USCGC SEA DOG (WPB-87378) W5 /DOCKSIDE REPAIRS

USCGC SEA DOG (WPB 87373) SPECIFICATION FOR DOCKSIDE REPAIRS FY2016 Developed By: Steven C Vanhevelingen (Rev-0, 12 Feb 2016) 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 1 WORK ITEM 1: Port Main Diesel Engine Assembly, Perform W-5 Maintenance and Update Control System Configuration 14 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. 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 87 WPB 182-001, Rev B, Main Engine & Generator Foundations Coast Guard Drawing 87 WPB 243-001, Rev M, Propulsion Shaft 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 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 Bollinger Shipyard, USCG CPB Project MTU-FA 771903, 07 Feb 2000, Engine/Gearbox Plant Alignment Instructions 8V396 TE94/Flange Mounted BW 255 Installation of MTU Electronic Systems E 530 606/06E 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. WORK ITEM MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST ($/UNIT) 1 Y Cylinder Head 2815-12-345-1076 8 $5000 1 Y "A" Bank Turbocharger 2950-12-347-2009 1 $11500 1 Y "B" Bank Turbocharger 2950-12-347-2010 1 $12,000 1 Y Sea Water Pump 2930-12-344-4810 1 $9800 1 Y Jacket Water Pump 2930-12-344-4606 1 $6500 1 Y Starter 2920-12-156-2556 1 $3000 1 Y **Charge Air Cooler 2930-12-344-4608 1 $20,000 1 Y **Injector with retainer 2910-12-341-9988 8 $700 1 N **Cylinder Liner 2815-12-361-3855 8 $800 1 N **Piston 2815-12-362-8999 8 $3600 1 N/A Engine Acceptance Test Record N/A 1/MDE N/A 2 Y *Alignment kit N/A 1 ea. $5000.00 *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)): Work Item Title This section is not applicable to this package. PRINCIPAL CHARACTERISTICS 87' WPB PHYSICAL Length overall 87' Length between perpendiculars 81' 7" Depth 10' 11" Maximum beam 19.4' Draft, mean to design waterline 5' 9" Height of highest projection 50.2' Full load displacement 93.5 long tons Minimum operating displacement 83.9 long tons Displacement, light ship 77.9 long tons Framing Longitudinal Bulkheads Four watertight bulkheads located below the Main Deck Anchor 40 lb Fortress with 480 ft. 3 strand 5/8" dia. Line stayset HULL Hull/main weatherdeck material ABS Grade AH 36 Superstructure 5086 Aluminum MACHINERY Main propulsion Two MTU 8V396TE94, sequential turbo-charged diesels Reduction gears Two ZF Type BW 255 Propulsion shaft Two AQUAMET 22, 101.6mm Shaft diameter 4" Shaft seal Two John Crane mechanical seals Shaft bearing, intermediate Thordon Elastomeric Bearing Shaft bearing, aft Thordon Elastomeric Bearing Number of propellers 2 Number of blades 5 Diameter of propeller 1040mm Pitch 1230 mm fixed Shaft RPM 828 Rudders Two 316L Stainless Steel Ship's service generators Two Man Model D08241F01 diesel with Stanford 60KW Generator TANK CAPACITIES 3-9-1-f (fuel oil) 1402 gal 3-9-2-f (fuel oil) 1402 gal 3-12-2-f (waste oil) 86 gal 3-12-1-f (oily water) 86 gal 3-7-0-q (sewage collection) 352 gal 3-7-1-q (grey water) 52 gal 3-12-1-w (fresh water) 200 gal 3-12-2-w (fresh water) 200 gal 00000_0315_FLT REC_00000_FLT_ Commercial Project @ CG Facility (1212) General Requirements 1. SCOPE 1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed by commercial contractors at a Coast Guard facility for Coast Guard vessels. 1.2 Term interchangeability. The terms 'Contractor', 'CG Yard', 'NAVSTA EVERETT', 'shipyard', 'Base', and 'Coast Guard Industrial' are used interchangeably in this specification. Where the primary service provider is Coast Guard personnel, references to contractor and other noted descriptors within this specification or within drawings, publications, SFLC Standard Specifications or other commercial and military references are deemed the same as prime service provider. 2. REFERENCES COAST GUARD DRAWINGS None COAST GUARD PUBLICATIONS Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures OTHER REFERENCES None 3. REQUIREMENTS 3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability. NOTE The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract. 3.2 Contractor-provided fire watch personnel. The Contractor shall provide fire watch personnel and equipment. 3.2 Fire watch requirements. The Contractor shall refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task: - Provide portable fire extinguishers for Coast Guard fire watch personnel. Coast Guard fire watch is in lieu of contractor personnel during the hours of 0800-1600, Monday through Friday, and limited to two Coast Guard fire watch personnel. - Provide fire watch personnel and fire extinguishers for the duration of the availability period, during and beyond noted Coast Guard fire watch support. 3.3 Preservation requirements. The Contractor shall accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310. 3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec 6310, Appendix C (Authorized Coatings for Use on Cutters and Boats). 3.3.2 Coating colors and system color schemes. Ensure that all colors and color coat/paint schemes are in accordance with COMDTINST M10360.3, Chapter 6 (Cutter and Boat Colors Exterior and Interior). NOTE Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes (provided in Chapter 6 of COMDTINST M10360.3) are strictly prohibited. 3.4 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740. 3.5 Environmental protection requirements. The Contractor shall adhere to the following environmental protection requirements in accordance with the SFLC Stand Spec 0000: 3.5.1 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, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The Contractor shall submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications shall be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint. 3.5.4 Environmental manager. The Contractor shall appoint in writing an Environmental Manager for the project, and shall be responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager shall ensure compliance with Hazardous Waste Program requirements, including hazardous waste handling, storage, manifesting, and disposal; implement the Contractors' Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to adequately accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas; ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the Environmental Records binder and required documentation, including environmental permits compliance and close-out. 3.5.5 HW disposal. Contractor shall comply with SFLC Std Spec 0000 Appendix B, Requirements For Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays). 3.5.6 Additional Requirements. The Contractor shall be aware of the following: 3.5.6.1 No Contractor or Subcontractor shall have the authority to sign a Hazardous Waste Manifest using the Coast Guard facility's EPA Generator ID Number or remove contract generated hazardous waste from the Coast Guard facility without COR or KO-approval. 3.5.6.2 Local environmental regulations at the Government facilities may be more stringent. As with all environmental regulations, the Contractor shall prepare for and comply with local and state regulations. 3.5.6.3 Coast Guard facilities do not maintain Facilities Response Plans (FRPs) per 33 CFR 154. Contractor shall furnish the FRP when required for over-the-water liquids transfers to and from vessels, and is required for oil/fuel transfers to/from vessels for 250 barrels (10,500 gallons) or more. 3.6 Local Policy. None. 3.7 SFLC standard specification approved changes. The Contractor shall be aware that the following are approved changes to published SFLC 2014 Edition Standard Specifications and supersede published content: - None. 4. NOTES 4.1 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 6310 to be completed and submitted during preservation of "critical-coated surfaces", are provided at the end of this document. QA-1 - QUALITY ASSURANCE INSPECTION FORM (PRESERVATION CHECKLIST) Vessel Name Hull # Work Item # Work Item Title Location of Work (incl. frame #'s) Area (sqft) CHECKPOINT 1 - COATING SYSTEM COMPLIANCE Ensure all coatings are in compliance with SFLC Std Spec 6310, Appendix C. CHECKPOINT 2 - PAINT STORAGE Ensure all coatings are kept at a temperature of 65 to 85'F at all times, unless otherwise specified by the coating mfgr. CHECKPOINT 3 - AMBIENT CONDITIONS Ensure surface and surrounding temperatures are each between 50 and 90'F for water-containing coatings, and 35 and 95'F for other coatings, unless otherwise specified by the coating manufacturer(s). Ensure maximum relative humidity (RH) is as follows, from surface preparations through final curing of topcoat: 50% for tanks, voids, and vent plenum; and 85% for all other areas, unless otherwise specified by manufacturer(s). Ensure surface temperature is at least 5'F above the dew point, unless otherwise specified by the coating mfgr. CHECKPOINT 4 - PRE-SURFACE PREPARATION Remove surface contaminants (soluble salts, loose rust, mud, and marine growth) with low pressure fresh water wash down (maximum 5,000 psi). If oil and grease are present, perform solvent cleaning, as per SSPC SP-1. Verify equipment setup, blast media, and surface preparation methods match designated test coupon. CHECKPOINT 5 - SURFACE PREPARATION Verify environmental conditions (see CHECKPOINT 3). Ensure cleanliness of prepared surface is as per specification (i.e.: SSPC SP-11, SP-10, SP WJ-2...). Verify surface anchor profile using ASTM D4417-Methods B or C against SFLC Std Spec 6310. Conduct profile readings at a minimum of 5 locations for the first 1000-sqft area, and 2 locations for each succeeding 1000-sqft area. Measure soluble salt conductivity in accordance with SSPC-Guide 15. Conduct 5 measurements per each 1000-sqft area (max. threshold: 70 microsiemens/cm for non-submerged surfaces, 30 microsiemens/cm for submerged surfaces). CHECKPOINT 6 - PRIMER COAT APPLICATION Verify environmental conditions (see CHECKPOINT 3). Verify proper mixing and stand-in (induction) times. Ensure no paint is applied when the temperature is expected to drop to freezing before the paint has dried. Ensure surfaces are completely dry, unless otherwise allowed by the coating manufacturer(s). Verify wet film thickness (WFT) at random, to prevent under or over application. Verify final DFT. Brush out all runs, sags, drips, and puddles. Perform visual inspection for holidays and other defects. CHECKPOINT 7 - STRIPE COAT APPLICATION Verify environmental conditions (see CHECKPOINT 3). Ensure overcoating window is as per manufacturer's instructions. After primer coat (mist coat after inorganic zinc), brush-apply un-thinned coat of same primer paint over edges, weld seams, cut-outs, and areas of complex geometries @ 3-4 mils wet film thickness (WFT). CHECKPOINT 8 - TOP COAT APPLICATION Verify environmental conditions (see CHECKPOINT 3). Ensure overcoating window is as per manufacturer's instructions. Verify proper mixing and stand-in (induction) times, as applicable. Verify wet film thickness at random, to prevent under or over application. Brush out all runs, sags, drips, and puddles. CHECKPOINT 9 - FINAL INSPECTION Verify final system dry film thickness. Conduct 5 sets of 3 readings for each of the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area. Ensure that system cure is in accordance with manufacturer's recommendation for intended service. Ensure potable water tank exhaust ventilation is maintained continuously from and during coating application through final system cure, to exhaust all solvent to the atmosphere and to prevent solvent entrapment. For immersion coatings (including tank U/W body), record date and time of the following events: Final coat application: _____/_____; Return to service or removal from environment controls: _____/_____ CHECKPOINT 10 - RECORD KEEPING Complete, sign, and submit all provided QA Inspection Forms. Name of QP-1/NACE Inspector Signature Cert. # Date / Time QA-2 - QUALITY ASSURANCE INSPECTION FORM (ENVIRONMENTAL READINGS) Vessel Name Hull # Work Item # Work Item Title 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 ?T | DP - Surface | Name of QP-1/NACE Inspector Signature Cert. # Date / Time QA-3a - QUALITY ASSURANCE INSPECTION FORM (SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-C) Vessel Name Hull # Work Item # Work Item Title 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: ______________ Name of QP-1/NACE Inspector Signature Cert. # Date / Time QA-3b - QUALITY ASSURANCE INSPECTION FORM (SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-B) Vessel Name Hull # Work Item # Work Item Title Location of Work (incl. frame #'s) 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: _________________________________ 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 Name of QP-1/NACE Inspector Signature Cert. # Date / Time QA-4 - QUALITY ASSURANCE INSPECTION FORM (SURFACE SOLUBLE SALT CONDUCTIVITY LOG) Vessel Name Hull # Work Item # Work Item Title Location of Work (incl. frame #'s) Area (sqft) SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15 DATE TEST LOCATIONS CONDUCTIVITY (microsiemens/cm) Name of QP-1/NACE Inspector Signature Cert. # Date / Time QA-5 - QUALITY ASSURANCE DATA FORM (COATING THICKNESS) (Use one sheet for each sequence) Vessel Name Hull # Work Item # Work Item Title 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 2 3 Before Adjustments After Adjustments Avg. Location (Frame Reference): ___________________ SPOT 1 2 3 4 5 Overall Avg. DFT ADJUSTMENTS 1 Avg. BMR Deviation 2 3 Before Adjustments After Adjustments Avg. Location (Frame Reference): ___________________ SPOT 1 2 3 4 5 Overall Avg. DFT ADJUSTMENTS 1 Avg. BMR Deviation 2 3 Before Adjustments After Adjustments Avg. Application Method (Airless, Conventional Spray, Rolled) Average DFT Name of QP-1/NACE Inspector Signature Cert. # Date / Time 23001_MWS_1115_87WPB WORK ITEM 1: Port Main Diesel Engine Assembly, 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 port main diesel engine (MDE) and to update the control system configuration. 1.2 Government-furnished property. MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST ($/UNIT) Y Cylinder Head 2815-12-345-1076 8 5000.00 Y "A" Bank Turbocharger 2950-12-347-2009 1 11,500.00 Y "B" Bank Turbocharger 2950-12-347-2010 1 12,000.00 Y Sea Water Pump 2930-12-344-4810 1 9800.0 Y Jacket Water Pump 2930-12-344-4606 1 6500.00 Y Starter 2920-12-156-2556 1 3000.00 Y **Charge Air Cooler 2930-12-354-2436 Tbd 24,985.26 Y **Injector with retainer 2910-12-341-9988 Tbd 700.00 N **Cylinder Liner 2815-12-361-3855 Tbd 800.00 N **Piston 2815-12-362-8999 Tbd 3752.16 N/A Engine Acceptance Test Record N/A 1/MDE N/A **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), 2014, 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, dtd 18 July 94, Inspection System 3. REQUIREMENTS 3.1 General. 3.1.1 CIR. None. 3.1.2 Tech Rep. The Contractor shall, for disassembly and repair work, provide an on-site technical representative certified by MTU to the 396 CM2 level and have a minimum of five years experience working on MTU marine propulsion engines over the last ten years. The technical representative shall advise on the latest manufacturer's information, dimensions, and clearances associated with the system, conduct proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, and reassembly of the marine propulsion diesel engine. 3.1.2.1 For dock and sea trials, provide an on-site qualified technical representative certified by MTU to the ECS-UNI 396 CE3 Level. 3.1.2.2 Provide & legally possess a certified, current, and authorized USB style, 1B MTU Service Dongle, and version 2.60 SP1 or newer of DIASYS installed on a suitable laptop computer. 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 - 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 shall 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 IAW M020046/21E Section 2.1 This check shall require the cutter to get underway in order to...