SAWFISH SOW - Attachment 2.doc

USCGC SAWFISH (WPB 87357)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2022

Developed By: Christian M Lynch (Rev-0, 19 Oct 2021)

TABLE OF CONTENTS

iii

Revisions Record iv

Consolidated List of References vi

Consolidated List of Government-furnished Property vii

Consolidated List of Critical Inspection Items viii

Principal Characteristics

General Requirements

WORK ITEM 1: Main Diesel Engine Assemblies, Perform W-5 Maintenance And Update Control System Configuration

WORK ITEM 2: Grey Water Holding Tanks, Clean and Inspect

WORK ITEM 3: Sewage Holding Tanks, Clean and Inspect

WORK ITEM 4: Grey Water Piping, Clean and Flush

WORK ITEM 5: Sewage Piping, Clean and Flush

WORK ITEM 6: SEWAGE SYSTEM (TOILET), MODIFY

WORK ITEM 7: Soft Patch, Remove and Inspect

WORK ITEM 8: Fire Pump Motor Controller, Replace

WORK ITEM 9: Interior Deck Covering System, Renew

WORK ITEM 10: Insulation, Renew

WORK ITEM 11: Unmanned Space Ventilation Modify

WORK ITEM 12: Stern Door Cross Connect Valves, Modify

WORK ITEM 13: Fire Main Bleed Line, Modify

WORK ITEM 14: Cathodic Protection/Zinc Anode(s), Remove

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.

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.

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 the 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 – from links located on the SFLC website. Commercial sites provide access to their respective documents.

COAST GUARD DRAWINGS

Coast Guard Drawing 87 WPB 113-001, Rev G, Platform Plating & Framing Coast Guard Drawing 87 WPB 131-001, Rev J, Deck Construction Plan Coast Guard Drawing 87 WPB 186-001, Rev -, Foundations for Install of Jets Vacuum System Coast Guard Drawing 87 WPB 201-001, Rev G, Machinery Arrangement Coast Guard Drawing 87 WPB 252-002, Rev P, Alarm & Monitoring System Coast Guard Drawing 87 WPB 259-001, Rev J, Engine Exhaust Piping Coast Guard Drawing 87 WPB 302-001, Rev AC, Misc. Controls Wiring Diagram Coast Guard Drawing 87 WPB 302-003, Rev -, Jets Vacuum Toilet Electrical Details Coast Guard Drawing 87 WPB 310-001, Rev J, Ship’s Service One-Line Diagram Coast Guard Drawing 87 WPB 310-007, Rev -, Unmanned Spaces Ventilation modification Electrical Coast Guard Drawing 87 WPB 321-001, Rev L, Power System Deck Plan Coast Guard Drawing 87 WPB 331-001, Rev R, Lighting System Deck Plan Coast Guard Drawing 87 WPB 514-005, Rev B, Ventilation Mods to Unmanned Spaces Coast Guard Drawing 87 WPB 521-002, Rev -, Fire Main Bleed Line Mod Coast Guard Drawing 87 WPB 526-001, Rev J, Scuppers & Deck Drains Piping Coast Guard Drawing 87 WPB 556-005, Rev A, Hyd Steering Sys mods for Emer Door Operation Coast Guard Drawing 87 WPB 593-001, Rev K, Sewage Piping Coast Guard Drawing 87 WPB 593-001, Rev L, Sewage Piping Coast Guard Drawing 87 WPB 593-004, Rev B, Sewage System Modifications Jets Vacuum System Coast Guard Drawing 87 WPB 601-001, Rev R, Outboard Profile & General Arrangements Coast Guard Drawing 87 WPB 621-001, Rev K, Joiner Work Details Coast Guard Drawing 87 WPB 633-001, Rev A, Cathodic Protection Coast Guard Drawing 87 WPB 634-001, Rev G, Deck Covering & Details Coast Guard Drawing 87 WPB 634-001, Rev G, Deck Coverings & Details Coast Guard Drawing 87 WPB 635-001, Rev C, Linings and Insulation Plan & Details

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Jun 2006, Coatings and Colors Manual Coast Guard Technical Publication (TP) 4573, Coolant Heating System, 17 March 2003 Coast Guard Technical Publication (TP) 9115, SWBS 593, March 2016, Jets Vacuum Sewage System Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 3041 (SFLC Std Spec 3041) 2020, Shipboard Electrical Cable Test Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042) 2020, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, and Installation Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2020, Auxiliary Machine Systems Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures Surface Forces Logistics Center Standard Specification 6341 (SFLC Std. Spec 6341), 2020, Install Interior Deck Covering Systems

OTHER REFERENCES

ASTM International (ASTM) D1330, 2010, Standard Specification for Rubber Sheet Gaskets ASTM International (ASTM) D1330, 2015, Standard Specification for Rubber Sheet Gaskets Installation of MTU Electronic Systems E 530 606/06E MIL-PRF-24613A, Nov 2007, Deck Covering Materials, Interior, Cosmetic Polymeric MTU 8V 396 TE.4 Maintenance Manual M020046/21E MTU 8V 396 TE94 Description and Operation Manual M011511/00E MTU 8V 396 TE94 Parts Catalog M033971/00DE, Order #771903 MTU 8V396 TE.4 Tolerances & Wear Limits List M070026/00E MTU Customer Connecting System CCS for ECS 396, E 531 415/00EMTU Electrical Start Device SUE-ES for ECS 396, E 531 482/00E MTU Customer Connecting System CCS for ECS 396, E 531 416/00E MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED MTU Engine Management System Typ ECS 396/S Version E & F with ETB 4E/ETB 4F Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E MTU Exhaust Turbocharger ZR140 M040052/10E MTU Fluids and Lubricants Specification A001061/35E MTU Junction Box CCS-ECS 396E Illustrated Parts Catalog E 535 151/01ED MTU Local Operating Panel for ECS E 531 301/01E MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED MTU Monitoring & Control Unit Documentation E 535 164/00ED MTU Service Information 396-99/0562B Electric Governor Actuator with Oil Drain MTU Solenoid Actuator, Description, Assembly Instructions M040082/10E MTU Tool List M004021/20DE 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.

($/Unit)

*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

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)):

Principal Characteristics

87' WPB

Physical

Hull

Machinery

Tank Capacities

00000_0121_FLT

REC_00000_FLT_Commercial Project @ CG Facility (0121) 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), 2020, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures Other References None

3. REQUIREMENTS

3.1 General. The Contractor must 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.

3.2 Fire watch requirements. The Contractor must 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 must 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 must perform all welding and allied processes, and NDE in accordance with SFLC Std Spec 0740.

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

3.5.1 USCG facilities. The Contractor must 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 must 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 must 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 must 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 small.

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

3.5.3 Regulatory notifications. The Contractor must 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 must 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 must 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 must appoint in writing an Environmental Manager for the project, and must be responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager must 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 must 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 must be aware of the following:

3.5.6.1 No Contractor or Subcontractor must 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 must 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 must 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 must be aware that the following are approved changes to published SFLC 2020 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.

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

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 mfg.

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 mfg.

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.

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.

| DP - Surface |

QA-3a - QUALITY ASSURANCE INSPECTION FORM

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

Abrasive Manufacturer:

Abrasive Sieve Size:

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

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

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

QA-3b - QUALITY ASSURANCE INSPECTION FORM

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

Abrasive Manufacturer:

Abrasive Sieve Size:

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

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Mean Reading (mils)

Mean Reading (mils) IAW ASTM DD4417).

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY Measurements IAW SSPC-GUIDE 15.

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

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

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

Location (Frame Reference):

Avg.

Location (Frame Reference):

Avg.

Location (Frame Reference):

Avg.

23002_FJL_0220_87WPB

WORK ITEM 1: Main Diesel Engine Assemblies, Perform W-5 Maintenance And Update Control System Configuration

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a W-5 overhaul of the starboard main diesel engines (MDEs) and to update the control system configuration.

1.2 Government-furnished property.

($/UNIT)

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

2. REFERENCES

Coast Guard Drawings None Coast Guard Publications Coast Guard Technical Publication (TP) 4573, Coolant Heating System, 17 March 2003 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Other References MTU 8V 396 TE.4 Maintenance Manual M020046/21E MTU 8V 396 TE94 Description and Operation Manual M011511/00E MTU 8V 396 TE94 Parts Catalog M033971/00DE, Order #771903 MTU 8V396 TE.4 Tolerances & Wear Limits List M070026/00E MTU Tool List M004021/20DE MTU Exhaust Turbocharger ZR140 M040052/10E MTU Solenoid Actuator, Description, Assembly Instructions M040082/10E MTU Service Information 396-99/0562B Electric Governor Actuator with Oil Drain MTU Fluids and Lubricants Specification A001061/35E MTU Engine Management System Typ ECS 396/S Version E & F with ETB 4E/ETB 4F Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E MTU Customer Connecting System CCS for ECS 396, E 531 416/00E MTU Customer Connecting System CCS for ECS 396, E 531 415/00EMTU Electrical Start Device SUE-ES for ECS 396, E 531 482/00E MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED MTU Junction Box CCS-ECS 396E Illustrated Parts Catalog E 535 151/01ED MTU Local Operating Panel for ECS E 531 301/01E MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED MTU Monitoring & Control Unit Documentation E 535 164/00ED Installation of MTU Electronic Systems E 530 606/06E ANSI/NCSL Z540 3 2006.08.03, Requirements for the Calibration of Measuring and Test Equipment ANSI/ASQC Q90003-1994, dated 18 July 94, Inspection System

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of a Qualified Technical Representative who is familiar with overhauling and commissioning MTU marine engines, to accomplish the following on site:

· Advise on manufacturer's proprietary system information.

· Assist with installation and repair method(s)

· Ensure compliance with manufacturer's procedures and standards during system disassembly, inspection, and reassembly as applicable.

3.1.2.1 Ensure the Tech Rep has experience with the system/equipment stated above and demonstrated on their résumé.

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

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

· Piping

· Valves

· Electrical Wiring

· Insulation

3.1.5 Labor. Provide all necessary labor to perform disassembly, reassembly, and any other required repairs associated with this contract.

3.1.6 Training. Allow Coast Guard personnel to observe all diagnostic and repair tasks; advise ship’s force on proper operation and maintenance of the equipment in the normal course of performing disassembly, reassembly, and repairs. Coast Guard personnel may be allowed to perform minor tasks, at the discretion of the Contractor, if those tasks will assist in training and in no way compromise schedule. Coast Guard personnel will NOT be utilized to complete contract obligations; the Contractor shall supply adequate labor to complete the contract within the performance period without Coast Guard supplied labor.

3.1.7 Reports. All reports shall be forwarded to the Contracting Officer, Port Engineer (COR), MTU Equipment Specialist in AMS1 and copied to 87 PDM Section Chief.

3.2 Maintenance, overhaul and repair work. The Contractor shall perform the following on each:

3.2.1 Engine condition pre-check. Perform engine condition check prior to W-5 Maintenance in accordance with M020046/21E Section 2.1. This check shall require the cutter to get underway in order to run the engines at the maximum possible power.

3.2.2 W5 Maintenance. Perform an in-place MTU 8V396TE94 Maintenance Operation W-5 in accordance with the references listed beneath Section 2 above. Submit Condition Found Reports (CFRs) for all inspections.

NOTE

Engine lube oil and coolant/inhibitors will be supplied and disposed of by the government.

3.2.3 Non-Government-furnished part and component renewal. Renew all gaskets, seals, and o-rings disturbed during the performance of disassembly and reassembly. Renew all other components required by the MTU 8V396TE94 Maintenance Operation W5. Furnish all required components not identified as Government-furnished Property (GFP). The contractor shall use only MTU certified components; the use of aftermarket non-certified components is not permitted.

3.2.4 Government-furnished part and component renewal. Renew the following components using Government-furnished property.

· “A” Bank Turbocharger

· “B” Bank Turbocharger

· Cylinder Heads

· Jacket Water Pump

· Sea Water Pump

· Starter Motor

3.2.5 Clean and inspect components. Remove, clean, inspect, and reinstall the following components. Submit CFR for all inspections.

· Sequential Turbo Charging Actuator

· Sequential Turbo Charger Mechanism

· Lube Oil Cooler

· Plate Cooler

· Charge Air Manifold

· Fuel Injectors

· Charge Air Cooler (must be cleaned ultrasonically)

· Exhaust sleeves

3.2.5.1 Inspect the cylinder liners in place, without removal. Record dimensions on the “Data Sheet Cylinder Liner (installed)”. Submit CFR if cylinder liners are found out of tolerance. Renew components using Government-furnished property if a Change Request is released by the Contracting Officer.

3.2.5.2 If during the course of conducting the W5 maintenance the contractor discovers any damaged parts or parts worn beyond specification, the contractor shall submit a Condition Found Report (CFR) to the Contracting Officer, COR, & MTU Equipment Specialist in AMS1 for review and approval. The CFR shall include any applicable MTU Data Sheets that documents the damage or out of tolerance condition and the price of any parts that cannot be furnished by the Government as well as the estimated labor cost to correct the discrepancy.

3.2.6. Configuration update. The Contractor shall validate and update, as needed, the system parameters to match the current 87' WPB configuration.

3.3 Quality assurance. The Contractor shall maintain an inspection system which shall ensure each item offered to the Government for acceptance conforms to contract requirements. The system shall be documented and in compliance with ANSI/ASQS Q90003.

3.3.1 Records. The Contractor shall maintain records of all inspections and tests. The records shall indicate the nature and number of observations made, type of deficiencies found and the corrective action taken. Records shall be furnished upon arrival of the Coast Guard Representative.

3.3.2 Contractors calibration system. The Contractor, as well as any Subcontractors, shall be required to maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540-3. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to ensure adherence to calibration schedules. Calibration standards shall be traceable to the National Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for Government review.

3.3.3 Responsibility For inspection. The Contractor shall be responsible for all inspections/test requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all inspection requirements. Testing and inspection shall be at the Cutter’s location or other facilities acceptable to the Government. The Government reserves the right to verify or have performed any of the inspection/tests set forth in this specification where such inspections are deemed necessary to ensure that supplies or services conform to the prescribed requirements.

3.3.4 Reports. The Contractor shall complete & submit the following data sheets & reports: Cylinder Liner (installed), Valve & Injection Timing, Piston Crown Clearance Adjustment (if any pistons & liners are replaced), and Sea Trial Test results. All reports shall be forwarded to the Contracting Officer, Port Engineer (COR), MTU Equipment Specialist in AMS1, and copied to 87 PDM Section Chief.

3.4 Dock and sea trials. Under the supervision of the COR, the Contractor shall commission the engine and conduct dock and sea trials utilizing the Diagnostic System (DIASYS) and the original Engine Acceptance Test Record Data to ensure proper operation of the marine propulsion diesel engines in accordance with MTU 8V396 TE.4 Workshop Manual M020046/21E Section 2 & SFLC Std Spec 0000. The contractor shall demonstrate for the CG Inspector or COR that all engine parameters are within the correct range and the engine is operating properly. Submit CFR detailing all sea trial test results.

4. NOTES

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

59301_ESD_0121_FLT

REC_59301_FLT_87’ WPB (ALL) (1017)

WORK ITEM 2: Grey Water Holding Tanks, Clean and Inspect

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to clean and inspect the following tank(s):

table 1 – tanks

1.2 Government-furnished property.

None.

1. REFERENCES

Coast Guard Drawings Coast Guard Drawing 87 WPB 601-001, Rev R, Outboard Profile & General Arrangements Coast Guard Publications Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Other References ASTM International (ASTM) D1330, 2015, Standard Specification for Rubber Sheet Gaskets

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

3.1.3.1 Plug all inlet and outlet piping in the tank(s) to prevent contaminants from entering. Use plugs with an attached lanyard, ring or other system that will ensure plugs are not lost in the pipe openings.

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

· Piping.

· Pump(s).

· Stateroom berthing locker.

· Toilet (to be removed by CG personnel).

· Speed log.

3.2 Plug log. The Contractor must keep a written record of all plugs put in any tank vents. A separate list must be kept for each tank being entered.

3.2.1 Ensure that all plugs are removed from each tank upon completion of work in the tank.

3.2.2 The plug log must be available to the Coast Guard Inspector when the inspector is performing his close-out inspection on each tank.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.3 Operational test, initial. Prior to commencement of work, the Contractor must 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.

3.4 Service disruption. When grey water is disrupted due to Contractor repairs, the Contractor must refer to SFLC Standard Spec 0000 par 3.2.11 to provide required temporary facilities.

3.5 Cleaning. The Contractor must accomplish the following for the tank(s) listed. The Contractor must refer to Coast Guard Drawing 87 WPB 601-001 for guidance.

3.5.1 Content removal. Remove and dispose of all contents, fluids, and/or residues in accordance with all applicable Federal, state, and local regulations

3.5.2 Cleaning requirements. Remove manhole cover(s). Clean all tank structure’s interior surfaces free of all foreign materials, sediment, and sludge. Remove all persistent residues, taking care not to damage the tank coating system. Remove cleaning media and residues continuously from the tank during the washing process. Remove any residual wash media and wipe up residual moisture with clean lint-free cloths. Collect, contain, and dispose of all wash media, residues, and cleaning materials in accordance with all Federal, state, and local regulations. Clean all tank vent lines. Remove and clean the eductors and level switches inside of the tank(s). Reinstall the eductors and level switches upon completion of tank cleaning. Use new gaskets and o-rings to install/reinstall all removed/disturbed components.

3.6 Inspection. The Contractor must visually inspect all interior surfaces, including, but not limited to bulkheads, floor and overhead plating, structural members, manhole cover surfaces, fasteners and gasket seating surfaces. Submit the Tank and Void Inspection Form, and a CFR including the following, as applicable:

· Tank structural condition.

· Inaccessible areas.

· Condition of tank coating, including measurements taken, percentage, location, and type of coating failure (not applicable for stainless steel tanks).

· Tank level indicator (TLI), vacuum and/or float switch condition.

· Suction and discharge piping and vent line condition.

· Fastener material (stainless steel) and condition.

· Zinc anode condition (remaining percentage).

3.7 Control panel assembly. The Contractor must open and vacuum clean the control panel assembly. Inspect the control panel assembly for any indications of overheating or loose wiring or connections. Submit a CFR

3.8 Closing. The Contractor must notify the COR at least 24 hours prior to closing the tank(s). After satisfactory inspection by the Coast Guard Inspector, and completion of all authorized repairs, close the manhole cover(s) with new gasket material conforming to ASTM D1330.

3.8.1 Renew 100% of nylon insert/nylock nuts and washers.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.9 Operational test, post repairs. After completion of work, the Contractor must thoroughly test, in the presence of the Coast Guard Inspector and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

3.9.1 The Contractor must adjust the set point on each of the vacuum pressure switches (as applicable) to the set points noted previously.

3.9.2 The Contractor must verify operation of the low and high level switches/alarms and that the pumps cycle from lead to lag status during operation. Demonstrate proper operation of tank TLIs to prove satisfactory operating condition.

3.9.3 Upon completion of testing and, in the presence of the Coast Guard Inspector, the Contractor must pump tank(s) to the limit of the ship’s installed pumps.

4. NOTES

This section is not applicable to this work item.

59302_ESD_0121_FLT

REC_59301_FLT_87’ WPB (ALL) (1017)

WORK ITEM 3: Sewage Holding Tanks, Clean and Inspect

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to clean and inspect the following tank(s):

table 1 – tanks

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 87 WPB 601-001, Rev R, Outboard Profile & General Arrangements Coast Guard Publications Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Other References ASTM International (ASTM) D1330, 2015, Standard Specification for Rubber Sheet Gaskets

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Not applicable.

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

3.1.3.1 Plug all inlet and outlet piping in the tank(s) to prevent contaminants from entering. Use plugs with an attached lanyard, ring or other system that will ensure plugs are not lost in the pipe openings.

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

· Piping.

· Pump(s).

· Stateroom berthing locker.

· Toilet (to be removed by CG personnel).

· Speed log.

3.2 Plug log. The Contractor must keep a written record of all plugs put in any tank vents. A separate list must be kept for each tank being entered.

3.2.1 Ensure that all plugs are removed from each tank upon completion of work in the tank.

3.2.2 The plug log must be available to the Coast Guard Inspector when the inspector is performing his close-out inspection on each tank.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.4 Operational test - initial. Prior to commencement of work, the Contractor must 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.

3.4 Service disruption. When sewage collection service is disrupted due to contractor repairs, the Contractor must refer to SFLC Standard Spec 0000 par 3.2.11 to provide required temporary facilities.

3.5 Cleaning and inspection requirements. The Contractor must accomplish the following for the tank(s) listed in paragraph 1.1 (Intent), referring to Coast Guard Drawing 87 WPB 601-001 for guidance:

3.5.1 Content removal. Remove and dispose of all contents, fluids, and/or residues in accordance with all applicable Federal, state, and local regulations

3.5.2 Cleaning requirements. Remove manhole cover(s). Clean all tank structure’s interior surfaces free of all foreign materials, sediment, and sludge. Remove all persistent residues, taking care not to damage the tank coating system. Remove cleaning media and residues continuously from the tank during the washing process. Remove any residual wash media and wipe up residual moisture with clean lint-free cloths. Collect, contain, and dispose of all wash media, residues, and cleaning materials in accordance with all Federal, state, and local regulations. Clean all tank vent lines. Remove and clean the eductors and level switches inside of the tank(s). Reinstall the eductors and level switches upon completion of tank cleaning. Use new gaskets and o-rings to install/reinstall all removed/disturbed components.

3.5.3 Inspection. Visually inspect all interior surfaces, including, but not limited to bulkheads, floor and overhead plating, structural members, manhole cover surfaces, fasteners and gasket seating surfaces. Submit a CFR including the following, as applicable:

· Tank structural condition.

· Inaccessible areas.

· Condition of tank coating, including measurements, percentage, location, and type of coating failure (not applicable for stainless steel tanks).

· Tank level indicator (TLI), vacuum and/or float switch condition.

· Suction and discharge piping and vent line condition.

· Fastener material (stainless steel) and condition.

· Zinc anode condition (remaining percentage).

3.5.4 Control panel assembly. Open and vacuum clean the control panel assembly. Inspect the control panel assembly for any indications of overheating or loose wiring or connections. Submit a CFR

3.6 Closing. The Contractor must notify the COR at least 24 hours prior to closing the tank(s). After satisfactory inspection by the Coast Guard Inspector, and completion of all authorized repairs, close the manhole cover(s) with new gasket material conforming to ASTM D1330.

3.6.1 The Contractor must renew 100% of nylon insert/nylock nuts and washers.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.7 Operational test, post repairs. After completion of work, the Contractor must accomplish the following in the presence of the Coast Guard Inspector, and submit a CFR:

3.7.1 Adjust the set point on each of the vacuum pressure switches (as applicable) to the set points noted previously.

3.7.2 Verify operation of the low and high level switches/alarms and that the pumps cycle from lead to lag status during operation. Demonstrate proper operation of tank TLIs to prove satisfactory operating condition.

3.7.3 Upon completion of testing and, in the presence of the Coast Guard Inspector, pump tank(s) to the limit of the ship’s installed pumps.

4. NOTES

This section is not applicable to this…