chapter 090 INSPECTIONS, RECORDS, REPORTS AND

TESTS 090-1

090.A General 090-1 090.B Cutter Engineering Report (CG-4874) 090-1

090.C Underwater Body Inspections and Reports 090-1 090.D Diver Inspections and Reports 090-2 090.E Boat Inspections and Reports 090-2 090.F Tank and Void Inspections 090-2 090.G Web-Based Self-Assessment Program 090-3

Chapter 233 INTERNAL COMBUSTION ENGINES 233-1 233.A Jacket Water Treatment Program 233-1 233.B Diesel Engine Overhaul Program 233-1

Chapter 262 LUBE OIL ANALYSIS 262-1 262.A General Guidance 262-1 262.B MLCPAC Requirements 262-1

Chapter 593 ENVIRONMENTAL POLLUTION CONTROL 593-1 593.A General 593-1 593.B Uniform National Discharge Standards (UNDS) Program 593-1 593.C Sewage (black water) 593-2 593.D Wastewater (gray water) 593-2 593 E Ballast Water Management 593-2 593.F Washdown, Cleaning, Sanding 593-3 593.G Garbage 593-3 593.H Oil and Oily Wastes 593-4 593.I Hazardous Substances 593-4 593.J Air Emissions 593-5 593 K Incinerator Operations 593-6 593.L Environmental Noise 593-6

Chapter 631 PAINTING GUIDANCE/PHILOSOPHY 631-1 631.A MLCPAC Surface Preparation (New Technology) 631-1 631.B MLCPAC Underwater Body Painting Philosophy 631-2 631.C Environmental and Volatile Organic Compounds (VOC) Compliance 631-4

Chapter 834 INFORMATION SYSTEMS 834-1 834.A General 834-1 834.B Applicability 834-1 834.C CG Intranet and Internet Accessibility 834-1 834.D Logistics Programs 834-1

Chapter 997 DOCKING INSTRUCTIONS 997-1 997.A General Instructions 997-1 997.B Drydock/ Cutter Lifting Facilities 997-1 997.C Fuel Offloading 997-2

997.D Emergency Drydocking Position 997-2 997.E Underwater Body Hull Inspection Board 997-2

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001-1

CHAPTER 001 - INTRODUCTION

A. Scope B. Changes C. Distribution

A. Scope.

The Organization and Operating Procedures Manual, Naval Engineering Division, Maintenance & Logistic Command Pacific, (MLCPACINST M9000.6E) is published for the information and guidance of Coast Guard personnel afloat and ashore who are responsible for the operation, maintenance, and repair of our cutters and boats. The contents of this manual pertain to issues and services under the cognizance of the Naval Engineering Division.

This manual contains administrative and technical instructions gathered from a number of sources.

The information has been reviewed, updated, and organized to correspond to the administrative organization of the Commandant’s Naval Engineering Manual (NEM), COMDTINST M9000.6 (series), also referred to as the NEM. Chapters 001 through 099 address administrative processes.

Chapters 100 through 999 address technical issues. Stand-alone topics that do not fit into the two general sections have been deleted and can be found on the MLCP(v) intranet website at http://cgweb.mlcpac.uscg.mil/mlcpv/

The format of each chapter generally conforms to the U.S. Navy's Ship's Work Breakdown Structure (SWBS), NAVSEA 0910-LP-062-8500, as used in the Naval Ships Technical Manual (NSTM).

Information is provided to supplement the NSTM and the NEM, especially in the area of administration as it applies to the Maintenance and Logistics Command Pacific (MLCPAC). When this manual and NSTM conflict, this manual applies. When this manual and NEM conflict on administrative procedures, this manual applies. However, the NEM is the governing document regarding Naval Engineering policy for the Coast Guard. If in doubt, contact MLCPAC, Naval Engineering Division, for resolution of conflicting guidance.

B. Changes.

This version MLCPACINST M9000.6E is a complete revision of the previous MLCPACINST M9000.6D to reflect the promulgation of the Naval Engineering Manual (NEM), COMDTINST M9000.6E. Official changes to this manual will be issued as insert pages. A vertical solid bar in the margin of the page will identify future changes. Suggestions for improvement are welcomed. The process is explained in Chapter 002.

C. Distribution.

A web version of this manual is posted on the MLCP(v) intranet site listed above. Distribution of paper copies of this manual will be determined by the Chief, Naval Engineering Division, MLCPAC. Requests for changes to the distribution shall be addressed to Commander (v), Maintenance and Logistics Command Pacific.

001-2

002-1

CHAPTER 002 - ORGANIZATION

A. Mission and Vision Statements B. Organizational Relationships / Responsibilities C. Services and Functions D. Routine Correspondence E. Continuous Change Process

A. Mission and Vision Statements.

This chapter describes the functions of the various components of MLCP(v), their relations to one another within the organization, and how to communicate with us.

1. The mission of the MLCPAC Naval Engineering Division is to provide the Coast Guard’s Pacific fleet the most materiel readiness for every dollar and resource hour we expend.

2. The vision for the MLCPAC Naval Engineering Division is that MLCP(v) is regarded service-wide as the best provider of materiel readiness and logistics in the Coast Guard.

B. Organizational Relationships / Responsibilities.

1. MLCPAC Naval Engineering Division.

a) The Naval Engineering Division is one of seven divisions within the Maintenance and Logistics Command Pacific. It is responsible for planning and executing maintenance and repair for all afloat units, including cutter and shore based standard boats, within the Pacific Area. The organizational charts for the PACAREA and MLCP(v) are shown in Figures 002-1 and 002-2.

b) Under the Chief of the Naval Engineering Division there are seven organizational units. This includes four staff branches and three separate commands: the Naval Engineering Support Units (NESUs). The staff branches, located in the Oakland Federal Building in Oakland, CA, are the Support Branch MLCP(vr), Specifications Branch MLCP(vs), Procurement and Logistics Branch MLCP(vpl), and Administration Branch MLCP(vad).

(1) The Support Branch, MLCP(vr), is a "customer service group" which provides direct naval engineering and combat systems support for cutters and boats.

Working with shore and afloat units, MLCP(vr) normally coordinates the requirements of the cutters and boats into maintenance actions. The cutter, boat, and combat systems Type Desks reside in MLCP(vr). In addition, the ASSIST (Advanced Ship System, Instruction and Support Team) resides in this branch. Primary functions of the Type Desks are planning for major repair availabilities (drydocks and docksides) (Availability Project Manager) and providing casualty support (CASREP Support Manager).

002-2

Pacarea Organization

District 11 District 13

Naval Engineering Division v

Civil Engineering Division s

Command Control & Communications

Division t

Finance Division f

Personnel Division p

Health & Safety Division k

Legal Division l

Maintenance & Logistics Command

Pacific

District 14 District 17

Pacific Area

Figure 002-1

(2) The Specifications Branch, MLCP(vs), works closely with MLCP(vr) to develop specifications and independent government estimates to accomplish the projects for cutters and boats. MLCP(vs) also works closely with the Type Desks to resolve technically complex maintenance issues. The all civilian staff has many years of experience in the Marine Engineering field; as such, they are an excellent source of corporate knowledge. MLCP(vs) also has a Technical Services Section and an Environmental Section. The Technical Services Section provides engineering technical support by maintaining drawings and technical manuals. The Environmental Section provides full-service in-house environmental consulting services. This may range from issues related to fueling, maintenance, and contaminated liquid disposal, to underway operations and natural resource (animal) avoidance measures.

(3) The Procurement and Logistics Branch, MLCP(vpl), awards and administers contracts and other procurement actions for services and supplies required in

002-3 support of the Naval Engineering Program, including shipboard electronics, and combat systems. The branch also coordinates logistics support for cutters deployed.

(4) The Administration Branch, MLCP(vad) provides program management and logistics support. The Program, Planning & Budget Section coordinates availability planning, performs financial management, and program analysis.

It also manages the Finance and Procurement Desktop (FPD). The Information Technology Section (mis) provides user support for systems including standard workstations, the Fleet Logistics System (FLS) and the Contract Workbook Database. The Logistics Management Section (vadl) provides configuration, maintenance and supply support for units using CMplus, assists Pacific Area units in the management of Operating Materiels and Supplies (OM&S) and supports units in meeting Chief Financial Officer requirements.

(5) The Naval Engineering Support Units, NESUs, located in Alameda, Seattle, and Honolulu, are servicing commands assisting in the support of all cutters and boats in PACAREA. All three NESUs have Maintenance Augmentation Teams (MATs) assigned to them. MAT responsibilities are described in Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) and this manual’s Chapter 088. MLCP(v) may direct personnel from any NESU to assist any cutter or boat regardless of location or homeport.

(a) NESU Honolulu has a 110’ WPB MAT, 225’ WLB MAT and 378’ WHEC MAT. The NESU in Honolulu primarily serves units home ported in the Fourteenth District.

(b) NESU Alameda has one 378’ WHEC MAT in Alameda CA and a PC179’ MAT and 378’ WHEC MAT in San Diego CA. The NESU in Alameda primarily serves units home ported in the Eleventh District.

(c) NESU Seattle has a 378’ WHEC MAT, CGC Healy MAT, and a Polar Ice Breaker MAT. The NESU in Seattle primarily serves units home ported in the Thirteenth District.

002-4

Figure 002-2

Division Chief (v)

Assistant Division Chief (va)

Support Branch (vr)

Administration Branch (vad)

Procurement & Logistics Branch (vpl)

Specifications Branch (vs)

Naval Engineering Support Units

(NESUs)

Asst Branch Chief (vra1)

Asst Branch Chief (vra2)

Ice Breakers (vr1)

High Endurance (vr2)

Medium Endurance (vr3)

Buoy Tenders (vr4)

Program, Planning & Budget Section (ppbs)

Logistics Management Section (vadl)

Information Technology Section

Contracts Section (vpl1)

Icebreakers Contract Section (vpl1)

Logistics Support Section (vpl2)

Mechanical Section

Electrical Section

Environmental Section

NESU

Alameda

NESU

Honolulu

NESU

Seattle

Technical Section

Buoy Tenders (vr4)

Patrol Boats (vr5)

Boats (vr6)

Combat Systems (vr7)

WMSL – National Security Cutter (vr10)

ASSIST

(vr9)

002-5

C. Services and Functions.

With our seven organizational units we work as a team to deliver quality services and products. The MLCPAC Naval Engineering Division provides the following services and functions for afloat units including cutter and shore based standard small boats in PACAREA:

1. Maintenance Planning and Support. Provide technical and managerial expertise for monitoring and scheduling of maintenance and repair work of cutters and standard boats, and engineering guidance for hull and equipment maintenance, repair and renewal. This consists of development and review of Long Range Maintenance Plans (LRMPs) and Class Maintenance Plans (CMPs). Prepare specifications and estimation of project costs.

2. Casualty Support. Provide technical, procurement and/or logistics assistance to correct casualties. Coordinate response with NESU as necessary. Initiate preventive measures to avoid recurrent failures.

3. Technical Support. Plan and coordinate technical support assistance to all of our cutters and standard boats via commercial or DOD interdepartmental contracts. Services include but are not limited to condition based maintenance and infrared surveys, failure analysis, fuel oil and lube oil analysis, planned and periodic maintenance. Provide Naval Engineering expertise to review inspections, investigations and claims, and participate on boards of investigation, safety, survey, contract review, budget review, and planning.

4. Training. Provide training on the proper operation and maintenance of machinery and equipment aboard units to prolong service life and prevent casualties. .

5. Engineering Change Support. Evaluate Engineering Change Requests (ECR) to determine requirements and impact on current operations. Identify source of funding and complete a cost/benefit analysis for implementation. Endorse ECR and forward to the ELC for development and approval.

6. Preventive Maintenance System (PMS) Support. Provide input for review and changes to existing PMS procedures for all cutters and standard boats. Evaluate PMS scope and complexity in order to assign funding and resources.

7. Procurement and Logistics Support. Provide logistics support for PACAREA and District units when requirements exceed the procurement authority of procurement offices organizationally closer to the unit. Appoint Contracting Officer's Technical Representatives (COTR) when appropriate. Provide small purchase support for the Naval Engineering Division staff, its field units, and PACAREA cutters and standard boats. Provide contracting support and guidance on simplified acquisition procedures. Provide procurement planning, solicitation, award and administration of cutter and standard boat repair contracts. Provide transportation management for material for cutters and standard boats. Coordinate logistics support for cutters calling on foreign ports.

002-6

8. Fiscal Management Support. Administer AFC-30/45/77 financial programs for maintenance, repair and alteration of cutters and standard boats. Provide and/or prepare annual budget requests, justification of supplemental funding, accounting for funds, and management and execution of Navy or OGA reimbursable funding.

9. Engineering Drawing Support. Produce electronic Bid Sets of drawings for availability support on CD-ROM. Respond to unit requests for copies of drawings. Coordinate drawing revisions and new drawing creation for the units we service.

10. CSMP Support. Conduct planning and scheduling efforts conducive to Current Ship Maintenance Project (CSMP) completion once the NESUs evaluate, endorse and approve CSMPs.

11. Spare Parts Allowance and Configuration Management Support. Provide logistics support by review of allowance changes; recommendation of centrally supported supply items; technical input on Coast Guard-unique items not supported by the Engineering Logistics Center;

engineering product evaluation; prototype testing; and expediting procurements to satisfy cutter requirements. Provide assistance with software systems managing both spare parts and configuration data.

12. Ordnance System Support. Conduct Ordnance Technical Inspections. Directly perform or assist in, the maintenance, repair, and alteration of combat systems and ordnance materiel on cutters and standard boats.

13. Electronic Support. Serve as liaison with the respective ESU and MLCP(t) to provide guidance, technical assistance, and scheduling of maintenance and repair work for electronic CASREPs, ECs and CSMPs.

14. Aviation Facilities Support. Provide funding, logistics and technical support to cutters with aviation facilities for HME&O equipment. Assist PACAREA with coordination of NAVAIRWARCEN Lakehurst, N. J., aviation facility certification.

D. Routine Correspondence.

1. Units should address routine correspondence concerning naval engineering matters per the following paragraphs D2-6. Specific routing instructions for required document submissions found elsewhere in this instruction or in Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) shall be used as specified.

2. PACAREA Units. Direct from the Commanding Officer of the unit to Commander (v), USCG MLCPAC, Oakland Federal Building, 1301 Clay St., Suite 800N, Oakland, CA.

94612, copy to the PACAREA Program Manager.

3. District Units. Direct from the Commanding Officer of the unit to Commander (v), USCG MLCPAC, Oakland Federal Building, 1301 Clay St., Suite 800N, Oakland, CA. 94612, copy to the District Program Manager.

002-7

4. Sector/Group Units. From the Commanding Officer of the unit to Commander (v), USCG MLCPAC, Oakland Federal Building, 1301 Clay St., Suite 800N, Oakland, CA. 94612, via the Sector/Group Commander, with copy to the District Program Manager or other established chain of command.

5. Headquarters Units. Same as that for PACAREA Units or other established chain of command for that particular unit.

6. Message traffic and computer communications (such as Electronic Mail) are covered in other sections of this instruction.

E. Continuous Change Process.

1. To ensure that this instruction remains up-to-date, coincides with current practices, and continues to meet program needs, change proposals are encouraged as specified in the following paragraphs:

2. Change proposals may be originated at any organizational level. Proposals shall be submitted to MLCP(v) via the chain of command as identified above. To facilitate the submission of, and expedite the response to change proposals, originators shall complete and forward change proposals using the format in Figures 002-3 and 002-4.

3. Upon receipt, MLCP(v) will initiate the following action:

a) MLCP(vad) will log each proposal and inform originator of receipt.

b) MLCP(v) will review each proposal to justify the need, identify possible conflicts with other directives and publications, and assess the affects of implementation.

c) Future change notices to this instruction will promulgate approved change proposals.

Disapproved change proposals will be returned to the originator with an explanation for disapproval.

002-8

Staff Symbol:

Phone:

Fax:

Email:

MEMORANDUM

From: Commanding Officer, USCGC _____________ Reply to

Attn of:

To: Commander, Maintenance & Logistics Command Pacific (v) Thru: (insert chain of command)

Subj: RECOMMENDED CHANGE PROPOSAL TO THE MLCPAC NAVAL

ENGINEERING ORGANIZATION AND OPERATING PROCEDURES MANUAL

Ref: (a) MLCPACINST M9000.6(series)

1. Per reference (a), enclosure (1) is forwarded for consideration. Should you have any questions, my point of contact is ________________________

Enclosure: Recommended change to the MLCPAC M9000.6(series)

Figure 002-3

002-9

RECOMMENDED CHANGE TO THE MLCPAC M9000.6(series)

1. Chapter Section Page #

Synopsis of Recommendation:

Justification:

Added Value to Current Policy and Procedures:

Applicable Reference Materiel:

Point of Contact

Unit

Name ____________________ Phone #

Figure 002-4

002-10

036-1

CHAPTER 036 – MAINTENANCE PHILOSOPHY AND DEFINITIONS

A. Background. 1 B. Maintenance Philosophy. 1 C. Outputs of a Streamlined RCM Philosophy. 1 D. Other Maintenance Definitions. 3

A. Background.

As good stewards of our resources, the Coast Guard must continuously look for new ways and ideas to keep our shipboard equipment operational and our cutter and boat fleets, safe and ready to perform their intended missions at the lowest cost possible. Within Naval Engineering, this requires a constant review of our maintenance philosophy and maintenance policies to reduce the amount of intrusive and costly maintenance that has traditionally been based on subjective time intervals. We must look at incorporating new approaches, techniques and tools into our maintenance philosophy and polices which emphasize performing only that maintenance that is required based on the actual condition or performance of the particular equipment or system in question. This chapter outlines MLC Pacific Naval Engineering’s philosophy to provide the Coast Guard Pacific fleet the most material readiness for every dollar and resource hour we expend.

B. Maintenance Philosophy.

Where practicable, MLC Pacific Naval Engineering will incorporate Reliability Centered Maintenance (RCM) tools, techniques and practices into the Coast Guard’s organizational, intermediate and depot level maintenance programs in an effort to maximize equipment and fleet material condition and readiness. Our focus will be to continuously review, validate and update or revise all cutter and boat maintenance actions performed on hull, mechanical, electrical, and ordnance equipment and systems. Our maintenance philosophy is a streamlined RCM approach emphasizing condition monitoring and condition based maintenance. See Chapter 076 for additional information on RCM.

C. Outputs of a Streamlined RCM Philosophy.

There are four possible outputs of a streamlined RCM philosophy. The first three of these outputs are the three general “Types of Maintenance” that can be performed on any equipment or system.

The fourth output is a conscious decision to run the equipment or system to failure; or “Run to Failure.” These four outputs are discussed in more detail below.

1. Types of Maintenance:

Chapter 081 of the Coast Guard’s Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) breaks down cutter and boat maintenance into three levels of maintenance;

organizational, intermediate and depot. This approach to defining maintenance is based on who (which unit(s)) within the Coast Guard are responsible for performing the particular maintenance in question. Within each of these three “levels of maintenance,” there are three distinctive “types of maintenance” that are performed on all equipment and systems (afloat

036-2 and ashore); they are: (1) preventive maintenance; (2) corrective maintenance; and (3) alterative maintenance (engineering changes or redesign). All work performed onboard cutters or standard boats can be categorized into one of these three “types of maintenance.”

Below is a more detailed explanation for these three types of maintenance and how the Coast Guard’s existing maintenance programs and processes fit within each type. It should be noted that Standard Boats are undergoing a pilot program under the Logistics Transformation Project that is testing “bi-level” maintenance. These two levels will consist of organization and depot.

a) Preventive Maintenance (PM):

(1) Preventive maintenance (PM) is the performance of scheduled tasks that serve to restore or retain the functional capabilities of equipment or systems. These tasks can be grouped into three general categories:

(a) Time based tasks - maintenance tasks performed at a set interval, regardless of condition; such as a 5 year flexible hose renewal, 16,000 hour center section overhaul, or 4 year sea valve overhaul.

(b) Condition monitoring tasks - tasks designed to predict the onset of a failure, such as vibration checks on a pump/motor or infrared thermography on a switchboard or controller.

(c) Failure finding tasks – tasks designed to test if a failure has already occurred, such as testing a boiler or pressure vessel relief valve.

(2) Most of the budgeted and scheduled AFC-30 and AFC-45 maintenance performed in the Coast Guard could be classified as preventive maintenance.

This includes just about all the MLC Pacific recurring work items that are contained on unit NEPLs. Chapter 081 of the Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) provides additional details and information on the Coast Guard’s Preventive Maintenance System (PMS).

b) Corrective Maintenance (CM):

(1) Corrective maintenance (CM) is the performance of planned or unplanned tasks that are designed to restore the functional capabilities of equipment or systems after a failure or pending failure. In most cases for Coast Guard cutters and boats, a/an (unplanned) failure of a piece of equipment or system will have a detrimental affect on the unit’s mission capabilities, the unit’s operating environment, or the safety of the unit’s personnel. Accordingly, unplanned CM is typically the most costly of all maintenance performed on our cutters and boats. A well planned and managed preventive maintenance program that includes time, condition, and failure finding tasks will result in a shift of resources from unplanned CM to (less costly) planned CM.

(2) Most work associated with correcting an equipment casualty would be classified as unplanned CM, while most tasks associated with correcting

036-3 discrepancies found after performing condition monitoring tasks are classified as planned CM. In addition, most of the maintenance associated with completing CSMP work, such as replacing damaged compartment insulation or renewing a hatch are examples of planned CM.

c) Alterative Maintenance (AM):

(1) Performing preventive maintenance and/or corrective maintenance over and over on a piece of equipment or system may be more costly than to change, redesign or “alter” the equipment or system. In many cases, failures are the result of inadequate design. Accordingly, performing alterative maintenance (AM) tasks that are essentially engineering changes (EC) or redesign is often the best course of action in order to improve the functionality or reliability of a piece of equipment or system. These types of tasks often are geared towards resolving the root cause of a particular failure or functionality problem, which is often due to inadequate design. In addition, engineering changes or redesign work may be associated with adding new functionality, such as an incinerator or oily water separator, due to changes in mission requirements, safety or environmental laws, or obsolescence.

(2) Chapter 041 of the Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) and Chapter 041 of this manual contain policy and guidance on Engineering Changes within the Coast Guard.

2. Run To Failure (RTF):

a) RTF is an output of an RCM process that is a deliberate decision to run a piece of equipment or system to failure in lieu of performing preventive maintenance on it. In some cases, the summation of all the “failure consequences” or costs associated with a failed piece of equipment or system does not outweigh the cost of predicting or preventing a particular failure through preventive maintenance. In these cases, the right decision might be to “run the item to failure” and not perform any preventive maintenance. An example might be to allow a water cooler to “run to failure” rather than performing checks or maintenance on any of the installed components.

b) “Run to Failure” is sometimes referred to as the fourth category of PM, or a “do nothing” category.

D. Other Maintenance Definitions.

1. Condition Based Maintenance (CBM): A form of planned corrective maintenance that serves to restore or retain the functional capabilities of some equipment or system and which is triggered by a measured condition or observation. This condition or observation is almost always based on a change in the performance characteristics of the equipment or system such as an increase in vibration or a decrease in flow or output for a pump. CBM is a major component or subset of all Reliability Centered Maintenance programs.

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2. Condition Monitoring: Condition monitoring is another term used to define fault finding preventive maintenance tasks. The purpose of condition monitoring tasks is to monitor the performance and functionality of equipment or systems. Planned (and corrective) condition based maintenance tasks typically follow condition monitoring tasks where the condition monitoring tasks uncovered a developing problem or failure.

3. Failure Modes: A listing of all the events (failures) that are likely to cause the failure of a piece of equipment or system to perform the function that it is designed to perform. For example, a wiped bearing would be a failure mode for a fire pump, as it would prevent the fire pump from rotating at sufficient speeds to produce the required volume of water at the required pressure for fire fighting. A full listing of all failure modes for some equipment or systems could be quite extensive.

4. Failure Effects: Failure effects are a description of what happens when each failure mode occurs. For example, a wiped bearing for a fire pump would have several failure effects associated with it, including (possibly) high vibration, screeching noise, poor (or no) flow.

Failure effects are also a description of what CM work needs to be done to repair the failure.

5. Failure Consequences: Failure consequences is the listing of all costs associated with the particular failure mode in question. Some of these costs are straightforward and easy to compute such as the cost of the replacement bearing and the time associated with installing it.

However, failure consequences also must consider other “hidden” consequences to the organization such as lost operational days, violations of safety or environmental laws and costs to crew morale and well-being. After completing this kind of analysis for some failure modes for some of our equipment or systems, it is clear that the consequences for failure can be extremely high in some cases. Accordingly, we must constantly adjust our maintenance programs and policies to reflect the need to avoid costly failures wherever possible.

6. Maintenance-Induced Failures: A failure that immediately follows or is the direct result of performing PM, CM or AM improperly on a piece of equipment or system. The more complicated a maintenance task or group of tasks is, the more likely we are to see a maintenance-induced failure.

7. Mean Time Between Failures: A calculated average duration of time between successive (like) failures.

8. Predictable Failure: A failure of a piece of equipment or system that can be predicted through condition monitoring.

9. Random Failure: A failure of a piece of equipment or system that cannot be predicted through condition monitoring.

10. Recurring Maintenance (RM): Another term to define preventive maintenance that is time based, such as a four-year drydock or haulout of a cutter or standard boat. This term is used to describe all MLCP Naval Engineering time based “Recurring Work Items” that are contained on a unit’s NEPL. The only real distinction between “recurring maintenance” items and other time based preventive maintenance items is who within the Coast Guard organization is normally responsible for planning and executing the work. Typically, cutters

036-5 or boats are responsible for completing organizational level preventive maintenance and the MLCs or Groups/Sectors are responsible for completing intermediate and depot level preventive maintenance.

11. Reliability Centered Maintenance (RCM): Reliability Centered Maintenance (RCM) is a formal process used to determine the maintenance requirements for engineering equipment, systems or facilities (e.g. cutters and boats) in their operating environment in an effort to ensure the equipment, systems or facilities perform their intended function safely and at the least possible cost. A fully developed RCM program would require extensive (and ongoing) analysis on functionality, failure modes, failure effects and failure consequences on all the equipment or systems that comprise a cutter or boat. Although this type of research and analysis is done for some equipment or systems at certain points in a cutter’s or boat’s service life, it is not done on all equipment or systems due to the time and costs of gathering this information and performing this analysis.

12. Root Cause of Failure: A term used to describe the actual causation of a failure of a piece of equipment or system. Although performing root cause analysis could go on almost indefinitely, the intent is to find the bottom line cause for the particular failure mode that is within our control. Additional information on Root Cause Analysis is located in Chapter 076.

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CHAPTER 037 – MAINTENANCE RESPONSIBILITIES

A. General. 1 B. COMDT Naval Engineering. 1 C. Engineering Logistics Center (ELC). 1 D. MLC Pacific Naval Engineering Division. 1 E. Naval Engineering Support Units (NESU). 2 F. Unit Commanding Officers and Officers-in-Charge. 3 G. Operational Commanders. 3 H. Sector/Group Commanders. 3

A. General.

The following is an outline of responsibilities for providing for the repair, maintenance and alteration on hull, mechanical and electrical (HM & E) equipment and systems on Pacific Area cutters and standard boats. COMDTINST 4100.7, Coast Guard Engineering Logistics Concept of Operations (ECONOP) defines the logistics system functional roles in chapter IV.

B. COMDT Naval Engineering.

COMDT (CG-45) serves as the program manager for Naval Engineering and is responsible for setting Naval Engineering technical, administrative and fiscal policies for all Coast Guard cutters and boats. CG-45 delegates much of the technical policy authority to the Engineering Logistics Center (ELC). The Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) and the Naval Engineering Policy Review Board Instruction, COMDTINST 9070.1 (series) provides additional details on some of CG-45’s responsibilities.

C. Engineering Logistics Center (ELC).

ELC is responsible for developing, managing, and providing life cycle technical and logistical information support for vessel platforms, including cross-platform configurations for electronics and ordnance systems. ECONOP roles include Platform Manager, Equipment /System Manger, and Supply Manager. The ELC manages equipment configurations for communication, navigation, auxiliary, propulsion and electrical systems; providing design and engineering support. The ELC performs provisioning, item management, cataloging, procurement, warehousing, quality assurance, and requisition management and distribution of material; performing project management and depot level testing and repair for electronic equipment.

D. MLC Pacific Naval Engineering Division.

The Naval Engineering Division (or Vessel “V” Division) is responsible for the repair, maintenance and alteration of Pacific Area cutters and standard boats within the policies established by higher authority. In ECONOP terms, (v) fills the “Maintenance Manager” role. The Naval Engineering Division’s collective purpose is to provide the most materiel readiness for the Pacific Area cutters and standard boats within our resources by:

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1. Setting maintenance policy for hull, mechanical, electrical and ordnance equipment or systems as authorized by COMDT (CG-45) or the ELC. This includes reviewing applicable Class Maintenance Plans (CMP) in accordance with COMDTINST 4100.7 (series).

2. Scheduling and executing all repair, maintenance and alteration processes. These processes are outlined in Chapter 040 of this manual.

3. Performing standard boat and cutter inspections and other assessments as required for monitoring or determining material condition.

4. Providing technical, logistical and contractual assistance.

5. Administering AFC-45 (Naval Engineering) funds, AFC-30 (Boat Maintenance), AFC-77 (Naval Ordnance or Other Government Agency(OGA)) funds, and assisting with the management of WAGB AFC-30/77 (Organizational Maintenance) and Cutter AFC 30 funds to address the maintenance and repair needs, both planned and unplanned, of Pacific Area cutters and standard boats.

6. Providing training and other maintenance and logistics support as necessary to improve or enhance the safety and readiness.

7. Providing program guidance, policy, oversight and direction to all three MLC Pacific Naval Engineering Support Units (NESUs).

8. Managing all shore based support teams as outlined in Chapter 088 of this manual.

9. Serving as MLC Pacific and the Pacific Area Commander’s representative with all other Coast Guard and other government and commercial agencies on issues relating to Pacific Area cutter and standard boat maintenance, repair and alteration.

10. Managing all related reports, data and records.

E. Naval Engineering Support Units (NESU).

NESUs are independent commands under the operational control and program guidance of MLC Pacific Naval Engineering Division. NESUs provide direct support to Pacific Area cutters and standard boats within their area of responsibility (AOR). Specific responsibilities and duties of the

NESU:

1. Performing some organizational and intermediate level maintenance on selected cutters through Maintenance Augmentation Teams (MAT) as outlined in Chapter 088 of this manual and Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) or as outlined in local memorandums of understanding.

2. Providing contract, technical and adminstrative support through staff Port Engineers.

3. Assisting with administering AFC-45, AFC-77 and WAGB AFC-30/77 funds.

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F. Unit Commanding Officers and Officers-in-Charge.

Unit Commanding Officers and Officers-in-Charge are ultimately responsible for the safe operation, repair, and maintenance, aboard their assigned cutter or boats in accordance with established regulations and policies. Unit responsibilities which support the maintenance process include: :

1. Ensure the safe operation of all equipment and systems aboard the cutter or boat.

2. Inspect and monitor all equipment and systems for changes to material condition.

3. Report changes to material condition and readiness, for example, Casualty Reports (CASREPs) or Current Ships Maintenance Projects (CSMPs).

4. Manage, supervise and execute all repair, maintenance, and alteration work performed on the cutter or boat, including work performed by commercial contractors during scheduled repair availabilities.

5. Initiate requests for support or services to address needs beyond the unit’s capabilities, as outlined in this manual and Naval Engineering Manual (NEM), COMDTINST M9000.6 (series).

6. Manage and execute AFC-30 unit funds for repair, maintenance, and alteration of equipment and systems and any AFC-45 or AFC-77 funds that the unit has been authorized to expend.

7. Manage unit’s spare parts, allowances and configuration. Manage local receipt and disposition of all parts and associated turn-in items.

8. Maintain and update local records and administrative programs that relate to the operation, repair, maintenance, and alteration of all equipment and systems.

9. Ensure compliance with all applicable environmental and hazardous material regulations.

G. Operational Commanders.

Operational Commanders ensure unit commanders comply with responsibilities outlined in the prior CO/OIC section, manage and oversee AFC-30 for repair, maintenance and alteration needs, facilitate and oversee unit spare parts and allowance management, remain aware of unit’s materiel condition of readiness, and ensure cutters and boats are made available for repair, maintenance and alterations when planning and executing operational schedules.

H. Sector/Group Commanders.

In addition to the responsibilities outlined for Operational Commanders and COs/OICs, Sector/Group Commanders are also responsible for providing the technical, fiscal and logistical support for cutters and stations under their command and are the primary provider and resource for “organizational level” boat repairs, maintenance and alterations.

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CHAPTER 038 - MAINTENANCE POLICY AND PLANNING

A. Maintenance Policy 1 B. Maintenance Planning: 2

A. Maintenance Policy

1. General: The Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) provides policy for all Naval Engineering repair, maintenance and alterations on cutters and standard boats. All specific maintenance policies described in Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) and other applicable regulations and instructions (such as the Naval Ships Technical Manual (NSTM)) shall also be outlined in either the Class Maintenance Plans (CMP) or the Preventive Maintenance System (PMS).

2. Class Maintenance Plans (CMP): The primary purpose of the CMP is to provide a consolidated list of maintenance policy which reflects the organization’s maintenance philosophy. The CMP specifically outlines what needs to be done, on what equipment or system, at what interval and through what funding source. In short, the CMP is a succinct summary of the following maintenance policies:

a) All maintenance policies required by applicable regulation and instruction, such as the Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) or Naval Ships Technical Manual (NSTM).

b) Current ELC / MLC maintenance policies not specifically addressed in other regulations or instructions or where Naval Engineering Manual (NEM), COMDTINST M9000.6 (series) requires the MLC to provide maintenance policy, such as Level II inspections and repairs to anchor windlasses or sewage tank cleaning and inspections.

c) Selected (high visibility) PMS maintenance procedures: These are listed on the CMP as well to facilitate maintenance planning and policy oversight, such as diesel engine center section overhauls or critical gauge calibration.

The CMP is a living document and is routinely updated by the ELC. Changes or updates to the CMP normally are driven by changes in equipment or system performance, changes in cutter / boat readiness, changes to technology, changes to applicable regulations and instructions or recommendations from the maintenance managers (MLCs). Units can obtain copies of their CMP from their MLCP(vr) Type Desk or on the ELC web site under http://cgweb.elcbalt.uscg.mil/rcmtigerteam/ccmp/ccmp.htm

3. Preventive Maintenance System (PMS): The primary purpose of PMS, as defined in Naval Engineering Manual (NEM), COMDTINST M9000.6 (series), Chapter 081, is to outline http://cgweb.elcbalt.uscg.mil/rcmtigerteam/ccmp/ccmp.htm

038-2 minimum organizational and some intermediate level preventive maintenance policy and procedures for Hull Mechanical & Electrical (HM&E), damage control and electronic and ordnance equipment aboard cutters and standard boats. PMS is also a living document and is routinely updated by the ELC based on change procedures defined in Chapter 081, Section C6 of the Naval Engineering Manual (NEM), COMDTNST M9000.6 (series). Update announcements are promulgated to the fleet through message traffic from ELC-017, which includes directions on how to update the cutter’s CMplus with the most current MPCs. PMS Manuals can be found at the ELC website:

http://cgweb.elcbalt.uscg.mil/RCMtigerteam/pms/pms.htm

B. Maintenance Planning:

1. General: Whether planning a five year long-range maintenance schedule for the entire cutter or standard boat fleet or planning a short-term maintenance worklist for a cutter’s upcoming inport, effective maintenance planning requires adherence to, or consideration of, a number of factors. These factors can be grouped into four general categories: maintenance planning inputs, maintenance planning resources, maintenance planning constraints, and maintenance planning tools. The results of this process are the various maintenance plans which could also be termed “maintenance planning outputs.”

2. Maintenance Planning Inputs: Effective maintenance planning starts by considering key inputs to the plan. These key inputs essentially cover what we are required to do based on policy (which is driven by our philosophy) and what we should do based on material assessments.

a) Maintenance Policies: All maintenance plans should start with an understanding of the maintenance policies that drive the maintenance plan. For example, if the PMS schedule says a maintenance item is due, it should be listed at the start of the maintenance planning cycle.

b) Materiel Assessments: All current materiel assessments must be considered in order to prepare an effective maintenance plan. Material assessments are varied in terms of scope and frequency and often occur at odd times throughout the year, often by different entities. Gaining a comprehensive understanding of all the assessments performed on a cutter or boat can sometimes be overwhelming and requires exceptional organizational skills and close scrutiny (and follow-up) of all the data and information generated during the assessment. Below is a listing of some of the major equipment and system assessments that are performed on cutters and standard boats:

(1) Unit Materiel Inspections

(2) Ship Structure and Machinery Evaluation Board (SSMEB)

(3) Materiel Condition Review (MCR) & Long Range Maintenance Plan (LRMP) Visits

(4) Standardization & Certification Visits http://cgweb.elcbalt.uscg.mil/RCMtigerteam/pms/pms.htm

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(5) Command Assessment of Readiness for Training (CART) Visits

(6) CBM & Similar Condition Monitoring Visits

(7) PMS “Fault Finding” or “Condition Monitoring” Tasks

(a) Diesel Engine Maintenance Program (DEMP) / Performance Analysis…