ATTACHMENT_1_-_WAESCHE_(WMSL_418)_MPDE_Rev_00.pdf

USCGC WAESCHE (WMSL 751)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2017

Developed By: Kevin O’Brien

(Rev-00, 02 Jun 2016)

USCGC WAESCHE (WMSL-751) DOCKSIDE AVAILABILITY FY2017

ii (Rev-00)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property ................................................................................. vi Consolidated List of Critical Inspection Items ........................................................................................... vii Principal Characteristics ............................................................................................................................ viii General Requirements WORK ITEM 1: Main Propulsion Diesel Engine- DEI WORK ITEM 2: Main Propulsion Diesel Engine (MPDE),12,000 Hour Repair iii (Rev-00)

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-00)

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 101-9, Rev A, Equipment Removal Route Drawing (NSC-1 & NSC-2

Only) (ASC101009)

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) 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)

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 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-00)

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

OTHER REFERENCES

MTU Technical Documentation S000082/00E (MTU Tech Pub S000082/00E), 2011, Functional

Descriptions, Operating Instructions, and Instructions for General Overhaul vi (Rev-00)

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 Diesel Engine

Inspection Kit

P/N: 584-DEI-KIT

NSN: 016280945

02 ea 3051.97

2 Y Injector Replacement

Kit

P/N: 584-INJ-RPL-KIT

NSN: 015911763

20 ea. 2377.54

2 Y Cylinder Head

Replacement Kit

P/N: 584-CYL-HD-RPLM

NSN: 016192838

20 ea. 15450.56

2 Y Cylinder Liner Kit P/N: 584-CYL-LINR-KIT

NSN: 016192672

20 ea. 3672.81

2 Y Fuel Injection Pump

Kit

P/N: 584-FL-INJ-PMP-KIT

NSN: 016192228

40 ea. 12245.35

2 Y Piston Engine P/N: 5840301117

NSN: 123349610

20 ea. 10180.72

2 Y Conrod Bearing P/N: 5840301960

NSN: 123587417

20 ea. 941.03

2 Y Jacket Water Pump LS

Replacement Kit

P/N: 584-JWPMPLS-RPLM

NSN: 016263405

1 ea. 13360.14

2 Y Jacket Water Pump RS

Replacement Kit

P/N: 584-JWPMPRS-RPLM

NSN: 016192545

1 ea. 13577.89

2 Y Sea water pump

Replacement Kit

P/N: 584-SWPMP-RPLM

NSN: 016192264

1 ea. 27071.07

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

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

***Government-furnished property, which is to be supplied by either the vessel or the C4IT ServiceCenter vii (Rev-00)

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

01 Main Propulsion Diesel Engine - DEI

This section is not applicable to this package.

viii (Rev-00)

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-00)

00000_1015_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-00)

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

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

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec

6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

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

NOTE

Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes

(provided in Chapter 6 of COMDTINST M10360.3) are strictly prohibited.

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

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

3.5.1 USCG facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC

Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, during the performance of this availability. Contractor shall plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor shall comply with applicable

Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.1.1 USCG Generator status. The activity Generator Status for the Coast Guard Facility is _________.

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, 3 (Rev-00) and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The

Contractor shall submit copies of all regulatory notifications to the Contracting Officer and the local Facility

Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications shall be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System

(NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

3.5.4 Environmental manager. The Contractor shall appoint in writing an Environmental Manager for the project, and shall be responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager shall ensure compliance with Hazardous Waste

Program requirements, including hazardous waste handling, storage, manifesting, and disposal; implement the

Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas;

ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the

Environmental Records binder and required documentation, including environmental permits compliance and close-out.

3.5.5 HW disposal. Contractor shall comply with SFLC Std Spec 0000 Appendix B, Requirements For

Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

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

3.5.6.1 No Contractor or Subcontractor shall have the authority to sign a Hazardous Waste Manifest using the

Coast Guard facility’s EPA Generator ID Number or remove contract generated hazardous waste from the Coast

Guard facility without COR or KO-approval.

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

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

3.6 Local Policy. None.

3.7 SFLC standard specification approved changes. The Contractor shall be aware that the following are approved changes to published SFLC 2014 Edition Standard Specifications and supersede published content:

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

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

4 (Rev-00)

3.7.1.2 SFLC Std Spec 6310, Page 4, Section 2 References, Group- Other References. Add “The Society for

Protective Coatings (SSPC) Paint Application Guide No. 11, 2008, Protecting Edges, Crevices, and Irregular Steel

Surfaces by Stripe Coating”

3.8 Work Plan Contractor shall perform the work on the following work items in the first 2 weeks of the contract availability.

Work Item: Main Propulsion Diesel Engine- DEI

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-00)

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.

6 (Rev-00)

Name of QP-1/NACE Inspector Signature Cert. # Date / Time

7 (Rev-00)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

VESSEL NAME HULL #

WORK

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

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

DATE /

TIME

8 (Rev-00)

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL #

WORK

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: ______________

9 (Rev-00)

10 (Rev-00)

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL #

WORK

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

11 (Rev-00)

12 (Rev-00)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

VESSEL NAME HULL #

WORK

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15

DATE TEST LOCATIONS

CONDUCTIVITY

(MICROSIEMENS/CM)

13 (Rev-00)

14 (Rev-00)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

VESSEL NAME HULL #

WORK

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

15 (Rev-00)

24300_JAH_1114_418

WORK ITEM 1: Main Propulsion Diesel Engine- DEI

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform DEI (Diesel Engine

Inspection on both MPDE’s listed in 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 /5840276

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

Main Propulsion Diesel Engine,9666

HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93 / 5840277

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

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST ($/UNIT)

N Diesel Engine Inspection Kit P/N: 584-DEI-KIT

NSN: 016280945

02 ea 3051.97

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL-100-001, Rev C, 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, 2014, General

Requirements

Surface Forces Logistics Center Standard Specification (SFLC Std Spec) 6310, 2014, 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

16 (Rev-00)

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

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

3.1.2 Technical Representative. The Contractor shall provide the services of qualified Tech Rep, who is familiar with - MTU America, 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 America, 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 America Inc personnel.

3.1.2.5 Point of Contact is: Mr. David Sears, Acting Director, Large Engine Business; MTU America

Inc. (510) 333-0701.

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.

17 (Rev-00)

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 Operational Test. Ship’s force will conduct an operational test of the Starboard Main Diesel engine prior to inspection in presence of contractor and USCG inspector. Submit CFR.

3.4 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.

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

Propulsion Diesel Engines. The tech rep shall perform the following actions:

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

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

3.5.3 Turbocharger Inspections. Using a boroscope, inspect the HP and LP turbocharger wheels. Each engine has five (5) Hp and five (5) LP turbochargers. Submit CFR with photo documentation.

3.5.3.1 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.

3.5.4 Gear Case Inspections. Remove casing side covers and inspect the wear patterns on the main pump drive gears on each engine. Submit CFR with photo documentation.

3.5.5 Cylinder Liner Inspections. Using a boroscope, inspect intake and exhaust valves, and cylinder head liners and piston crowns on each cylinder. Submit CFR with photo documentation.

3.5.5.1 Remove air start valve plugs on each cylinder.

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

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

18 (Rev-00)

3.5.6 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.

3.5.7 Piston cooling oil Filter Inspection: Remove one of the three Piston Cooling Oil Filters and cut open and inspect filter media for signs of contamination. Replace all three Piston Cooling filters from DEI kit.

3.5.8 Visual Inspections. Visually inspect each engine for leaks or other necessary repairs. Submit CFR for any necessary repairs.

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

3.5.10 Submit a report of cast numbers on all cylinders on both engines.

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

3.5.12 Reassemble all parts of each engine which were disassembled to perform inspections.

3.6 Operational Test. Ship’s force will conduct an operational test of each engine upon completion of inspections. Submit CFR.

4. NOTES

This section is not applicable to this work item.

19 (Rev-00)

23300_TAB_0516_751

WORK ITEM 2: Main Propulsion Diesel Engine (MPDE),12,000 Hour Repair

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform 12,000 hour maintenance on both MPDE for items listed on table 1.

TABLE 1 – MAINTENANCE ITEMS FOR MPDE #1 AND MPDE #2

ITEM MAINTENANCE TASK TASK # MPDE #1 MPDE #2

Emergency air shut-off flaps Inspection Only X

Jacket water thermostat Renew X

Centrifugal oil filter Check and replace elements X

Fuel filter Replace element X

Valve gear Check valve clearance X

Engine mounts Check Buffer clearance W1026 X

Fuel injectors Renew X

Engine coolant pump Renew W1384 X

Raw water pump Renew W1383 X

Cylinder heads Renew W1063 X

Cylinder liners Renew W1101 X

Fuel prefilter Replace filter element X5900 X

Preheater / Jacket water heater Inspect for leaks

X5602 X X

Preheater Renew X5601 X

Level probes (expansion tank) Inspect

X5501 X X

Lube-oil tank Inspect X X

Auxiliary priming unit Inspect X X

Cooler installation

Clean cooler and replace seals

(PCHE)

X X

Pressure reducing station

Clean air filter, renew if necessary. Renew diaphragm

(Block)

X7650

X7651

X X

Compressed-air starting system Inspect

X X

Fuel Injection pumps Renew X X

Charge-air preheating

Remove, clean and check control valve (TC valve)

X

Intercooler (low pressure)

Clean interior of cooler, check for damage

W1133 X

Conrod bearings Renew W1083 X

Gear train Perform visual inspection W1086 X

Governor actuator Inspect governor linkage X X

20 (Rev-00)

Vibration damper

Remove and inspect vibration dampener

W1129 X X

Pistons Renew W2044 X

Oil thermostat Renew W1128 X

Component maintenance

Starting air distributor: Inspect components, check settings.

Adjust if Necessary.

Fuel thermostat (if fitted): Fit new thermostat actuator.

Check rockers, roller tappets, pushrods and pushrod ball heads for wear.

Check engine alignment.

W2041

W2036

W2084

X X

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST ($/UNIT)

Y Cylinder Liner Kit P/N: 584-CYL-LINR-KIT

NSN: 016192672

20 ea. 3672.81

Y Fuel Injection Pump Kit P/N: 584-FL-INJ-PMP-KIT

NSN: 016192228

40 ea. 12245.35

Y Injector Replacement Kit P/N: 584-INJ-RPL-KIT

NSN: 015911763

20 ea. 2377.54

Y Piston Engine P/N: 5840301117

NSN: 123349610

20 ea. 10180.72

Y Conrod Bearing P/N: 5840301960

NSN: 123587417

20 ea. 941.03

Y Cylinder Head Replacement

Kit

P/N: 584-CYL-HD-RPLM

NSN: 016192838

20 ea. 15450.56

Y Jacket Water Pump LS

Replacement Kit

P/N: 584-JWPMPLS-RPLM

NSN: 016263405

1 ea. 13360.14

Y Jacket Water Pump RS

Replacement Kit

P/N: 584-JWPMPRS-RPLM

NSN: 016192545

1 ea. 13577.89

Y Sea water pump

Replacement Kit

P/N: 584-SWPMP-RPLM

NSN: 016192264

1 ea. 27071.07

*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.

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)

21 (Rev-00)

COAST GUARD PUBLICATIONS

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

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

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

MTU Technical Documentation S000082/00E (MTU Tech Doc S000082/00E), 2011, Functional

Descriptions, Operating Instructions, and Instructions for General Overhaul

MTU Maintenance Schedule M050711/06E.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative. The Contractor shall provide the services of an OEM-certified Tech Rep, who is familiar with the MTU 20 V Series 1163 TB93 Main Propulsion Diesel Engine and its intake air and exhaust turbocharger controls, to accomplish the following tasks – on site:

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

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

3.1.2.1 Ensure that the Tech Rep is a Certified Representative of MTU America, Inc., the OEM.

3.1.2.2 Submit the Tech Rep’s name and résumé 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:

Disassembly

22 (Rev-00)

Inspection and qualification of parts

Reassembly

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). Known interferences include, but are not limited to the below-listed:

Piping systems

Engine parts including exhaust piping

Electrical cables

Catwalks

Engine oil

Jacket Water

3.1.5 Work location. The concerned work area is AFT Main Machinery Room (AMMR) 5-52-01-E. See the applicable drawings in References in Paragraph 2 of this work item for guidance, locations, and details.

3.1.6 MPDE Information. The MPDE Name plate data is listed in the Table 2.

TABLE 2 – MPDE NAME PLATE DATA

EQUIPMENT MODEL NUMBER LOCATION

Port: Main Propulsion Diesel

Engine,9666 HP, MTU America , Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

STBD: Main Propulsion Diesel

Engine,9666 HP, MTU America, Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

3.1.7 Operational test - initial. Prior to commencement of work, the Contractor shall witness Coast

Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR.

3.2 Maintence and Inspection. The Contractor shall be follow directions from Tech Rep and TP 7028 and

MTU Technical Documentation S000082/00E as needed to accomplish the maintence, inspections and repairs required for the 12000 hr Maintence Schedule items listed on Table 1. Submit CFR.

3.3 Materials with core return. The Contractor shall use the boxes and packing materials from the new parts to pack the used cores. Deliver the boxes with the used parts to COR.

3.4 Operational test – post repairs. After completion of all authorized work, the Contractor and CG

Inspector shall witness an operational test (by Coast Guard personnel) of the main diesel engines to prove satisfactory operating condition. Submit a CFR.

23 (Rev-00)

3.5 Touch-up preservation. The Contractor shall prepare and touch-up coat all disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, Appendix B (Cutter and Boat

Interior Painting Systems). Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

4. NOTES

This section is not applicable to this work item.