TGI_3819P31001A05_c0v0_redact.pdf

FOUO

FOUO: Public availability to be determined under 5 USC 552

TASK GROUP INSTRUCTION

AIM REV 20.11.4.0 (OCTOBER 2020)

TGI COMPONENT NAME: TYPE: PHASE: REPEAT: CHANGE:

NO.: SA79243K REPLT EDG#1 AY A 0 0

SHIP/HULL NO.: SHIP/HULL NAME: SYSTEM: PROJ/WO NO: CASREP CAT:

LCC-19 USS BLUE RIDGE 19P

CU PHASE TITLE:

*(RE) F/O-S/A 79243K, REPLACE EDG NO. ONE, ESLP SS/EDG GENSET UPGRADE

PREPARING ACTIVITY:

PREPARED BY: CODE PHONE DATE

KAZUKI ONO 233.1 080-9350-1438 17-FEB-2025

APPROVED BY: CODE PHONE DATE

MASAHIRO HOSONO 233.1 080-9350-1455 17-FEB-2025

CONCURRED BY: CODE PHONE DATE

CONCURRED BY: CODE PHONE DATE

CONCURRED BY: CODE PHONE DATE

CONCURRED BY: CODE PHONE DATE

REASON FOR WORK/NEED FOR CHANGE:

CHANGE INSTRUCTIONS:

SPECIAL REQUIREMENTS:

CLEANLINESS FOR PIPING SYSTEM/EQUIPMENT LEVEL II

WORK CERTIFICATION SIGNATURES

COMPLETION OF WORK REVIEW: BADGE NO.: SHOP/CODE: PHONE: DATE:

ACCEPTANCE OF COMPLETED WORK

PHYSICAL INSPECTION PHYSICAL INSPECTION COMPLETED: BADGE NO.: SHOP/CODE: PHONE: DATE:

REQUIRED:☐YES ☒NO

RECORDS REVIEW: BADGE NO.: SHOP/CODE: PHONE: DATE:

TGI NO.: SA79243K REPLT EDG#1 AY A 0

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SHIP: LCC-19 CHG/VER: 0/0

LIST OF EFFECTIVE PAGES

SHT NO. CHG NO. SHT NO. CHG NO. SHT NO. CHG NO. SHT NO. CHG NO. SHT NO. CHG NO.

1-5 J1-2 M-1

1. SCOPE/PURPOSE

1.1 Title: Emergency Diesel Generator No. One, Extended Service Life Program Ship Service/Emergency Diesel Generator Generator-set Upgrade; replace

1.2 Location of Work:

1.2.1 Emergency Generator Room No. One (7-30-0-E)

1.2.2 SD Storeroom (7-30-1-A)

1.2.3 Storeroom (6-36-3-A)

1.2.4 Crew Living Space (5-30-01-L)

1.2.5 Underwater Hull Weather, Frames between 35 and 40, Starboard (Stbd)

1.2.6 Freeboard Weather, Frames between 35 and 40, Stbd

1.2.7 Dry Dock No. 6

1.3 Identification:

1.3.1 Quantity (One EA), Existing Emergency Diesel Generator Set No. One Engine Mfr: Caterpillar Inc Engine Mfr Id: 3508B Engine Configuration: Vee 8-Cylinder, 4-Stroke Cycle Diesel Generator Spec: 750KW, 450VAC, 60Hz, 3 Phase Remarks: See Item R1 of 2.3 for details

1.3.2 Quantity (One EA), New Emergency Diesel Generator Set No. One Engine Mfr: Caterpillar Inc Engine Mfr Id: 3516E Engine Arrangement Number: 549-7519 Engine Configuration: Vee 16-Cylinder, 4-Stroke Cycle Diesel Generator Spec: 2000KW, 450VAC, 60Hz, 3 Phase Remarks: See Item One of 2.3 for details

1.4 Security Classification: None.

1.5 Initial Condition:

1.5.1 Potential Asbestos Hazard.

1.5.2 Potential Lead Hazard

1.5.3 Dry Dock Work.

1.6 Contractor work start date: 1/12/2026

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SHIP: LCC-19 CHG/VER: 0/0

1.7 Contractor work completion date: 8/5/2027

2. REFERENCES:

REF.

NO.

DOCUMENT

/DRAWING

NUMBER

DOCUMENT/DRAWING TITLE REV CHG

NO.

COPY

REQ’D

(Y/N)

SOURCE

DOC

(Y/N)

PARA SEC PG CHP

1 NSI FY-25 NAVSEA Standard Items - ORG N 2 LI FY-25 Local Standard Items - ORG N

3 DWG 345-

8574539 SCD-9243.00K Genset Upgrade Equipment Arrangement EDG Rm 1 & Emer Switchgear Rm

B Y AL

L

4 DWG 113-

8578023

SS/EDG Genset Upgrade Foundation Instl & Prefab Emergency Diesel Generator Rm 1

B Y AL

L

5 DWG 649-

DIMENSIONS - INSTALLATION

FOR LCC-19 PROGRAM

06 Y AL

L

6 PDD 300-

ELM-250197

ALIGNMENT PROCEDURE OF

DIESEL ENGINE & GEN SET

CPLG FOR UPGRADED EDG &

SSDG

- Y AL

L

7 PDD 300-

ELM-250198

FLUSING PROCEDURE OF

DIESEL ENGINE FOR UPGRADED

EDG & SSDG

- Y AL

L

3. APPENDICES:

3.1. Appendix “J” TGI Job Summary Information Sheet

3.2. Appendix "M" TGI Material List

3.3. Appendix “D” Deficiency Form

4. GENERAL REQUIREMENTS:

4.1 Not Applicable.

5. PROCEDURE:

5.1 Remove the equipment listed in 1.3.1 in accordance with 2.3.

5.1.1 Disassemble the equipment listed in 1.3.1 for unshipping.

5.2 Install the equipment listed in 1.3.2 in accordance with 2.3 and 2.4.

5.2.1 Disassemble and assemble the equipment for shipping in accordance with the procedure provided by OEM (CAT Hawthorne), using 2.5 for guidance.

5.2.1.1 Install each blanking plate onto the diesel engine until installation.

5.2.2 Measure and record the crankshaft deflection of the diesel engine in accordance with Notes 2 and 4-1 through 4-4 of 2.6.

(V) “CRANKSHAFT DEFLECTION” (First Measurement, Notes 4-1 of 2.6)

(V) “CRANKSHAFT DEFLECTION” (Second Measurement, Notes 4-2 of 2.6)

(V) “CRANKSHAFT DEFLECTION” (Third Measurement, Notes 4-3 of 2.6)

(V)(G) “CRANKSHAFT DEFLECTION” (Fourth Measurement, Notes 4-4 of 2.6)

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SHIP: LCC-19 CHG/VER: 0/0

5.2.3 Measure and record the crankshaft thrust clearance of the diesel engine in accordance with Notes 3 and 4-1 through 4-4 of 2.6.

(V) “THRUST CLEARANCE” (First Measurement, Notes 4-1 of 2.6)

(V) “THRUST CLEARANCE” (Second Measurement, Notes 4-2 of 2.6)

(V) “THRUST CLEARANCE” (Third Measurement, Notes 4-3 of 2.6)

(V)(G) “THRUST CLEARANCE” (Fourth Measurement, Notes 4-4 of 2.6)

5.2.4 Measure and record the coupling alignment of the equipment in accordance with Notes 6 and 7-1 of 2.6.

(V) “COUPLING ALIGNMENT” (First Measurement, Notes 7-1 of 2.6)

5.2.5 Accomplish the coupling alignment of the equipment in accordance with Notes 6, 7-2 and 7-3 of 2.6.

(V) “COUPLING ALIGNMENT” (Second Measurement, Notes 7-2 of 2.6)

(V) “COUPLING ALIGNMENT” (Third Measurement, Notes 7-3 of 2.6)

5.2.6 Measure and record the coupling alignment of the equipment in accordance with Notes 6 and 7-4 of 2.6.

(V)(G) “COUPLING ALIGNMENT” (Final Measurement, Notes 7-4 of 2.6)

5.2.7 Accomplish the requirements of 009-92 of 2.1 for equipment.

5.2.8 Measure and record the flywheel runout of the diesel engine in accordance with Notes 8 of 2.6.

(V)(G) “FLYWHEEL RUNOUT”

5.2.9 Drill and ream each generator support foot and foundation in accordance with Notes 5 of 2.6. Fit and install each new dowel.

5.3 Accomplish the requirements of 009-09 of 2.1 for the diesel engine of the equipment listed in 1.3.2.

5.4 Accomplish the lube oil flushing for the diesel engine of the equipment listed in 1.3.2 in accordance with 2.7.

(I)(G) “EXTERNAL FLUSHING”

(I)(G) “FINAL FLUSHING”

5.5 Accomplish the requirements of 009-32 of Ref. No. One for each new and disturbed surface.

5.6 Notes:

5.6.1 Planner: Code 233 K. Ono, 080-9350-1438

Planner: Code 232 T. Nonaka, 243-4507 Planner: Code 231B, A. Suzuki, 243-0968 Planner: Code 231B, M. Haga, 243-2513

5.6.2 OEM (CAT Hawthorne) will provide the procedure to uncouple the gensets and remove them from the skid and to facilitate rigging onboard the ship. The blanking plate and lifting beams will be packaged with the gensets from the OEM. NSWCPD will have a contract with the OEM in place for support in bringing the gensets onboard and coupling the diesel and generator together and will assist in bringing the gensets onboard the ship.

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SHIP: LCC-19 CHG/VER: 0/0

5.6.3 Preservation work for new and disturbed exterior surfaces of underwater hull and freeboard will be covered by

ICN 3819P11001 (KTR TGI).

5.6.4 Periodic Maintenance Requirements (PMR) and Naval Surface Warfare Center Philadelphia Division (NSWCPD) will provide one person on-site to resolve any technical issues that may arise.

5.6.5 PMR Technical Representative:

Point of Contact: Mr. Edward (Bud) Twigg, 243-4242 Email Address: edward.twigg.ctr@srf.navy.mil

5.6.6 NSWCPD On Site Installation Coordinator (OSIC):

Point of Contact: Mr. Brian Lopez, 445-238-7002 Email Address: brian.o.lopez.civ@us.navy.mil

5.6.7 Work Integration Manager (WIM): Code 333 T. Yaginuma, 080-5419-0598

5.6.8 JCN EE01-L106 is related to this TGI.

5.7 Government Furnished Material (GFM):

5.7.1 All GFM listed in each S/A drawing will be provided as kitted material.

5.7.2 SRF-JRMC will provide GFM listed in Appendix “M”.

5.8 SRF-JRMC will provide the following service work: (TGI No. 3819P31001S02)

5.8.1 [C740] Crane and crane rigging service.

5.8.2 [X99E] Utility service, electrical.

5.8.3 [X99M] Utility service, including low pressure air supply, water supply, and steam supply.

5.8.4 [C106.1] Safety inspection for SRF-JRMC employees.

5.8.5 [C106.2] Gas free inspection for SRF-JRMC employees.

5.8.6 [C133] QA inspection for (G) symbol(s).

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J-1

SHIP: LCC-19 CHG/VER: 0/0

APPENDIX "J"

TGI JOB SUMMARY INFORMATION SHEET

SYSTEM: PLANT NO.: COMPONENT NAME: TYPE: PHASE: REPEAT: CU PH

VERSION:

CASREP

CAT:

SA79243K REPLT EDG#1 AY A 0 0

CU PHASE TITLE:

*(RE) F/O-S/A 79243K, REPLACE EDG NO. ONE, ESLP SS/EDG GENSET UPGRADE

PRIMARY COMPONENT:

COMPONENT UNIT LIST (FOR ASSEMBLIES):

#1 EDG GE #1 EDG ENGINE EN

ATTACHMENT LIST:

ZONE MANAGER: ZONE: COMPARTMENT: LEVEL: FRAME: SIDE:

YAGINUMA ,TAKEHIDE

JO: KO: TOTAL MAN HRS: PLANNING ACCEPTANCE:

3819P31001 A05

TOTAL MAT’L COST TOTAL DURATION:

CU PHASE DESCRIPTION:

The purpose of this TGI is to replace emergency diesel generator no. one, extended service life program ship service/emergency diesel generator genset upgrade.

Location of Work:

Emergency Generator Room No. One (7-30-0-E) SD Storeroom (7-30-1-A) Storeroom (6-36-3-A) Crew Living Space (5-30-01-L) Underwater Hull Weather, Frames between 35 and 40, Starboard Freeboard Weather, Frames between 35 and 40, Stbd Dry Dock No. 6

TASK NAME

SHOP TSD/WC TS CREW# MHRS

HIGH RAD

HOURS

RC

GRID#

5.1 ELEC , SFTR , WELD , QA , RGRS , CARP , INSL ,

SMTL , PNTR , OMCH .

22 KE PC

5.2 ELEC , SFTR , WELD , RGRS , CARP , INSL , SMTL ,

PNTR , OMCH .

22 KE PC

5.3 QA . 22 KE PC

5.4 OMCH , PFTR , RGRS , LBR , QA . 22 KE PC

5.5 PNTR , QA . 22 KE PC

Electrical Work CFM: for banding material, fasteners, insulation tape, plastic bags, rope, and other consumable.

22 MQ CS

Machinery Work CFM: or marine chemist cost, dowel pin, gasket, muslin bag, lubricating oil, filter element, hose, and MISC such as rags, sandpapers, plastic bag/sheet, cleaner, lubricant, and etc.

22 MQ CS

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J-2

SHIP: LCC-19 CHG/VER: 0/0

TASK NAME

SHOP TSD/WC TS CREW# MHRS

HIGH RAD

HOURS

RC

GRID#

Rigging Work CFM: for staging for unshipping/shipping, fastener, transportation cost, mobile crane cost, forklift cost, material of temporary padeye, MT inspection cost, fire watch cost, gas, electrode, lead sampling/analysis cost, ---continue to below---

22 MQ CS

---continued from above---asbestos sampling/analysis cost, adhesive, anchor pin, tyvex suit, masking tape, plastic bag, all paints, thinner deck covering material, and MISC such as covering material and other consumable.

22 MQ CS

Process Funding Document. 10 CT OM

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M-1

SHIP: LCC-19 CHG/VER: 0/0

APPENDIX “M”

TGI MATERIAL LIST

SYSTEM: PLANT NO.: COMPONENT NAME: TYPE: PHASE: REPEAT: CU PH

VERSION:

CASREP

CAT:

SA79243K REPLT EDG#1 AY A 0 0

CU PHASE TITLE:

*(RE) F/O-S/A 79243K, REPLACE EDG NO. ONE, ESLP SS/EDG GENSET UPGRADE

MATERIAL REFERENCES

REF

NO.

DOCUMENT/DRAWING

NUMBER

DOCUMENT/DRAWING TITLE REV

JOB ORDER: KEY OP:

3819P31001 A05

MATERIAL LIST

ITEM

NO.

PC

NO.

REF

NO.

M

C DESCRIPTION

STOCK

NUMBER

GENERIC

MATL

TYPE LVL QA

HAZ

MAT

DOC

NO.

QTY

REQD/

UNIT

QTY

USED/

UNIT

101 M INSULATI, MATERIAL ORDER

FOR KTR

ORIG: C231B M.HAGA 243-2513

9Q 5640 008096312 NA 4 N 20/EA

102 M TAPE,TEX, MATERIAL ORDER

FOR KTR

ORIG: C231B M.HAGA 243-2513

9B 8315 002671632 NA 4 N 2/RO

103 M TAPE,TEX, MATERIAL ORDER

FOR KTR

ORIG: C231B M.HAGA 243-2513

9B 8315 002671633 NA 4 N 2/RO

104 M ADHESIVE, MATERIAL ORDER

FOR KTR

ORIG: C231B M.HAGA 243-2513

9B 8040 002738708 NA 4 Y 2/GL

105 M CAP,SNAP, MATERIAL ORDER

FOR KTR

ORIG: C231B M.HAGA 243-2513

9B 5325 007377648 NA 4 N

200/EA

NOTES:

FOUO: Public availability to be determined under 5 USC 552 SHEET_____OF_____

☐ NUCLEAR APPENDIX "D"

DEFICIENCY FORM

☐ NON-NUCLEAR

1. SHIP/HULL NO.: 2a. DL or DR No.

(Circle One)

2b. REVISION: 3a. COMPONENT NAME: 3b. TYPE: 3c. PHASE: 3d. REPEAT:

LCC-19 SA79243K REPLT EDG#1 AY A 0

4a. ICN: 4b. KEY OP: 5. LOC SPACE/LVL: FRAME: P/S/C: 6. CAUSED BY:

3819P31001 A05

7. DESCRIPTION:

8. ORIGINATOR: NAME: BADGE: SHOP/CODE: DATE: PHONE NO.:

9. CORRECTIVE ACTION:

10. EVALUATOR: NAME: BADGE: SHOP/CODE: DATE: PHONE NO.:

FOR NON-NUCLEAR USE ONLY

11. RFD/RFW REQ’D ☐ LAR REQ'D ☐

ILS MOD REQ’D ☐

SRD/PLAN REV REQ'D ☐

DWG NO.: _____________________ S/A NO.: ___________________

12. ISOLATION SIGN: BADGE: SHOP/CODE: DATE: PHONE NO.:

SATISFACTORY:

13. SUBSAFE OQE RECORD? SIGN: BADGE: SHOP/CODE: DATE: PHONE NO.

YES ☐ NO ☐

14. CORRECTIVE ACTION SIGN: BADGE: SHOP/CODE: DATE: PHONE NO.

COMPLETE:

15. INSPECTION REQ’D? INSPECTION COMPLETE/SIGN: BADGE: SHOP/CODE: DATE: PHONE NO.

_________:YES ☐ NO ☐

16. RECORDS REVIEW SIGN: BADGE: SHOP/CODE: DATE: PHONE NO.

COMPLETE (DR ONLY)

DL’s ISSUED

(DR ONLY)

FOUO: Public availability to be determined under 5 USC 552 SHEET_____OF_____

☐ NUCLEAR Deficiency Form Continuation Sheet ☐ NON-NUCLEAR

1. SHIP/HULL NO.: 2a. DL or DR No.

(Circle One) 2b. REVISION: 3a. COMPONENT NAME: 3b. TYPE: 3c. PHASE: 3d. REPEAT:

LCC-19 SA79243K REPLT EDG#1 AY A 0