ATTACHMENT_2_SOW_R-311-2040.pdf

Overhaul Specification For Northern Lights Ship’s Service Diesel Generator

Specification R-311-2040

REVISION No. A Change ____________

TITLE

OVERHAUL SPECIFICATION FOR

Northern Lights M1066A1.11CG(P/S) Ship’s Service Diesel Generator

10,000 HRS

SPECIFICATION NUMBER

R-311-2040

ORGINATED BY MKC Carlos A. Harris DATE 09/10

ORGINATOR'S COMMAND Surface Forces Logistics Center

DEPARTMENT/DIVISION 110 Patrol Boat Product Line

INTERNAL REVIEWER CWO Brian Rogers DATE____09/10______

SOWRB APPROVAL DATE

1.0 SCOPE

1.1 This specification provides the requirements for overhaul reassembly, testing, painting, preservation, packaging, and marking to the U.S. Coast Guard standard configuration of the Northern Lights M1066A1.11CG(P/S) diesel engine generator set.

1.2 This specification sets forth the requirements for the 110’ WPB “A” and “B” Class

Cutter’s Ship Service Diesel Generator Set (NSN 01-539-8540 / NSN 01-540-3513) consisting of the following components:

a. John Deere Diesel Engine (Model# PE6068HF275)

b. MagnaPlus Generator, Alternating Current (Model# 431PSL6351)

2.0 APPLICABLE DOCUMENTS

2.1 DOCUMENT AVAILABILITY - For the methods and conditions for obtaining the referenced documents refer to section 6.0.

2.2 APPLCABLE DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein.

2.3 GOVERNMENT DOCUMENTS

a. MIL-DTL-24441-C Dated 19 May 99, Coating, Primer Alkyd.

b. MIL-PRF-2104-G Dated 10 February 97, Lubricating Oil, 15w 40.

c. MIL-C-104-C Dated 24 June 93, Crates Type II, Class II, Style A.

d. MIL-D-3464-E Dated 21 April 87, Desiccant, Activated Bag.

e. USCG-SFLC SPECIFICATION D-000-100 Rev. G, Change 1, Dated 02/06, Bar

Coding for USCG SURFACE FORCES LOGISTICS CENTER material.

f. TP 3988 Dated 22 December 2008, Ship Service Diesel Generator Set.

g. NSTM Chapter 300

h. MLCA STD SPEC 3141 STD

2.4 COMMERCIAL DOCUMENTS

a. ASTM-D-975-10 Dated 10 October 10, Diesel Fuel #2.

b. ASTM-D-4649-95 Dated 15 July 95, Selection of Stretch Wrap Films.

c. NCSL Z540-3, Dated 1/1/2006 Requirements for the Calibration of Measuring and

Test Equipment

d. ANSI/ASQC Q90003-1994, Dated 18 July 94, Inspection System.

e. John Deere Component Technical Manual (CTM170) Dated MAY 03, PowerTech

4.5& 6.8L Diesel Engines Level 4 Electronic Fuel Systems.

f. Northern Lights Parts Catalog (P1066A1) Dated November 04.

g. Magnaplus Generator 280–430 Frame Installation, Operation, and Maintenance

Manual

2.5 SPECIFICATION ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

2.6 DEPARTUARE FROM SPECIFICATION – Departure from this specification shall not be permitted unless approved by the Patrol Boat Product Line.

a. If the overhaul facility finds it necessary to implement a change or depart from applicable specifications they shall request authorization.

b. Request for change shall clearly describe the changes proposed, the reason for change, advantages of the proposed changes, price increase or decrease (if any) resulting from the change.

3.0 REQUIREMENTS

3.1 GENERAL - The overhaul facility shall provide all labor, equipment, special tools, and materials required to store, inspect, clean, overhaul, test and package the U.S. Coast

Guard configuration of the Northern Lights Generator set M1066A1.11CG(P/S) NSN:

6115-01-539-8540 / 6115-01-540-3513.

a. The listed mandatory replacement parts, Original Equipment Manufacturer (O.E.M) service bulletins, U.S. Coast Guard ship alterations, along with any other part determined unusable shall be replaced.

b. The overhaul shall be performed only by OEM Certified Technicians and shall return the equipment to OEM specifications.

c. Upon receipt of any generator set, regardless of condition, the overhaul facility shall provide covered, climate-controlled storage.

3.2 DISASSEMBLY INSPECTION - The overhaul facility shall disassemble and clean each generator set using the procedures specified in the CG TP-3988, John Deere Component

Technical Manual (CTM170), and Magnaplus Generator 280-430 Frame Installation, operation, and maintenance manual.

a. All parts on the Mandatory Replacement List as well as any additional parts necessary to return the generator set to Original Equipment Manufacturer specifications shall be disposed of by the overhaul facility.

b. Resistance readings shall be taken on the generator main stator, main rotor, exciter rotor, exciter stator, and PMG stator. Nominal Readings shall be as per APPENDIX B.

3.3 SERVICE BULLETINS/SHIP ALTERATIONS - The overhaul facility shall accomplish all service bulletins authorized by the Government during the term of the contract.

3.4 REASSEMBLY - Using only Original Equipment Manufacturer parts, each generator set shall be reassembled using the new mandatory replacement parts list and any contingency parts as needed in accordance with John Deere Component Technical

Manual (CTM170) and Northern Lights Parts Catalog (P1066A1)

a. All critical dimensions shall be recorded while assembling the generator set as per CG

TP-3988, and John Deere Component Technical Manual (CTM170).

3.5 MANDATORY REPLACEMENT PARTS - The parts listed in Appendix A (10,000 HR

Overhaul) shall be replaced with O.E.M. NEW parts or factory reconditioned parts conforming to O.E.M. specifications.

3.6 GENERAL TEST REQUIREMENTS

a. Engine dyno test parameters detailed in APPENDIX C shall be recorded in the format per APPENDIX C.

b. Generator test parameters shall be as per 3.2.b and APPENDIX B.

b. All generator set testing shall be made available to be witnessed by a Product Line

Representative.

c. Any unusual noises, external leakage, failure to maintain the electrical test load, or any other noncompliance to this specification, shall be cause for the Ship’s Service

Diesel Generator set to be found unacceptable.

d. All heat exchangers shall be pressure tested and repaired and or replaced in accordance with manufacturer’s technical publications.

3.7 WARRANTY - A warranty of one year from installation or 1000 operating hours, whichever occurs first, and 24 months of storage is required covering the entire ships service diesel generator. Storage commences upon receipt of engine at the designated

Coast Guard facility. The Contractor shall provide a Project Manager who shall be responsible for all Contractor warranty work performed under this specification.

a. The name of the Project Manager, and the name of any alternate who shall act for the

Contractor in the absence of the Project Manager, shall be provided to the

Contracting Officer. The Project Manager or alternate shall have full authority on all warranty matters relating to the requirements of this specification.

b. The Project Manager shall be available via telephone between the hours of 0800 and

1630 EST, Monday through Friday, and shall respond to a request for discussion or resolution of technical problems within twenty-four (24) hours of notification.

c. The Project Manager shall contact SFLC’s Contracting Officers Technical

Representative (COTR) to evaluate the Contractor’s proposed duration of warranty repair time.

d. The Contractor shall contact the field unit to arrange a resolution of a claim within

24 (twenty-four) hours after receiving notification by the Coast Guard of a warranty claim.

e. The Contractor shall provide OEM certified personnel, tooling, & software to perform the warranty requirements of this specification. The contractor shall be capable of providing the required warranty work and or parts at any geographic location the 87WPB fleet operates without affecting the contract’s delivery schedule.

f. In the event the Coast Guard decides the proposed warranty repair time compromises the Coast Guards mission and decides on removal/replacement, the Contractor shall coordinate and fund all necessary shipping arrangements for the failed SSDG to be returned to the origin of exchanged/remanufactured facility for repairs and returned to a designated Coast Guard facility after repairs have been completed.

g. The Contractor shall repair/rebuild the failed SSDG including painting and preservation to the condition level necessary for the contractor to honor a new full warranty. The Contractor shall submit to the Contracting Officer an inspection report for approval containing any parts and pricing for any work/repairs that are required that were not a result of the specific casualty.

4.0 QUALITY ASSURANCE

4.1 GENERAL - The overhaul facility shall maintain an inspection system, which meets

ISO requirements. The system shall be documented and in compliance with ANSI/ASQS

Q90003.

4.2 CALIBRATION SYSTEM - The overhaul facility 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 ISO in accordance with

ANSI/NCSL Z540-1. The system includes 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).

4.3 RESPONSIBILITY FOR INSPECTION - The overhaul facility shall be responsible for all inspections/test requirements specified herein. The overhaul facility shall provide space, personnel, and test equipment to conduct all inspection requirements. All testing and inspection shall be at the overhaul facility or another acceptable facility as required.

4.4 REQUIRED TESTS - Each engine provided shall be operationally tested in accordance with section 3.6.

4.5 TEST REPORT - The overhaul facility shall deliver a test report in accordance with section 3.6 of this specification.

a. One copy of the test report shall be packed and delivered with each generator set.

b. One copy of the test report shall be provided to the Patrol Boat Product Line.

5.0 PRESERVATION PACKAGING & MARKING

5.1 PRESERVATION (Internal) - The generator set(s) shall be preserved as per the requirements of CG TP-3988 after acceptance by the Government.

5.2 PRESERVATION (External) - After completion of the final test run and internal preservation the generator set will be prepared in accordance with the procedures listed:

a. All surfaces shall be cleaned of grease and oil

b. All loose scale and paint shall be removed

NOTE. These items shall be masked and not painted;

1. Rubber hoses and wires

2. Glass and chrome gauge bezels and covers

3. "Hot" surface areas of Turbo-Chargers

4. All identification plates

5. Breathers and intake, discharge, flanges of openings

6. Flywheel, Rear bolt face

7. Front and rear seals

c. All exposed metal surfaces shall be cleaned prior to being primed with one coat (2-3 mil Minimum Dry Film Thickness) of primer in accordance with MIL-DTL-24441C.

Allow a minimum seven (7) hours to dry.

d. OEM white paint shall be sprayed on all surfaces 3-5 mils thick, allow a minimum of seven (7) hours drying for primed surfaces.

e. When all paint is dry, the maskings shall be removed.

f. Coat all unpainted metal surfaces with a light amount of grease, except for hot surfaces.

g. Plug or cap any fittings/flanges or openings that will allow seepage from the engine during storage.

h. Overhaul Facility shall attach to the fuel oil pump, in a plastic envelope, a completed copy of the final test report (APPENDIX C).

5.3 PACKAGING - The shipping container if missing or damaged shall be constructed and mounted to the metal base skidded pallet as per MIL-C-104C.

a. Overhaul facility shall securely fasten the generator set into the approved shipping container. It shall be fastened in a matter that adequately ensures mechanical protection during multiple common carrier practices.

5.4 MARKING - Each preserved, packed, and packaged item shall be stenciled in the upper left-hand side of the two longest sides, (two opposite sides if square) of each box.

a. Machine made stencils shall be used for all marking.

b. All marking shall be in black print, against a white background, and at least 2" high.

c. The marking shall be in the format as follows:

STOCK NUMBER 6115-01-539-8540 or 6115-01-540-3513 (as appropriate)

ITEM NAME Generator Set, Diesel Engine

PART NUMBER M1066A1.11.CGP or M1066A1.11.CGS (as appropriate)

SERIAL NUMBER "As per Enclosed Generator set"

CONTRACT NUMBER See Contract

DELIVERY ORDER NUMBER As submitted on the Order

SHIPPING WEIGHT As per Overhaul Facility

QUANTITY & UNIT OF ISSUE 1- EA

PRESERVED FOR LONG TERM

STORAGE ON Date preserved

CONDITION CODE CONDITION A

OTHER DATA AS COAST GUARD SFLC MATERIAL

DIRECTED REUSABLE CONTAINER,

DO NOT DAMAGE.

DO NOT STACK.

d. The following marking shall be placed on all four sides and the top of each box, in stenciled black print, against a white background, at least 2" high.

Reusable Container- Do Not Damage

Remove Bolts Prior To Removing Cover

Use Forklift To Unload Do Not Lift By Cover

5.5 BAR CODING - Bar code labels shall be supplied on all Contract Line Item Numbers

(CLIN), except for those that require data submissions only.

a. All bar coded labels shall be in accordance with ELC specification D-000-0100.

b. The actual labels shall be Type "V", Grade "A", Style"2", Composition "b" with plastic laminate.

c. Each label shall contain encoded data for the Stock Number, the Delivery Order

Number and the Contract Number.

6.0 NOTES

6.1 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

a. Specifications and Standards (DODISS Documents)

Standardization Document Order Desk

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA 19111-5094

b. DOD & Navy Pubs & Forms (Other Than DODISS)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

c. USCG Surface Forces Logistics Center

2401 Hawkins Point Rd.

Baltimore, MD 21226-5000

410-762-6471, Code 046 Mail Stop 25

d. Northern Lights Inc.

8 Connector Road

Andover, MD 01810

978-475-7400

6.2 APPENDICES - The following appendices apply:

Appendix A Mandatory Replacement Parts (10000 HR)

Appendix B Generator Nominal Resistance Readings

Appendix C Engine Test Report

APPENDIX A

Mandatory Replacement Parts a.

PART# DESCRIPTION QTY PART# DESCRIPTION QTY

29-09601 GASKET SET, ENGINE OVHL 1 R114082 BUSHING 6

M41029 SNAP RING 12 R123177 PISTON PIN 6

RE507852 PISTON RING KIT 6 AR65507 O-RING KIT 6

RE507850 PISTON-LINER KIT 6 RE65908 BEARING, STANDARD 6

RE502269 OIL PUMP 1 RE504836 OIL FILTER 1

R92352 PACKING 6 RE507766 FUEL INJECTOR 6

RE505980 COOLANT PUMP 1 25-15703 CAM 1

25-15704 IMPELLER 1 9111241 BEARING 1

30-39627 TURBO CHARGER ASY 1 R123457 TENSIONER ASSEMBLY 1

22- 40915 Pressure Switch 15 PSI 1/8 NPT 1 19M8131 SCREW 1

22-40904 Temperature Switch 205°F 1 R123457 DRIVE BELT 1

22- 42802 Temperature Sender 250°F 1 RE68345 Fuel Pump 1

18- 55405 Hose Assembly 1/4” ID x 9” 1 RE61812 Air Temperature Sensor 1

22- 40440 Magnetic Pick-up 1

RE519144 Magnetic Pick-up 1

RE167207 Oil Pressure Sensor 1

40910

Temperature Switch 195°F 3/8

NPT 1

RE52722 Coolant Temperature Sensor 1 22- 40901 Pressure Switch 25 PSI 1/8 NPT 1

RE508195

ENGINE SPEED SENSOR,

M20X1.5 2

22- 40426 Thermocouple 1

51M7044 O-RING 2 9307204 Pressure Transmitter 100 PSI 1

RE509031 Filter Element 1

40427 Temperature Transmitter* 1

24-21000 Air Filter 1 R1M7041 O-RING 2

35-10002 Thermostat 1 RE57489 Cylinder head 1

22-41648 STARTER 1

RE518088 Fuel Injection Pump 1

As part numbers are superceded, the new part numbers shall be used as the given part numbers for this specification. All part numbers shall be verified by vendor for accuracy prior to ordering. This is not an all inclusive list, and additional parts may require replacement. In addition any disturbed surface shall have any gasket, o-ring, seal, etc. replaced.

APPENDIX B

Generator Nominal Resistance Readings, Northern Lights

M1066A1.11CG(P/S)

NOTE ALL READINGS TAKEN AT 20.5 DEG C 68.9 DEG F

Main Stator Nominal Actual

T1-T2 .02668Ω ________

T2-T3 .02666Ω ________

T3-T1 .02675Ω ________

Main Rotor Nominal

.6705Ω ________

Exciter Rotor Nominal

.1126Ω ________

.1120Ω ________

.1110Ω

Exciter Stator Nominal

17.85Ω ________

PMG Stator Nominal

1.985Ω ________

APPENDIX C

Engine Test Report, Northern Lights M1066A1.11CG(P/S)

1.0 General Test Requirement

a. Test parameters detailed in this Appendix shall be used during the test procedure and a test report in the format as per this Appendix shall be submitted to the Contracting

Officer for approval.

b. Any unusual noises, external leakage, failure to hold the electrical test load, or any other noncompliance to this specification, as determined by the Product Line representative, shall be cause for the Diesel Generator Set to be found unacceptable.

c. All engine testing will be made available for verification to a Product Line Representative.

1.1 Pre-Test Preparation Requirements

a. Each engine shall be fitted with a new lube oil filter.

b. Each engine shall be filled with New MIL-PRF-2104 grade SAE

15W40 lube oil.

c. The fuel oil shall be as per ASTM-D-975 # 2 diesel and flow through a 20 micron filter/separator before entering pump.

d. The cooling system shall be filled with clean potable water. An outside clean potable water source shall be used as raw water cooling.

e. Each generator set shall be tested with all hang on attachments. (Exhaust Shields are required to be attached during test.)

1.2 Pre-Start Requirements

a. Fill engine cooling system.

b. Prime fuel system.

c. Fill and pre-lube engine lube oil system.

1.3 Post Test Preparations Requirements

a. ALL ENGINE LUBE OIL FILTER ELEMENTS SHALL BE REPLACED WITH

NEW FILTER ELEMENTS AFTER COMPLETION OF ENGINE TEST.

b. OLD FILTER ELEMENTS SHALL BE CUT OPEN AND INSPECTED FOR

FOREIGN MATERIAL IN THE PRESENCE OF THE CG REPRESENTITIVE.

1.4 TESTS & TEST PARAMETERS

a. Basic Run-In: 5-10 Minutes (idle no load)

Idle Engine Speed RPM _________

Lube Oil Pressure PSI _________

Jacket Water Temp DEG F _________

Fuel Pressure PSI _________

Exhaust Temp DEG F _________

STOP ENGINE: CHECK ALL FLUID LEVELS AND TOP OFF AS REQUIRED

b. Operational Test

Phase 1: 5-10 Minutes at 1800 RPM (no load)

NOTE - Readings shall be taken and recorded at the end of the phase. All line items with specific parameters are to be observed and actual readings recorded.

Jacket Water Temp DEG F _________

Phase 2: 10 Minutes at 25% continuous power rating.

NOTE - Readings shall be taken and recorded at the end of the phase. All line items with specific parameters are to be

1. GENERAL

Jacket Water Temp DEG F _________

2. ELECTRICAL

Hertz _________

Voltage _________

KW _________

Phase 3: 15 Minutes at 50% continuous power rating.

NOTE - Readings to be taken and recorded at the end of the hour. All line items with specific parameters are to be

Jacket Water Temp DEG F _________

Phase 4: 15 Minutes at 75% continuous power rating.

Jacket Water Temp DEG F _________

Phase 5: 15 Minutes at 100% continuous power rating.

Jacket Water Temp DEG F _________

CONDITION OF L/O

FILTERS:__________________________________________________________

REMARKS BY

Q/A:______________________________________________________________

REMARKS BY SHOP

FORMAN:___________________________________________________________

SIGNITURE OF SHOP FORMAN:_____________________ DATE:_____________

SIGNITURE OF DYNO OPERATOR:___________________ DATE:_____________