Spec_R-311-0609_SSGD_Overhaul_70Z08019Q17001B00_-_Copy.docx

REVISION No. . CHANGE NO. .

U.S. COAST GUARD 87’ WPB

SHIP SERVICE DIESEL ENGINE-GENERATOR SET

OVERHAUL

R-311-0609

ORGINATED BY Darren L. Tooley, EMC . DATE 08/2010 .

ORIGINATOR’S COMMAND Surface Forces Logistics Center .

DEPARTMENT / DIVISION Patrol Boat Product Line / Engineering & Products .

INTERNAL REVIEWER . DATE .

USCG – SFLC

DATE: 08/2010

SPEC NUMBER: R-311-0609

87’ WPB SHIP SERVICE DIESEL ENGINE – GENERATOR OVERHAUL

SWORB APPROVAL . DATE

1.0 SCOPE

1.1 This describes the requirements with which the Contractor shall comply completing the overhaul of Performance Diesel Incorporated (PDI) Ship Service Diesel Generators (SSDG) model D0824LF01/UCM224F13. Two (2) generator units are currently installed on each 87’ Coast Guard cutter nationwide.

1.2 Classification: This sets forth the requirements for the following equipment:

a. PDI SSDG NSN: 2815-01-F98-0167

1.3 Government Furnished Property (GFE) – The listed items are managed by the Coast Guard Surface Forces Logistics Center at Baltimore, MD.

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 Government Documents - The following specifications, standards, publications, and handbooks form a part of this overhaul description to the extent specified herein. Unless otherwise specified, the versions in effect are those listed in the GSA Index of Federal Specifications, Standards and Commercial Item Descriptions or the current Department of Defense Single Stock Point of Specifications and Standards, (DODSSP), and supplements thereto, cited in the solicitation or contract.

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

b. SFLC Specification D-000-0100, Rev G, Change 1, Feb 06, Bar Code Requirements

c. GSA Federal Supply Schedule (FSS) A-A-2787 T1, Dated 10/16/04 Enamel (Aerosol - Low VOC) Color 17875

d. COMDTINST M9000.6 (series) Naval Engineering Manual

e. NSTM Chapter 300

f. SFLC STD SPEC 3101

2.3 Commercial Documents – The following documents form a part of this overhaul description to the extent specified herein. The documents listed shall be the version listed by number and effective date from the referenced industry organization. Commercial documents may also be listed in the Department of Defense Index of Specifications and Standards (DODISS).

g. MAN Engines & Components Owner’s Checklist D0824LF01/D0824LE301 Engine Shipboard Generator

h. NEWAGE International Installation, Service & Maintenance Manual. Publication Number UCH-027, 27th Edition 2/001

i. Industrial Power Systems Incorporated, Generator Control Panel Operation and Maintenance Manual

j. National Conference of Standards Laboratories (NCSL) Z540-3, Dated 1/1/2006 Requirements for the Calibration of Measuring and Test Equipment

k. Society for Protective Coatings (SSPC) SSPC Paint 25, Dated 1/5/1997 Zinc Oxide, Alkyd, Linseed Oil Primer for Use Over Hand Cleaned Steel Type I and Type II - Editorial Changes 11/1/2004

l. American Society for Quality Control (ASQC) ASQ Q9003-1994, Dated 1/1/1994 - Quality Systems - Model for Quality Assurance in Final Inspection and Test

2.4. Specification Order of Precedence – In the event of a conflict between the text of this overhaul description and the references cited herein, this description shall take precedence, unless otherwise specified herein. Nothing in this description, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

2.5. Departure from Specification – Departure from this specification shall not be allowed unless approved by the Coast Guard Contracting Officer.

a. If the Contractor finds it necessary to suggest implementing change or depart from applicable specifications they shall request permission.

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 – OEM technical publications shall be utilized to complete the SSDG overhaul. The Contractor shall be required to legally possess all OEM technical publications and have them available at the Contractor’s facility. The Contractor shall be required to complete the following requirements. These requirements shall be required on all the units classified herein. The Contractor shall complete these requirements in accordance with the attached Delivery Schedule.

3.2. The Contractor shall provide all labor, equipment, special tools, materials, and parts required to clean, inspect, disassemble/reassemble, test components, test engine and generator.

a. The Contractor shall be able to provide, when requested by the Contracting Officer, detailed evidence of their experience with PDI Ship Service Diesel Generators model D0824LF01/UCM224F13.

b. All tools and test equipment shall be calibrated in accordance with section 4.3.

c. The overhauls and all component inspections shall be completed using only OEM unique parts, components, processes, and practices.

d. The SSDG load testing shall be conducted on-site at the Contractor’s facility in accordance with OEM and Coast Guard procedures. The USCG reserves the right to witness all testing.

e. The Contractor shall be responsible to provide the USCG all up-dated data in regards to engine configuration, service bulletins, TP changes/revisions, parts, and part number changes.

f. Upon receipt of any engine, regardless of condition, the Contractor shall store propulsion units inside and kept from all weather.

3.3. Required Reports – The Contractor shall submit the following reports within the time lines set herein:

a. Receiving Inspection Report (Appendix A). The Contractor shall submit Appendix A to the Contracting Officer for approval within seven (7) days after receiving the SSDG. No further work shall be accomplished until approval from the Contracting Officer.

b. Condition Found Report (Appendix B). The Contractor shall disassemble the engine and submit Appendix B to the Contracting Officer for approval within fifteen (15) days of receiving written approval of the Receiving Inspection Report. No further work shall be accomplished until approval from the Contracting Officer.

c. Cumulative Tracking Report (Appendix D). The Contractor shall submit Appendix D to the Contracting Officer quarterly no later than the 15th calendar day of the respective month.

3.4. SSDG Overhaul – Each SSDG shall be overhauled and returned to a condition that is equal to that of a new PDI SSDG part no. D0824LF01/UCM224F13 for use on the Coast Guard 87’ WPB patrol vessels to include any upgrades as applicable. All parts listed in Enclosure 1 shall be replaced. After completion of overhaul, Contractor shall perform standard production tests to assure maximum design performance IAW OEM specifications and standards. Contractor shall provide successful production testing certification to the C.G. Contract Administrator with a copy placed in the crate with each SSDG.

3.5. Generator - The Generator section of each SSDG shall be overhauled IAW Original Equipment Manufacturer (OEM) requirements.

3.6. SSDG Painting – Each SSDG shall be prepared and painted as described below as a minimum.

3.

3.1.

3.2.

3.3.

3.4.

3.5.

3.6.

3.7.

3.8.

3.9.

a. Abrasive Blasting: Abrasive blast all painted surfaces using a soft abrasive media so as to not remove any metal. Remove all label plates and replace them at the conclusion of painting, if applicable.

b. Primer: All exposed metal surfaces of SSDG exterior shall be primed with one coat (2-3 mils MDFT) of primer I.A.W SSPC Paint 25. Allow a minimum of (7) seven hours to dry.

c. Top Coat: Two coats, approximately two (2) mils, total thickness (3-5 mils MDFT) shall be sprayed on all primed surfaces. Allow a minimum of seven (7) hours drying for recoat and primed surfaces. Paint shall be color #17875 in accordance with A-A-2787 T1.

d. A Coating Thickness Gauge shall be used to determine coating thickness. A calibration certificate shall be provided to the Coast Guard Representative upon request. The calibration shall be traceable to the National Institute of Standards and Technology (NIST).

NOTE: Alternative requests to the requirements of section 3.6 shall be presented to the C. G. Contract Administrator for review and approval.

3.7. General Test Requirements

a. SSDG load test results detailed in APPENDIX C shall be recorded and submitted.

b. Generator – The Generator section of each SSDG shall be overhauled IAW Original Equipment Manufacturer (OEM) requirements.

c. All engine testing shall be verified and accepted by a Coast Guard Representative.

d. Any unusual noises, external leakage, or any other noncompliance to this specification, as determined by the U.S. Coast Guard Representative, shall be cause for the SSDG to be found unacceptable.

3.8. Notifications and Inspections - The Contractor shall be responsible for notifying the Contracting Officer at least seven (7) working days prior to being ready for any inspections or testing.

a. Prior to notification of testing, ensure the SSDG is installed on the dyno, test operated, and engine warmed up prior to Coast Guard Representative arrival.

3.9. 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. QUALITY ASSURANCE

4.1 General – Contractor shall maintain an inspection system which shall insure each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented, meet the requirements of ASQ Q9003 and be available for review by the Coast Guard. Contractor shall submit a Quality Assurance Plan for approval to the C.G. Contract Administrator.

4.2 Records – The contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3 Calibration System – Contractor, as well as any subcontractors, shall maintain a test equipment calibration program in compliance with NCSL Z540-3. The program shall be documented and traceable to the National Institute of Standards and Technology (NIST).

4.3.1 The calibration system records shall be maintained for inspection for the duration of any contract referencing this overhaul description.

4.4 Responsibility for Inspection – Contractor shall be responsible for the performance of all inspection requirements specified herein. Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractor’s facility prior to the Coast Guards acceptance of the contracted items. The Coast Guard reserves the right to verify or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements.

Contractor shall notify the C.G. Contract Administrator prior to the scheduled commencement of any inspections required by this overhaul description.

4.5 Responsibility for Compliance – All items shall meet the provisions of sections 3 & 5. The inspections set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.6 Inspection System – The contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Coast Guard.

4.6.1 Specifications currently in use:

4.1.

4.2.

4.3.

4.4.

4.5.

4.6.

a.

4.6.a.1. ANSI/ASQC Q9001-1994 – Quality Systems – Model for Quality Assurance in Design, Development, Production, Installation, and Servicing.

4.6.a.2. ANSI/ASQC Q9002-1994 – Quality Systems – Model for Quality Assurance in Production, Installation, and Servicing.

4.6.a.3. ANSI/ASQC Q9003-1994 – Quality Systems – Model for Quality Assurance in Final Inspection and Test.

4.7. Tests & Inspections – The inspections/tests required in section 3.0 are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item in question.

a. Contractor shall have the latest versions of the drawings, specifications, tolerances and approved test procedures available for inspection, if necessary.

4.8. Failure Responsibility – If an SSDG or any part thereof fails to pass any inspection/test the contractor shall report the failure and the recommended fix to the C.G. Contract Administrator. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

a. General Statements

4.8.a.1. The C.G. Contract Administrator reserves the right to totally reject any failed item without considering any suggested corrective action.

4.8.a.2. The inspection/test shall be discontinued until all corrective action has been taken.

4.8.a.3. After all corrective actions have been taken the inspection/test shall be continued or repeated at the option of the Contract Administrator.

4.8.a.4. Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

4.8.a.5. All corrective actions shall be documented as part of the contractor’s inspection system and submitted for approval to the Contract Administrator.

4.8.a.6. Each corrective action report shall include, but not be limited to the cause of each defect, corrective action suggested, and the steps taken to prevent a recurrence of each defect.

4.9. Test & Inspection Reports – A copy of any standard Contractor test or inspection report shall be turned over to the C.G. Contract Administrator upon his/her request.

4.10. Packing Inspection - The C.G. Contract Administrator shall be notified prior to the packaging, packing, marking and bar-coding of the overhauled SSDG in accordance with section 3.11 of this overhaul description.

5. PRESERVATION, PACKAGING, PACKING, MARKING AND BAR-CODING

5.1 General – Each overhauled SSDG shall be cleaned, preserved, packaged, packed, marked and bar-coded as specified herein.

5.2 Preservation – Each overhauled SSDG will be placed in warehouse storage and is not for immediate installation. The overhauled SSDG shall be individually preserved and wrapped for protection against moisture and deterioration in accordance with OEM standards and specifications to provide protection for a period of two (2) years minimum.

5.3 Packing – Each overhauled SSDG shall be packaged individually in its own framed-in wooden crate in accordance with SFLC specification SP-PP&M-001. The crate shall be constructed in such a manner to prevent the SSDG from shifting inside and be capable of providing adequate protection during multiple commercial shipments and long term warehouse storage and handling. The crate lid shall be secured with corrosion/rust resisting wood screws for easy removal and securing.

5.4 Marking – The marking described herein shall be placed on the longest two sides of each crate (on opposite ends) and include the requirements of section 5.5 of this description.

5.4.1 Other than the marking required in 5.5, all markings shall be done via machine-made stencils where applicable with the exception of the serial number. The serial number may be hand written in legible English using block lettering. The lettering shall be at least 3/4” high, in permanent black print on a painted white background.

NOTE: ALL PREVIOUS MARKINGS AND / OR QUALITY ASSURANCE DECALS SHALL BE COMPLETELY REMOVED FROM THE REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS.

5.4.2 This markings shall consist of the NATIONAL STOCK NUMBER, ITEM NAME, PART NUMBER, SERIAL NUMBER, CONTRACT NUMBER, SHIPPING WEIGHT (in lbs.,) condition code ie. CONDITION “A”, unit of issue with quantity (1) and the words COAST GUARD SFLC MATERIAL.

5.1.a.1. The marking shall be in the format as follows:

5.2. Bar Coding – The National Stock Number (NSN) shall be bar-coded in addition to the markings required above. Bar coded labels shall be in accordance with SFLC specification D-000-100 Rev. G. The bar-code label can be applied separately or as part of the marking required in 5.4 of this description.

5.2.a.1. The labels shall be Type "V", Grade "A", Style "2", Composition "b" with plastic laminate.

5.2.a.2. Each label shall contain encoded data for the National Stock Number.

5.3. Coast Guard Acceptance – Acceptance will be made at destination by a government representative. Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of order and Contractor’s conformance to preservation, packaging, packing, marking and bar-coding requirements.

6. NOTES

6.1. Government & Commercial Document Sources

a. Coast Guard Documents

6.1.a.1. USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD. 21226-5000

(410) 762-6434 Fax: (410) 762-6226 Attn: Scott Wood www.uscg.mil/hq/elcbalt

b. Other Government Documents

6.1.b.1. Department of Defense Single Stock Point (DODSSP) Building 4, Section D 700 Robins Avenue Philadelphia, PA 19111-5094

(215) 697-6396/6257 Fax: (215) 697-9398 www.assist.daps.dla.mil/quicksearch

c. Commercial Documents

6.1.c.1. Steel Structures Painting Council (SSPC) 40 24th Street, 6th Floor Pittsburg, PA 15222-4656

(412) 281-2331

Fax: (412) 281-9992 www.sspc.org

6.1.c.2. National Conference of Standards Laboratories (NCSL) 2995 Wilderness Place Suite 107 Boulder, CO 80301-5404

(303) 440-3339 Fax: (303) 440-3384 www.ncsli.org

6.1.c.3. American Society of Quality Control (ASQC) 600 N. Plankinton Ave.

Milwaukee, WI 53203

(800) 248-1946 Fax: 414-272-1734 www.asq.org

Appendix A

Work Order # ____________________ Delivery Order # __________________ Engine Serial # ___________________ Generator Serial # _________________

Core Acceptance is based on the following:

a. Core must have no non-operational damage.

b. Core must be a complete unit and not disassembled.

1. Core acceptable__________, non-acceptable___________ Remarks: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

2. Shipping crate: Serviceable_________ Needs Repair____________

Photograph of engine and gear; front, right side, left side, and rear views to include serial number in picture frame.

Appendix B Condition Found

Repairs Required

Parts Required

Parts Expended

Recommendations

Enclosure 1

Mandatory Replacement Parts

Engine D0824LE301

51.04410.0150

Generator Model # UCM224F1L 322D

Mandatory Generator Section Replacement Parts

051-01032 Generator Bearing 051-21784 Bearing O-Ring

RSK-2001 Diode Rectifier Assembly Kit

APPENDIX C

US Coast Guard 87 SSDG Test Procedures: Two (2) Hour Load Test (at 115% Rated Output = 69kW)

Delivery Order: Date: _____________

Engine Make/ Model: Engine Serial No:

Generator Make/ Model: Generator Serial No:

Ambient Conditions: Temperature (Deg F):

115% Capacity: 69kW

Min: 15

Engine Parameters

Generator Parameters

Comments: _________________________

Signatures:

Mechanic: Date:

Shop Foreman: Date:

USCG Rep. Date: