HAMILTON_(WMSL_753)_MPDE_FY15_FQ4_SEC_R0.pdf

USCGC HAMILTON (WMSL 753)

SPECIFICATION FOR MPDE MAINTENANCE FY15 FQ4

FY2015

Developed By: Sarah E Colmenero

(Rev-0, 24 June 2015)

USCGC HAMILTON (WMSL-418) DOCKSIDE AVAILABILITY FY2015

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property ................................................................................. vi Consolidated List of Critical Inspection Items .......................................................................................... viii Principal Characteristics ............................................................................................................................... ix General Requirements WORK ITEM 1: Diesel Engines, Long Term Lay-up Preservation WORK ITEM 2: Main Propulsion Diesel Engine-Statement of Work iii (Rev-0)

REVISIONS RECORD

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

DATE REV# WORK

ITEM#

CHANGES MADE

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

iv (Rev-0)

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 750 WMSL 100-001, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750 WMSL 501-002, Rev E, Machinery Arrangements (ASC501001)

Coast Guard Drawing 750 WMSL 801-001, Rev A, Booklet of General Plans (ASC801001)

Coast Guard Drawing 750-WMSL-100-1, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750-WMSL-501-2, Rev E, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Jun 2006, Coatings and Colors

Manual

Coast Guard Technical Publication (TP) 7024, 31-MAY-07, Main Diesel Engine - Removal Spaces and

Weights

Coast Guard Technical Publication (TP) 7025, 31-MAY-07, Main Diesel Engine - Fluids and Lubricants

Specifications (A001061/3

Coast Guard Technical Publication (TP) 7025, SWBS 233, May 2007, Main Diesel Engine - Fluids and

Lubricants Specifications (A001061/35E)

Coast Guard Technical Publication (TP) 7026, 31-MAY-07, Main Diesel Engine - Repair Tools

Coast Guard Technical Publication (TP) 7027, 31-MAY-07, Main Diesel Engine - Operating Instructions

Coast Guard Technical Publication (TP) 7028, 31-MAY-07, Main Diesel Engine - Maintenance Manual

Coast Guard Technical Publication (TP) 7031, 31-MAY-07, Main Diesel Engine - Parts Catalog

(M034562/01DE)

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-0)

Coast Guard Technical Publication (TP) 7119, SWBS 311, Dec 2013, Ship Service Diesel Generator

(SSDG) - Model 3500B - Caterpillar Manual Sections A and B [A00001, Q-8]

Coast Guard Technical Publication (TP) 7205, SWBS 252, Oct 2007, MTU Spare Parts Catalog

Coast Guard Technical Publication (TP) 7368, SWBS 311, Jun 2010, Ship Service Diesel Generator

(SSDG) - Model 3512B - Parts Manual

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0000, Jan 2012, General

Requirements

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 6310, Jan 2012, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2012, General

Requirements

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), 2012, Requirements for Preservation of Ship Structures

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

OTHER REFERENCES

CAT Engine and Storage Preservation Manual PEHJ0241 [A00001,Q-9]

MTU Preservation and Represervation Specifications Manual A001070/00E, dated 2012 vi (Rev-0)

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 N MTU Coolant Test

Kit

5605892099/00 1 $63.12

1 N Ring, Rubber 0029971248 2 $49.86

1 N Gasket 5800980465 2 $7.55

1 N Gasket 5800110259 2 $5.23

1 N Filter Element 0000925005 2 $42.18

1 N O-ring 700294327000 2 $11.12

1 N Gasket 007603048101 2 $1.67

1 N Seal 8499970036 2 $85.84

1 N Barring Device F300030459 1 $279.65

2 N Sealing Ring 5800110259

2 N Gasket 580098045

2 N Filter, Element, Fluid 0000921705

2 N O-Ring 700294125000

2 N Filter, Element 0000925005

2 N Oil Filter 0031845301

2 N Filter, Element, Fluid 00018646026

2 N Filter Sleeve 8491840210

2 N Ring, Sealing 007603030101

2 N Gasket 700429095004

2 N O-Ring 700294014005

2 N Washer, Copper 007603021100

2 N Sealing Ring 8499970870 1

2 N Gasket 5840150980

2 N Sealing Ring 007603012112

2 N Sealing Ring 007603080101

2 N Sealing Ring 8491840100

2 N O-Ring 700429058001

2 N Sealing Ring 007603039100

2 N Washer, Copper 007603014102

2 N Sealing Ring 007603026106

2 N Ring, Rubber 0029971248

2 N O-Ring 700429028000

2 N O-Ring 700429245001

2 N Sealing Ring 5840170160

2 N O-Ring 700429041000

2 N O-Ring 700429028002

2 N O-Ring 700429020003

2 N O-Ring 700429042002 vii (Rev-0)

2 N O-Ring 700429019000

2 N O-Ring 700429030000

2 N O-Ring 700429017002

2 N Sealing Ring 8499970036

2 N O-Ring 700429192000

2 N O-Ring 70042919003

2 N Washer, Copper 007603014106

2 N O-Ring 700429065001 *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 viii (Rev-0)

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.

ix (Rev-0)

PRINCIPAL CHARACTERISTICS

418' WMSL

PHYSICAL

Length overall 418' 0"

Length between perpendiculars 390' 0"

Maximum beam 54' 0"

Beam @ 01 level 47' 9-1/8"

Depth (01 level @ side to baseline) 39' 2-3/4"

01 deck camber foredeck 1/4" in 1'-0"

Minimum berth depth 20' 0"

Height of highest projection Approximately 119'

Draft, design 14.40'

Design displacement 3925 long tons

MACHINERY

Two diesel engines MTU 20V, 20-cylinder 9,730 SHP each

One gas turbine General Electric LM2500; 29,500 SHP

Type of propulsion CODAG

Electrical system 24 Volt DC

Two controllable pitch propellers Rolls-Royce 5 blade, 14' 0" diameter; 229 RPM max

Two reduction gears RENK

One cross connect gear RENK

HULL

Hull material 5086 Aluminum

HSLA-80 Steel

ABS EH 36 Steel

ABS AH 36

Frame spacing

FWD of FR 9 2' 3"

FR 9 to FR 10 6' 9"

FR 10 to FR 98 4' 1"

FR 98 to FR 99 3'-8"

ELECTRICAL

Power Three 1360 kW, 450 V, 60 Hz, 3 Phase, 1800 RPM Caterpillar 3512B diesel engines with Baylor ship service generators

Shore tie cable Seven MIL-C-24368/2 (NATO) shore power receptacles, 400 A each

TANK CAPACITIES

Diesel oil 220,359 gal

Fresh water 12,454 gal

JP-5 Fuel 35,182 gal

1 (Rev-0)

00000_0315_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-0)

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

3.2 Contractor-provided fire extinguishers. The Contractor shall provide portable fire extinguishers.

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 Contractor operated (non USCG) facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix A, Requirements for Environmental Protection at

Contractor Operated (Non USCG) Facilities, as applicable, 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 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 (Rev-0)

3.5.1.1 USCG Generator status. The activity Generator Status for the Coast Guard Facility is not applicable.

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.

3.5.2 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 adequately 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.

4 (Rev-0)

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 changes to published SFLC 2014 Edition Standard Specifications and supersede published content:

None.

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.

5 (Rev-0)

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-0)

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-0)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

Location of Work (Frame References) Area (sqft)

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 and 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

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

Place Surface Profile

Replica Tape Here

Reading:__________ mils

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

8 (Rev-0)

9 (Rev-0)

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 and 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 _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Reading: _____ mils _____ mils _____ mils _____ mils _____ mils

Mean Mil Reading (IAW ASTM D4417-Method B) for above 10 readings (by column):

_____ mils _____ mils _____ mils _____ mils _____ mils

10 (Rev-0)

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)

11 (Rev-0)

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.

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation

3 Before

Adjustments

After Adjustments

Avg.

Location (Frame Reference): ___________________

SPOT 1 2 3 4 5

Overall Avg. DFT

ADJUSTMENTS

1 Avg. BMR Deviation

3 Before

Adjustments

After Adjustments

Avg.

Application Method (Airless, Conventional Spray, Rolled) Average DFT

23000_JSP_0314_418

WORK ITEM 1: Diesel Engines, Long Term Lay-up Preservation

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to preserve Main Propulsion

Engines and Ship Service Diesel Generators listed in Table 1.

TABLE 1 – LIST OF ENGINES FOR LONG TERM PRESERVATION

EQUIPMENT MANUFACTURER

MODEL NO / SERIAL

NO

LOCATION

Main Propulsion Diesel Engine

No.1, 9655 HP, MTU-Detroit Diesel Inc http://www.mtu-online.com/mtu-northamerica/mtu/mtu-in-north-america

MTU 20 V Series 1163

TB 93

AFT Main

Machinery Room

(5-52-0-E)

Main Propulsion Diesel Engine

No.2, 9655 HP

MTU-Detroit Diesel Inc http://www.mtu-online.com/mtu-northamerica/mtu/mtu-in-north-america

MTU 20 V Series 1163

TB 93

AFT Main

Machinery Room

(5-52-0-E)

Ship Service Diesel Generator

No.1 (SSDG No.1)

Caterpillar Corp http://www.cat.com/

3512B / NSC 002 Auxiliary

Machinery Room

(5-36-01-E)

Ship Service Diesel Generator

No.2 (SSDG No.2)

Caterpillar Corp http://www.cat.com/

3512B / NSC 001 Forward Main

Machinery Room

(5-44-01-E)

Ship Service Diesel Generator

No.3 (SSDG No.3)

Caterpillar Corp http://www.cat.com/

3512B / NSC 003 Ship Service

Diesel Generator

Room (2-76-5-Q)

1.2 Government-furnished property. [A00003, Q-21]

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT )

N MTU Coolant Test Kit 5605892099/00 1 $63.12

N Ring, Rubber 0029971248 2 $49.86

N Gasket 5800980465 2 $7.55

N Gasket 5800110259 2 $5.23

N Filter Element 0000925005 2 $42.18

N O-ring 700294327000 2 $11.12

N Gasket 007603048101 2 $1.67

N Seal 8499970036 2 $85.84

N Barring Device F300030459 1 $279.65

*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 Service Center.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750 WMSL 100-001, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750 WMSL 501-002, Rev E, Machinery Arrangements (ASC501001)

Coast Guard Drawing 750 WMSL 801-001, Rev A, Booklet of General Plans (ASC801001)

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 7025, SWBS 233, May 2007, Main Diesel Engine -

Fluids and Lubricants Specifications (A001061/35E)

Coast Guard Technical Publication (TP) 7205, SWBS 252, Oct 2007, MTU Spare Parts Catalog

Coast Guard Technical Publication (TP) 7368, SWBS 311, Jun 2010, Ship Service Diesel

Generator (SSDG) - Model 3512B - Parts Manual

Coast Guard Technical Publication (TP) 7119, SWBS 311, Dec 2013, Ship Service Diesel

Generator (SSDG) - Model 3500B - Caterpillar Manual Sections A and B [A00001, Q-8]

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2012, General Requirements

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2012, Requirements for Preservation of Ship Structures

OTHER REFERENCES

MTU Preservation and Represervation Specifications Manual A001070/00E, dated 2012

CAT Engine and Storage Preservation Manual PEHJ0241 [A00001,Q-9]

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of certified Tech Reps, who are familiar with the MTU 20V1163TB93 Main Propulsion Diesel Engine and Caterpillar 3512B Diesel Engine to accomplish the following tasks – on site:

Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

Assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

3.1.2.1 Ensure that the Tech Rep is a Certified Representative of MTU America (i.e. http://www.mtu-online.com/mtu-northamerica/mtu/mtu-in-north-america) and Caterpiller (i.e. http://www.cat.com) http://www.mtu-online.com/mtu-northamerica/mtu/mtu-in-north-america http://www.mtu-online.com/mtu-northamerica/mtu/mtu-in-north-america http://www.cat.com/

3.1.2.2 Submit the Tech Rep’s name and résumé to the COR at the Arrival Conference.

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 in accordance with SFLC Std Spec

0000, paragraph 3.3.5 (Interferences). The Contractor shall be responsible for the removal and reinstallation of all interferences in way of specified work without regard to whether interferences are listed in this work item or Section J-4 SEDA Interference Database. 3.1.5 The Contractors shall provide all materials and tools required for Long Term Lay–Up preservation of Diesel Engines listed in Table 1.

3.2 Main propulsion diesel engine long term lay-up preservation. The Contractor shall

3.2.1 Supply all materials listed in Table 2.

TABLE 2 – LIST OF MATERIALS [A00003, Q-21]

QUANTITY

PART NUMBER DESCRIPTION

SUGGESTED SOURCE OF

SUPPLY

As required LPS3 Preservation Oil, Aerosol Can

As required SAE 30 Internal Preservation Oil

3.2.2 The Contractor shall perform the following work on each Main Propulsion Diesel Engine listed in

Table 1.

3.2.2.1 Close Fuel Supply Valve (i.e. STBD Supply Valve DFS-1V003 & Port Supply Valve DFS-

2V004) between Service/Day Tank and Engine Pre-filter.

3.2.2.2 Drain both pre-filters by opening the drain valve on bottom of filter housings. Drain fuel into buckets or to suitable waste tank.

3.2.2.3 Open fuel pre-filter lid using 13 mm wrench to loosen bolts.

FIGURE 1: CLEAN INSIDE PRE-FILTER HOUSING

3.2.2.4 Remove all (4) pre-filter elements in each (2) pre-filter housing and clean housings thoroughly (Figure 1).

NOTE

Open plug and drain fuel into clean buckets until engine is empty.

3.2.2.5 Fill only the fuel pre-filter housing in service with Shell V-1404 or equivalent See: MTU

Preservation & Represervation Specifications Manual A001070/00E, dated 2012, section 3.2.3. . Add a

50/50 mixture of engine oil and fuel oil.

3.2.2.6 Prime fuel system on free end of engine with engine’s hand priming pump in preparation for engine start. Continue adding preservation oil until engine fuel system is completely full.

3.2.2.7 Re-install pre-filter lids.

3.2.2.8 Line up pre-filters so that only one pre-filter is online.

FIGURE 2: CHARGE AIR MANIFOLD

3.2.2.9 Loosen and remove the 48mm plug at the end cap of each bank’s charge air manifold (Figure 2).

FIGURE 3: SPRAY TOOL CANISTER MTU P/N F6783579

3.2.2.10 Fill oil spray tool canisters (2) with Shell Ensis Engine Oil SAE 30 or Mobilarma 524 Internal

Preservation Oil (Figure 3).

3.2.2.11 Insert spray nozzle (MTU P/N F6783579) into the plug that was removed in Figure 2.

3.2.2.12 Run the engine at idle for approximately 3 minutes.

ANOTHER OPTION IS TO LEAVE THE PRE-FILTER HOUSING COVER

OPEN AND MONITOR THE FUEL LEVEL AS IT GETS CONSUMED.

ONCE THE FILTER IS CLOSE TO EMPTY SWITCH TO THE OTHER PRE-

FILTER BY MANUALLY MOVING THE VALVE TO THE OTHER SIDE.

3.2.2.13 At the same time, while the engine is running, spray the internal preservation oil into the air manifold (on both A and B bank sided). Ensure all banks are firing (no cylinder cut out).

3.2.2.14 Re-install the 48mm plug that was removed in 3.2.1.9 and torque to 145 Nm.

CAUTION

THE CURRENT CONTROLS CONFIGURATION REQUIRES THE

GEARBOX CONTROLS ARE SET IN "LOCAL" CONTROL.

COVER THE MDE AIR FILTER ASSEMBLIES ON BOTH PORT AND STBD

STACKS USING SHRINK WRAP OR VISQUEEN WRAPPING MATERIAL

(FIGURE 4).

FIGURE 4: MDE INTAKE FILTER ASSEMBLY

EXHAUST OUTLET TRUNKS ARE LOCATED ON THE EXTERIOR 04

DECK SUPERSTRUCTURE (FIGURE 5). COVERS WILL PREVENT ANY

DEBRIS, WATER, OR AIR FLOW INTO THE EXHAUST DUCT

FIGURE 5: MDE EXHAUST OUTLETS

3.2.2.15 Cover both port and starboard exhaust outlet trunks using designated canvas covers.

CAUTION

POWER MUST BE AVAILABLE TO MDE’S PRE-LUBE PRIMING PUMP,

LOCAL OPERATING PANEL (LOP), AND PRE-HEATER DURING

INITIAL PRESERVATION. SHIP’S COMPRESSED AIR SYSTEM

SHOULD BE AVAILABLE FOR USE IN THE AFT MACHINERY SPACE.

3.2.2.16 Allow MDE jacket water coolant system temperature to reach normal operating temperature of approximately 104degree Farenheit (40 degree Celcius).

3.2.2.17 Verify that MDE pre-heaters are in "ON" position on both engines (Figure 6).

FIGURE 6: MDE JACKET WATER PRE-HEATER CONTROL BOX

3.2.2.18 Verify engine coolant temperature is 104 degree Fahrenheit or 40 degrees Celsius, manually switch lube oil priming pump controller into "LOCAL" operating mode.

3.2.2.19 Turn spring-loaded switch to "ON" position and HOLD to begin lubrication cycle.

3.2.2.20 Manually hold switch in "ON" position until pressure at last bearing reaches 1 bar (14 psi), which can be viewed at MDE Local Operating Panel.

3.2.2.21 Loosen all valve covers from the engine by removing with 17 mm wrench (Figure 7). Each head cover has an o-ring that seals the cover to the head. This o-ring shall be removed as well.

FIGURE 7: VALVE COVER AND BOLTS

3.2.2.22 Spray rocker arms with preservation oil (Figure 8).

FIGURE 8: ROCKER ARMS

3.2.2.23 Install new o-rings and valve covers, torque valve cover bolts to 30 Nm.

3.2.2.24 Fill additional oil spray tool canister with Shell Ensis Engine Oil SAE 30 or Mobilarma 524

Internal Preservation Oil (Figure 9).

FIGURE 9: SPRAY TOOL CANISTER MTU P/N F30006432

3.2.2.25 Open and remove air plugs and sealing rings located on each cylinder head using 19mm socket drive (Figure 10).

FIGURE 10: AIR PLUG

3.2.2.26 Insert spray nozzle (MTU P/N F30006432) into air plug hole and spray continuously for 5 seconds. Repeat on remaining cylinders.

NOTE

TO ENSURE COMPLETE LUBRICANT COVERAGE, BAR

OVER ENGINE WHILE SPRAYING.

3.2.2.27 Remove all "A" bank crank case inspection covers by loosening the cover bolts with 17 mm socket. Remove the cover’s o-ring as well (Figure 11)

Figure 11: CRANKCASE COVER

3.2.2.28 With the spray gun, spray the surfaces of the main bearing studs, main bearing nuts, crankshaft, cylinder liners, counterweight, and connecting rods with the internal preservation oil. It will be helpful to turn the engine while spraying to cover all surfaces (Figure 12-13).

FIGURE 12: PRESERVATION AREAS

FIGURE 13: BEARING STUDS AND NUTS

3.2.2.29 Install new sealing rings and air plugs on each cylinder head and torque to 200Nm.

3.2.2.30 Install the crankcase inspection covers and torque the bolts to 42 Nm. Make sure the cover seals are in good condition prior to installation. Replace seals if necessary.

3.2.2.31 Close all decompression valves on cylinder head and torque to 20Nm.

WARNING

Emergency air flaps close abruptly. There is risk of crushing. Keep fingers clear of red lever when closing EMERGENCY air shut off flaps.

3.2.2.32 Inspect engine external areas for missing or loose bolts, rust, or shipped paint. For rust areas, clean surface with brake cleaner and Scotch Bright pad.

3.2.2.33 Spray cleaned areas with external preservation oil.

3.2.2.34 Spray any unpainted surfaces with external preservation oil (i.e. Cylinder Actuators).

3.2.2.35 Close both left and right emergency air flaps (2) on each MPDE (Figure 14).

FIGURE 14: RED HANDLE - EMERGENCY FLAPS

3.2.2.36 Loosen and remove the intake bellow bolts on each of the 5 intakes on the engine (Figure 15).

3.2.2.37 Slide sheet metal blanks between engine intake and flexible bellow and align holes.

3.2.2.38 Bolt intake bellows back in place.

3.2.2.39 Open gate valve on coolant pre-heater vent line and take a coolant sample (Figure 15).

FIGURE 15: JACKET WATER COOLANT SAMPLE POINT

3.2.2.40 Using test kit, test coolant sample for proper concentration in accordance with MTU Publication

A001061/34and current shipboard procedure

3.2.2.41 Lubricate all air flaps at grease fittings (Figure 16).

FIGURE 16: MDE AIR FLAPS GREASE FITTINGS

3.2.2.42 Report any deficiencies and submit a CFR.

3.2.2.43 When authorized, restore MDE to normal readiness and operational condition.

3.2.2.44 Borescope a few selected cylinders to check condition of internal components. Submit a CFR.

3.2.2.45 Remove sheet metal blanks from each of the 5 intakes on the engine (Figure 15).

3.2.2.46 Reposition emergency air flaps to normal position (Figure 14).

3.2.247 Remove and properly dispose of shrink wrap or visqueen used to cover MDE intake filter assemblies (Figure 4). Remove Red Danger Tags in accordance with COMDTINST 9077.1 (series) and place in normal position per shipboard Tag-Out Log. Submit a CFR.

3.3 Ship Service Diesel Generator Long Term Lay-Up Preservation. The Contractor shall perform the following work on each Ship Service Diesel Generator listed in the Table 1.

3.3.1 The Contractor shall cover exhaust outlet trunks with canvas covers.

3.3.2 The Contractor shall supply all materials required for long term lay-up preservation in accordance with Section 3 of Coast Guard Tech Pub 7119.

3.3.3 The Contractor shall perform the storage procedure on each Ship Service Diesel Generator listed in the Table 1 in accordance with Section 3 of Coast Guard Tech Pub 7119 (SEHS9031 Storage

Procedures).

3.3.4 General instructions for Caterpillar Engine Storage and Preservation are provided in CAT Engine and Storage Preservation Manual PEHJ0241. [A00001,Q-9]

3.3.5 The Contractor shall remove the canvas covers on the exhaust outlet trunks at the end of the availability.

4. NOTES

This section is not applicable to this work item.

24300_JAH_1114_418

WORK ITEM 2: Main Propulsion Diesel Engine-Statement of Work

1. SCOPE

1.1 Intent. This Statement of Work (SOW) describes the requirements for the Contractor to perform inspection on the Port and Starboard Main Propulsion Diesel Engines listed in the Table 1 onboard the cutter.

TABLE 1 – MPDE NAME PLATE DATA

EQUIPMENT

MODEL NUMBER /SERIAL

NUMBER

LOCATION

Main Propulsion Diesel Engine,9666

HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93 / 5840323

AFT Main Machinery Room (5-52-0-E)

Main Propulsion Diesel Engine,9666

HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93 / 5840324

AFT Main Machinery Room (5-52-0-E)

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST ($/UNIT)

N Sealing Ring 5800110259

N Gasket 580098045

N Filter, Element, Fluid 0000921705

N O-Ring 700294125000

N Filter, Element 0000925005

N Oil Filter 0031845301

N Filter, Element, Fluid 00018646026

N Filter Sleeve 8491840210

N Ring, Sealing 007603030101

N Gasket 700429095004

N O-Ring 700294014005

N Washer, Copper 007603021100

N Sealing Ring 8499970870 1

N Gasket 5840150980

N Sealing Ring 007603012112

N Sealing Ring 007603080101

N Sealing Ring 8491840100

N O-Ring 700429058001

N Sealing Ring 007603039100

N Washer, Copper 007603014102

N Sealing Ring 007603026106

N Ring, Rubber 0029971248

N O-Ring 700429028000

N O-Ring 700429245001

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST ($/UNIT)

N Sealing Ring 5840170160

N O-Ring 700429041000

N O-Ring 700429028002

N O-Ring 700429020003

N O-Ring 700429042002

N O-Ring 700429019000

N O-Ring 700429030000

N O-Ring 700429017002

N Sealing Ring 8499970036

N O-Ring 700429192000

N O-Ring 70042919003

N Washer, Copper 007603014106

N O-Ring 700429065001

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL-100-1, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750-WMSL-501-2, Rev E, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 0000, Jan 2012, General

Requirements

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 6310, Jan 2012, Requirements for Preservation of Ship Structures

Coast Guard Technical Publication (TP) 7024, 31-MAY-07, Main Diesel Engine - Removal

Spaces and Weights

Coast Guard Technical Publication (TP) 7025, 31-MAY-07, Main Diesel Engine - Fluids and

Lubricants Specifications (A001061/3

Coast Guard Technical Publication (TP) 7026, 31-MAY-07, Main Diesel Engine - Repair Tools

Coast Guard Technical Publication (TP) 7027, 31-MAY-07, Main Diesel Engine - Operating

Instructions

Coast Guard Technical Publication (TP) 7028, 31-MAY-07, Main Diesel Engine - Maintenance

Manual

Coast Guard Technical Publication (TP) 7031, 31-MAY-07, Main Diesel Engine - Parts Catalog

(M034562/01DE)

OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR

None.

3.1.2 Technical Representative. The Contractor shall provide the services of qualified Tech Rep, who is familiar with - MTU Detroit Diesel, Inc. to accomplish the following tasks – on site:

Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

Assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

Technical Representative shall be present for all disassembly, inspection, and reassembly of the Diesel Engine.

3.1.2.1 The Contractor shall ensure that the Tech Rep is a certified representative of MTU Detroit Diesel, Inc.

3.1.2.2 The Contractor shall submit the name of the Tech Rep to the COR at the Arrival Conference.

3.1.2.3 The Contractor shall be required to have this Technical Representative present (mandatory), on site, while the following engine work is being performed:

Diesel Engine Inspection

3.1.2.4 Tech Rep. All work in this work item shall be performed by MTU Tognum America Inc personnel.

3.1.2.5 Point of Contact is: Bill Emborsky OR Margarett Sicoracky Senior Manager Large Engine

Business; MTU America Inc. (313) 405-3410.

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

3.1.4 Interferences. The Contractor shall 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:

Access covers.

Exhaust stack.

Piping.

Vent ducting.

Electrical Cables

3.2 Contractor Furnished Material and Equipment. The contractor shall supply all consumable materials, equipment, and tools required to perform the inspection on the Port and Starboard Main Diesel Engines.

Additional parts beyond consumables shall be supplied by the government and are shown above.

Additional parts which may be required shall be subject of a contract modification.

3.3 Main Diesel Engine Description and Contract Performance Data. Each of the Main Diesel Engines is a 20 cylinder Model 20V1163TB63 manufactured by MTU. CG Tech Pubs references above describe each engine and will be available onboard the cutter for review. CG Tech pubs are available aboard the vessel.

3.4 Diesel Engine Inspection. Perform the standard diesel engine inspection on each of the two (2) Main

Propulsion Diesel Engines. The contractor shall perform the following actions:

3.4.1 Cylinder Compression Readings. Take and record compression readings on each cylinder of each main diesel engine.

3.4.2 Valve Clearance Readings. Check the valve clearance on all valves on each engine cylinder head.

3.4.3 Fluid Samples. Take samples of lube oil, engine coolant, and fuel on each engine.

3.4.4 HP and LP Cooler Inspections. Using a boroscope, inspect the internals of the HP and LP

Intercoolers.

3.4.4.1 Conduct the boroscope inspection of the low pressure intercoolers by removing the cover plate on top of the intercoolers. Reinstall the cover plates upon completion of work.

3.4.4.2 Conduct the boroscope inspection of the HP coolers by removing the two plugs on the supply side of all top covers.

3.4.5 Turbocharger Inspections. Using a boroscope, inspect the HP and LP turbocharger wheels. Each engine has five (5) Hp and five (5) LP turbochargers.

3.4.5.1 Remove plug screws and conduct boroscope inspections of turbochargers through plug screw holes on all low pressure intercoolers. Reinstall plug screws after completion of inspections. Coat plug screws with lithium grease prior to reinstallation.

3.4.6 Gear Case Inspections. Remove casing side covers and inspect the wear patterns on the main pump drive gears on each engine.

3.4.7 Cylinder Liner Inspections. Using a boroscope, inspect intake and exhaust valves, and cylinder head liners and piston crowns on each cylinder.

3.4.7.1 Remove air start valve plugs on each cylinder.

3.4.7.2 Bar over the engine as required to conduct boroscope examination of cylinder internals.

3.4.7.3 Reinstall and torque air start valve plugs on each cylinder Torque to 200 NM (+ or – 10 NM).

3.4.8 Air Bank Inspections. Remove the plug on the end of each charge air elbow and discharge of the

HP intercoolers on the “A” and “B” bank on each engine. Boroscope inspect the “A” and “B” bank manifolds on each engine. Reassemble the charge air pipes.

3.4.9 Filter Element Inspections. Cut open and inspect one (1) lube oil filer on each engine. Check the pre-filters for algae and inspect the centrifugal oil filter.

3.4.10 Visual Inspections. Visually inspect each engine for leaks or other necessary repairs.

3.4.11 Download engine operation data from the LOS program aboard the cutter.

3.4.12 Submit a final report noting the condition of each engine, any inspection results and LOS data plots.

3.4.13 Reassemble all parts of each engine which were disassembled to perform…