CAT_D398_Overhaul_SOW_PR__809P45270.docx

SOW_31110_0417_270WMEC

Statement of Work: Ship Service Diesel Generator (SSDG) Prime Mover, Overhaul

1. SCOPE

1.1 Intent. This statement of work (SOW) describes the requirements for the Contractor to overhaul, test, package and ship a designated SSDG prime mover.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings Coast Guard Drawing 901 WMEC 256-008, Rev B, SSDG Modification – Aux Sea Water Piping Mod Coast Guard Drawing 901 WMEC 256-009, Rev B, SSDG Jacket Water Cooling System and Mods Coast Guard Drawing 901 WMEC 310-016, Rev-, Cyl & Tchrgr Thermocpls Mods to SSDG Wiring Dia & Arrgmt Coast Guard Drawing 901 WMEC 320-045, Rev B, SSDG Modification – Power Modification Coast Guard Drawing 901 WMEC 504-003, Rev-, SSDG Temperature Gauges Coast Guard Publications Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures Coast Guard Technical Publication (TP) 2703, Oct 2016, Ship Service Diesel Generator (Set), Other References ASTM International (ASTM) D3951, 2010, Standard Practice for Commercial Packaging

3. REQUIREMENTS

3.1 General. The Contractor shall accomplish all work in accordance with the requirements of SFLC Std Spec 0000, and using the Coast Guard drawings and TP listed under Section 2 (References) as guidance.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of an OEM authorized/ licensed Tech Rep for the SSDG Prime Mover, (Model D398 Marine Engine), to accomplish the following tasks – on site at Contractor’s facility where SSDG engine is undergoing overhaul and test:

· Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

· Assist with and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, reassembly and final operational testing of the equipment/system.

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé.

3.1.2.2 Submit the name and résumé of the Tech Rep to the COR prior to Contract start.

3.2 Overhaul requirements. The Contractor shall accomplish the following tasks for the designated SSDG Prime Mover (Caterpillar PN: D398B-TA/ARGMT-3N1127), in accordance with TP 2703, and the SSDG manufacturer’s (Caterpillar) recommended procedures. The Contractor shall accomplish a complete overhaul of the Caterpillar engine to “like new” condition. The Contractor shall provide all labor and materials to accomplish the requirements within this SOW.

3.2.1 Removal. Package and ship the engine assembly to the Contractor’s facility.

3.2.2 Disassembly, cleaning and inspection. Disassemble, clean and inspect the engine components. Submit a CFR.

3.2.3 Bore alignment check. Measure the size, straightness, and the clearances related to the main bearing journals and cylinder blocks. Compare all measurements against the engine factory specifications in TP 2703. Submit a CFR.

NOTE

Maximum allowable line bore clearance shall be 0.002-inches.

3.2.4 Parts renewal. Furnish and install all parts listed in paragraph 4.1 (Contractor-furnished parts list), in place of existing parts. Validate parts list with Tech Rep prior to purchase.

3.2.5 Reassembly. Reassemble the prime mover in accordance with the applicable sections of TP 2703.

3.2.6 Testing. Test overhauled engine assembly in accordance with TP 2703 and Tech Rep’s recommendations. Test shall include a four-hour minimum dynamic test. Submit a CFR.

3.2.6.1 No-load testing. Prior to the dynamometer test, in the presence of the Coast Guard Inspector and in accordance with TP 2703, the Contractor shall run the engine for a period of 30 minutes under no load. Check the engine and all sub-assemblies, tubing, hoses, flanges, lines, fittings, joints, and plugs for leaks. Monitor the lube oil pressure and engine temperature. Submit a CFR. Correct any deficiencies and discrepancies found during testing and retest.

3.2.6.2 Dynamometer test. After all authorized repairs, the Contractor shall test the engine using an engine dynamometer in accordance with OEM recommendations. The Contractor shall correct any deficiencies and discrepancies found and retest. Submit a CFR of all test results; including RPM, torque, HP, oil pressure and temp, jacket water pressure and temp, fuel pressure and rate, and time of each reading. Test report shall include engine model number, serial number, date of testing, and signature of authorized tester.

3.2.6.3 Purging. After a successful Dynamometer test and acceptance by the Coast Guard Inspector; the Contractor shall purge the engine sea water and jacket water systems. The Contractor shall open and vent the sea water and jacket water systems by using the engine's petcocks, fittings and flanges to allow trapped fluid to drain from the engine, to prevent expansion damage due to possible freezing in cold weather. After the engine is drained, all external openings shall be securely capped, plugged or closed to prevent contamination of the engine or the storage container.

3.2.7 Packaging and shipping. Contractor shall arrange to receive engine from USCG Base Yorktown and ship to contractors repair facility. After all authorized repairs are complete, package and ship engine assembly in accordance with SFLC Std Spec 0000 to SFLC Baltimore. Preserve engine assembly prior to packaging in preparation for long-term storage in temperatures ranging from -20 to 120 degrees F. All exposed metal surfaces shall be prepared and preserved in accordance with SFLC Std Spec 6310. Coat all unpainted surfaces with a light amount of grease. Plug or cap fittings, flanges and openings that can allow foreign materials to enter the engine. Drain and protect all fluid systems with appropriate preservatives. Shrink wrap engine.

A warning tag shall be attached to the engine stating the preservation action taken and method to place engine back into service.

The shipping crate shall have the following markings in 2-inch black enamel letters:

· PN: D398B(TA)/ARGMT-3N1127

· Caterpillar Engine, D398

· Engine Serial Number #________________

· U. S. Coast Guard Material

· Gross Weight ______ Cube _____

· "__" Condition Code

· Contract Number/Delivery Order Number _____________

· Do Not Stack More Than Two High

· Do Not Lift By Cover Contractor shall notify COR at least 24 hours prior to closing shipping container.

4. NOTES

4.1 Contractor-furnished parts list.

RFQ NR 70Z080-19-Q-P4527000

Complete overhaul gasket kit

NEW OVERSPEED ASSEMBLY (NOT

INCLUDED WITH ENGINE)

GOOD USED EXPANSION TANK WITH

BRACKETS AND PIPING (NOT INCLUDED

WITH ENGINE)

SEA WATER AFTERCOOLER CORES

(ENGINE RECEIVED WITH FRESH

WATER CORES)