Joint Fleet Maintenance Manual

1

CINCLANTFLT/CINCPACFLT 4790.3

CHANGE 5

2

JFMM Volume IIJFMM Volume II

3

CNO Availabilities

Removed ISIC Sampling Audit of Industrial Activity SUBSAFE Work.

• Removed from Section 3.6.8.3.b.(5) for CNO Avails < 6 months

• Removed from Section 3.6.8.3.5 for CNO Avails > 6 months

Audits deleted from Volume V in Change 4. This is to correct oversight in not removing the auditing from this chapter.

Volume II, Section 3.6.8.3.b.(5) & 3.6.8.3.5

4

CNO Availabilities

Significant Changes to the Appendices:

• Messages Regrouped for easier use• Appendices A through P are general availability information

such as sea trial procedures, etc.

• Appendices AA through AC are for Surface Ship Availabilities

• Appendices BA through BL are for Submarine CNO Availabilities < 6 months in duration

• Appendices CA through CO are for Submarine CNO Availabilities > 6 months in duration.

Volume II, Chapter 3 Appendices

5

CNO Availabilities

Significant Changes to the Appendices:

• Messages have been placed into the order of use

• Messages modified to meet SUBSAFE Requirements Manual specifications

• Removed Shipyard and NAVSEA messages from the appendices. (Message formats already exist in the SUBSAFE Requirements Manual)

• Minor Editorial Changes to Minimum Sea Trials Requirements for CNO Availabilities

Volume II, Chapter 3 Appendices

6

JFMM Volume IVJFMM Volume IV

7

Diesel Engines

Clarified CASREP Reporting of Diesel Engine Deficiencies

• CASREPs are in addition to, and do not replace the reporting requirements of other documents (e.g., Naval Reactors Technical Bulletins, Operational Orders, Mishap Reports, etc).

• The significance of a submarine’s emergency and backup power supplies cannot be overstated. CASREP requirements of Out of Commission power generating or storage equipment require additional clarification.

• SSBN Class Submarine Emergency Diesel Generators. Report emergency diesel generator casualties by message as allowed by operational constraints.Volume IV, Part I, Section 7.4

8

Metrology And Calibration Program

• Combined the LANT and PAC TYCOM separate test equipment readiness programs into one process entitled Consolidated Test Equipment Readiness Program (CTERP)

• Changed process for increasing or decreasing the allowance changes for the Ship’s Portable Electronic Test Equipment Requirements List (SPETERL)

• Added exceptions to the generic frequency for calibration of dishwasher thermometers, magazine sprinkling gages and magazine bimetallic thermometers.

Volume IV, Part I, Section 12.6.1, 12.6.5 & 12.7.4

9

Miniature/Microminature

Electronics Repair ProgramUpdates Supply Support for Miniature/Microminature

Repairs

• Piece parts required for 2M repairs have been formalized into Allowance Parts Lists (APL) for each ship class having 2M/MTR repair capability.

• 2M/MTR piece part APLs are divided into two distinct groups, Baseline and Augmented APLs:

• Organizational-Level Baseline APL’s ensures that 100% of the listed 2M piece parts are stocked on board regardless of stocks presently on hand and/or past usage.

• Augmented APL’s ensures that sufficient piece parts are authorized to support increases in I- and O- Level2M/MTR repairs

Volume IV, Part I, Section 11.5.5

10

System Test Check Lists

• Appendix B: Non-Nuclear Test Rig Determination and Inspection C/L

• Clarified use of gage ranges for testing pressures < 30#.

• Revised referenced table to the correct NSTM Chapter 504 table

• Appendix C: Nuclear/Non-Nuclear Pre-Test Inspection C/L

• Revised the checklist to delete danger or caution tagging jumpers/gagging devices/blanks

• Appendix D: Nuclear/Non-Nuclear Performance Of Test C/L

• Specified increments for performing preliminary leak checks

Volume IV, Part I, Section 20, Appendix B, C, & D

11

Space, Tank, & Void Closeouts

Provides guidance on handling painting inspections of non-steel damping and acoustic restraining covers

• Painting not required

• Paint inspection to ensure paint does not bridge gap between the rubber and restraining cover over more than 75% of an area

Volume IV, Part I, Section 21.5.3

12

Work Authorization and Control

Changes to WAF instructions:

• Recognizes contractor personnel are not knowledgeable of ship systems to properly sign the WAF. Provides explanation of what contractor signatures on the WAF mean.

• Allows voltage checks prior to signing the WAF as authorized by the Commanding Officer

• Specifies that the original WAF does not have to be in the Work Authorization Log throughout the course of the work

• Specifies cases when outside activities desire to perform work within boundaries of the S/Y, the S/Y may allow work to added to an existing WAF vice a new WAF when the shipyard is acting as a Repair Activity Representative.

Volume IV, Part I, Section 21.5.4.e, 21.4.2.e & 21.4.3.m

13

Weight Handling Equipment

Volume IV, Part I, Section 30.3

Clarified that shore based weight handling equipment that has been certified to NAV P-307 requirements can be used for lifts shipboard when the ship is pierside with the exception of radiological and ordinance lifts.

• This change will reduce costs by providing clear guidance that shore based facilities do not have to have two sets of weight handling gear for shore lifts and then lifting shipboard.

• Shore based WHE rigging hardware are not subjected to the same or probable stresses as imposed at sea operations.

14

Submarine Salvage Inspection

Volume IV, Part III, Chapter 3, Appendix A

Recognized A & I’s have changed rescue/salvage equipment

• Upon completion of A & I 3124, the shackle is powder coated white - Ships that do not have the A & I will still be plastisol coated

• Checklists revised to recognize desalinators and Submarine Escape Immersion Equipment added by A & I’s.

Salvage air valve testing can now be completed up to one year prior to start of availability

• Present rules did not address how soon before an availability this testing could be completed and still count – this change allows greater flexibility - testing can be a part of the pre-overhaul test program which can be used for better planning

15

Periodic Maintenance Requirement Program

Volume IV, Part III, Section 7.6 & 7.8.3

Updated the method for the the tracking of PMR items assigned to the Shipyard during a CNO Availability by the ISIC

• Modified to meet the COMSUBPAC QAO memo 01-1. Ensures that the ISIC verifies the PMR was properly assigned and then proper notification from the Shipyard that the PMR was completed

Recognized the method being used by NAVIMFAC PACNORWEST in tracking and scheduling PMR requirements

• Recognizes NAVIMFAC PACNORWEST uses the LDS system

16

Electrolytic Oxygen Generator

Requirements

Volume IV, Part III, Section 13.3.1

Clearly indicates that workers performing maintenance on the EOG must also be graduates of the oxygen clean worker school

• A loss of cleanliness on an EOG would be extremely hard to recover. Current wording does not clearly address maintenance on sections of the EOG require MIL-STD-1330D controls

17

Unrestricted Operations

Volume IV, Part III, Section 8.2.4, 8.2.6.c, & 8.2.6.e

Authorized the use of the ship’s coolant discharge log for determining pierside and drydock time for URO extensions

• Previously only the ship’s deck log or engineering log could be used. The coolant discharge log is an official log and is an easier log to track pierside days.

Updated the method for the the tracking of URO items assigned to the Shipyard during a CNO Availability by the ISIC

• Modified to meet the COMSUBPAC QAO memo 01-1. Ensures that the ISIC verifies the URO was properly assigned and then proper notification from the Shipyard that the URO was completed

18

Unrestricted Operations (Also Volume V, Chapter 9: Audits,

Surveillance, Evaluations and Assessments)

Volume V, Part 1, Section 9.3.4.c

Revised the ISIC auditing Process for URO’s during all CNO availabilities (Less than six months and greater than six months)

• ISIC will audit all URO items assigned to Forces Afloat (S/F, FMA)

• ISIC will verify that all URO items that will come due within six months of availability completion are scheduled for accomplishment

• Clarifies that the ISIC is not responsible for auditing URO items that have been assigned to the Depot Activity

19

JFMM Volume VJFMM Volume V

20

Annual Self Evaluation

Volume V, Part I, Section 1.3.1

Re-added the requirement for Type Commanders to perform an annual self evaluation.

• Evaluation submitted to Fleet QAO and NAVSEA 92Q (submarines only)

• Evaluation to include SUBSAFE and DSS programs

• Requirement inadvertently dropped in JFMM during Change 3

21

Delegation of ISIC Responsibilities

Volume V, Part I, Section 1.4

ISIC functions that are delegated outside the squadron must be formally transferred with a Memorandum of Agreement

• Recognizes that ISIC functions are not wholly contained in squadrons in some geographical areas such as Pearl Harbor that use a Naval Submarine Support Command

• Provides accountability - formal transfer via MOA’s ensures that each organizations understands their responsibilities and accepts these duties

22

Training of Ship’s Force

QA Officers


Added additional ISIC function to conduct an oral interview with relieving Ship’s Force QAO’s

• Recognizes that S/F QAO do not have sufficient QA training and this will help to ensure a minimum basis of knowledge. It will result in less problems for the ISIC in the long run.

• Topics to be included in the interview include:

• URO Program Management including schedules

• DFS Program Management

• QA Training and Qualifications

• QA Surveillance and Assessment Program

• CWP opening and closing procedures

23

Responsibilities for QA Functions

Volume V, Part I, Section 1.5 & 1.6

Added functional statements to the responsibilities of individuals in Chapter 1 concerning review and approval of formal work packages.

• Updated Chapter 1 responsibilities section for FWP review and approval to match requirements already in effect in Chapter 2

• Following individual responsibility sections update:

• Ship’s Force: Department Head, Division Officer, Work Center Supervisor, & QAO

• FMA: Nuclear Repair Officer, Planning and Estimating Officer, Division Officer, Work Center Supervisor, & QAO

24

Certification Letters From Submarines

Volume V, Part I, Section 1.5.1.c

Corrected a conflict between sections of the JFMM.

• Chapter 5 requires a certification letter from a Ship’s Commanding Officer prior to each underway unless no SUBSAFE controlled work, SUBSAFE testing or URO’s were conducted.

• Chapter 1 under Commanding Officer responsibilities used to require a Certification Letter from the Commanding Officer prior to each underway even if no SUBSAFE work, testing or URO items were accomplished.

• Change 5 modified Chapter 1 to reflect the current requirements in Chapter 5

• Bottom Line: Certification Letter not required for an underway if no SUBSAFE work, SUBSAFE testing or URO items were accomplished.

25

REC Exemption

Volume V, Part I, Section 1.6.2 & 5.10.6

Changed retention of OQE

• Previously any QA-34 generated from a REC exemption re-assembly was held by the applicable Division Officer. Changed to have a single point of holding this OQE – the ship’s QAO

Added a note to clearly indicate that REC exemptions are for S/F use only and only for operations and not as part of Repair Activity repairs

• There have been instances where Repair Activities have attempted to have S/F invoke the REC exemptions to help the activity in performing the maintenance with less “paperwork”

26

Responsibilities for Work Performance of Other

Activities


Added information concerning use of technical support agencies and contracted organizations concerning performance of SUBSAFE work

• SUBSAFE work can be only performed by those activities listed in NAVSEANOTE 5000

• Fleet Technical Support Centers can assist in (NOT PERFORM) maintenance inside the SUBSAFE boundary IF

• S/F is ultimately responsible for all work performed

• S/F is responsible for the development in any CWP used in any technical assist visit

• Action taken to correct any misconception that any organization not on NAVSEANOTE 5000 can actually perform the maintenance

27

CWP Approval Process


Revised Chapter 2 concerning CWP numbering and issuing of the numbers by S/F

• Process merely reflects what was already required in the instructions for completing a QA-9 in Chapter 11.

28

QAO Qualification

Volume V, Part I, Section 3.4.1, 3.4.3, & 3.4.5

Removed the allowance that a QAO could go to a QAO course anytime within six months of appointment

• QAO now should have attended a QAO course prior to assuming the duties as a QAO.

• This will require closer coordination by organizations especially ship’s force in the appointment of new QAO’s.

29

In-process Control

Volume V, Part I, Section 5.5.4.3

Added specific caution that the O-Ring Lubricant Table (Table 5-4) is not applicable for nuclear systems

• Addresses a case where S/F incorrectly used a lubricant on this table for an o-ring in a nuclear system

Added two additional notes for use of o-ring lubricants

• Stated that silicon compound per MIL-S-8660 is an acceptable lubricant for seawater systems

• Termolene grease is not approved for use in Divers Life Support Systems

30

Testing

Changes to Testing Notes for Escape trunks, Hatches, Watertight Bulkhead Doors, & Sonar Spheres Testing on Appendix B (Testing Requirements for Submarine Systems)

• Revised Note 15: Clarified that a deep dive retest is not required for escape trunk penetrations not exposed to sea pressure during normal operations

• Revised Note 22: Specified method to check for leakage during the conduct of the structural watertight integrity check (deep dive)

• Added Note 28: Note deals with Removable Logistics Escape Trunks and Logistics Plug Trunks testing

• Added Note 29: Note deals with Sonar Sphere testingVolume V, Part I, Chapter 7, Appendix B

31

Testing

Clarified Testing Procedures for Periscopes• Periscope Types 2, 8, 15 and 22, after re-assembly will

be verified by gas testing to 50 psig internal pressure for 30 minutes with soap bubble test of work areas affecting periscope tightness

• Periscope Types 2, 8, 15 and 22, as an alternative, may be tested using the Nitrogen/Halogen leak check method

• Nitrogen/Halogen leak check is the only method for internal low pressure testing of Type 18 periscopes

Volume V, Part I, Chapter 7, Appendix B

32

Testing


Changes to Testing Notes for Diesel Water Testing on Appendix B (Testing Requirements for Submarine Systems)

• Deleted Note 25: Note 25 deals with URO-25 performance. No fleet submarine has flood control actuated DSW Hull/Backup valves

• Added Note 6: Note 6 deals with hull and backup valve testing. DSW has hull and backup valves

• Revised Note 9: Note 9 deals with pressure testing of DSW and if DSW is connected to the ASW system. Revised to match source document.

33

Testing


Clarified what maintenance will require performance of URO-25

• Due to the subjective nature of the Submarine Safety Requirements Manual and URO-25 Maintenance Requirements Cards concerning when URO-25 must be performed, the TYCOM has provided easy to use guidance.

• If a component is disturbed the retest the entire Emergency Flood Control System that was affected. For instance, a component in the Forward Emergency Control System is disturbed, then a retest of the entire Emergency Flood Control System in the Forward compartment is required.

34

Departure From Specifications


Official recognition of the Electronic DFS system

• This will be the primary method for DFS processing in the Submarine Force

Provides for administration of the DFS system

• Process procedures formalized for conducting of updates/changes to DFS items that have been approved

• Formalized that attachments will be in Adobe Acrobat format

35

Departure From Specifications


Clarifies when a new Job Sequence Number must be added to a DFS that will require future work to clear the discrepant condition

• Many cases a temporary DFS is sent to the TYCOM for approval without a new JSN added to the DFS even though it is very clear from the onset that future work is required

• New instructions require that this JSN be added prior to submission of the DFS to the ISIC

36

Audits and Surveillances


Revised areas requiring reviews during Assessments and Audits

• FMA and ISICs: Added Scope of Certification Compliance

• Type Commander: Added SUBSAFE and SOC Program Compliance and compliance to URO program requirements

Revised reporting of immediate corrective actions

• Any immediate corrective action audit or assessment comment must be answered and verified correct with the ISIC prior to the next underway of the ship

37

Record Retention


Revised Qualification Record Retention

• Added requirement to keep Oxygen Clean Worker and Oxygen Clean Instructor qualification records

• Change record keeping duration for qualification records from life of the ship to duration the individual is onboard

Added record keeping for REC exception QA-34 forms

• As previously discussed, records to be kept by the QAO vice each Division Officer

38

QA Form Changes - QA-1Material Receipt Control Record

Volume V, Chapter 11, QA-1

MATERIAL RECEIPT CONTROL RECORD QA FORM 1 (FRONT) 1. MATERIAL NOMENCLATURE

2. LEVEL OF ESSENTIALITY

3. MIC NO./ID NO.

4. REQUISITION NUMBER (REQ. NO.)

5. JULIAN DATE

6. NUMBER RECEIVED

7. NSN/SMIC

8. VENDOR'S MARKINGS

9. REQUIRED CERTIFICATION DOCUMENTS FURNISHED (SIGNATURE AND DATE) [ ] YES [ ] NO

10. ENTER APPROP CODE X – RECORDS REQ'D O – RECORDS NOT REQ'D

MT PT RT UT VT CHEM PHYS GENERIC MATERIAL IDENTITY CHECK

HARDNESS DIMEN

11. INSPECTION RESULTS, REMARKS, SIGNATURES, AND DATE:

Added Location for Indicating SOC Material Control Division

12. DISPOSITION [ ] ACCEPT [ ] REJECT

13. CERTIFIED [ ] SS [ ] LI [ ] NUC LI [ ] SOC MCD __ [ ] OTHER

14. DOWNGRADE [ ] GENERAL STOCK [ ] REJECT TO SOURCE

15. SIGNATURE AND DATE

39

QA Form Changes - QA-2Non-nuclear Material Id/control

Tag


• Added a block for NUC L1 and SOC Material

• Provides a Process for QAO signing of SOC MCD A or B material

QA-6 Forms

Deleted

40

QA Form Changes - QA-2Non-nuclear Material Id/control

Tag


Added additional Fabrication /

Transfer Blocks to help reduce

the number separate QA-2 tags to perform

work

Old Tag New Tag

41

QA Form Changes - QA-11

Controlled Work Package (CWP)/re-entry Control (REC)

Log

Volume V, Part I, Chapter 11, QA-11

Resolved conflicting statements in the process instructions for completing the QA-11 and QA-9 forms

Conflict was concerning CWP numbering and issuing of the numbers by S/F

•Change does not change any current practices, it merely reflects what was already required in the instructions for completing a QA-9 in Chapter 11.

42


Joint/component Torque and Assembly Record

Volume V, Part I, Chapter 11, QA-34

Updated QA-34 instructions to reflect block 7 receipt inspection procedures for SOC material

43


Volume V, Part II, Chapter I, Appendix D

Nuclear Material Control Tag

QA-6 Tags Deleted – Use QA-2

Tags

44

Scope of Certification

Volume V, Part III, Section 6.3 & 6.3.3

Revised receipt inspection requirements for Material Control Division (MCD) A, B , & C material - Rules incorporated in change 4 were too restrictive and added requirements above and beyond NAVSEA requirements

• MCD A and B material will be receipt inspected by the CMPO vice the QAO. The QAO will now only certify the material

• MCD C material will have a visual inspection by the craftsman and is certified by the QAI at installation

Documents

Joint Fleet Maintenance Manual