SHACKLE_(WYTL_65B)_REVO_SPEC__DS_FY18.doc

USCGC SHACKLE (WYTL 65609)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2018

Developed By: Michael W Check (Rev-0, 02 April 2018 )

TABLE OF CONTENTS

iiiRevisions Record ivConsolidated List of References vConsolidated List of Government-furnished Property viConsolidated List of Critical Inspection Items viiPrincipal Characteristics - Tender

8General Requirements

18WORK ITEM 1: Ship Service Diesel Generator Engine(s), Overhaul (Contractor’s Facility)

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.

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

None

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3973, SWBS 311, Sections A thru G, Jun 2005, Ship Service Diesel Generator (Model MDKAF)

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2014, Auxiliary Machine Systems

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None

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.

This section is not applicable to this package.

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)):

Principal Characteristics - Tender

65' WYTL (B-Class: 65607-65609)

Physical

Hull

Hull/ main weatherdeck material

Superstructure

Machinery

00000_1215_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 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 small generator.

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 an 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 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:

3.7.1 SFLC Standard Specification 6310, Requirements for Preservation of Ship Structures.

3.7.1.1 SFLC Std Spec 6310, page C-2, Section C1.5.1. Change from "lead-containing paint as 0.06%" to "lead-containing paint as 0.009%".

3.7.1.2 SFLC Std Spec 6310, page 4, Section 2 References, Group- Other References. Add “The Society for Protective Coatings (SSPC) Paint Application Guide No. 11, 2008, Protecting Edges, Crevices, and Irregular Steel Surfaces by Stripe Coating”

3.7.1.3 SFLC Std Spec 6310, page Appendix C-6, add "Hempel Hempadur Multi-Strength GF 35870" with FED-STD-595 color "Black/Red" under ANTI-ABRASION COATING, ICE BREAKING CAPABLE VESSELS, <235’.

3.7.1.4 Standard Spec 6310, page Appendix A-7, Under "UNDERWATER (U/W) BODY/BOOT-TOP", Add line Column 1: Option for U/W Body and Boot-Top, Steel Hulls, <154', in Salt Water. Column 2: Blank. Column 3: SSPC-SP 10/NACE NO. 2 using grit conforming to MIL-A-22262 / (1.5-3.5) - or - SSPC-SP WJ-2(M)/NACE WJ-2(M). Columns 4 and 5: Same as "U/W Body and Boot-Top, Aluminum Hull, High Speed (>30 knots)".

3.7.2 SFLC Standard Specification 0000 General Requirements.

3.7.2.1 SFLC Std Spec 0000, paragraph 1.3 ‘Acronyms and term definitions’, page 5, “PCL (Paint Containing Lead)” definition replaced by, “Any paint or coating containing lead in excess of 0.009 percent by weight (1.0 mg/cm2 or 90 ppm). Lead Based Paint (LBP) is an interchangeable term with PCL.”

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”, and are provided at the end of this document.

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

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.

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

Use one sheet for each activity. Record conditions every four hours from before surface preparation to application of final coating system coat.

| DP - Surface |

QA-3a - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-C)

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:

Abrasive 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 Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Mean Mil Reading (IAW ASTM D4417-Method C) for above 15 readings:

QA-3b - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-B)

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:

Abrasive 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):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Mean Reading (mils)

Mean Reading (mils) IAW ASTM DD4417).

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY Measurements IAW SSPC-GUIDE 15.

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

Dry Film Thickness (DFT) Measurements IAW SSPC-PA 2.

*BASE METAL READING (BMR) Required, If Magnetic Pull-Off (Type I/Banana) Gauge Is Used.

Location (Frame Reference):

Avg.

Location (Frame Reference):

Avg.

Location (Frame Reference):

Avg.

31102_MWC_0814_65WYTL

WORK ITEM 1: Ship Service Diesel Generator Engine(s), Overhaul (Contractor’s Facility)

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to overhaul the Ship Service Diesel Generator (SSDG) diesel engine(s), at the Contractor’s facility.

___X SSDG #1

___X SSDG #2

1.1.1 Cummins/Onan marine generator set – #1 SSDG Model MDKAF S/N: E973688151, Kubota diesel engine Model 2803B, S/N F2803-136195.

1.1.2 Cummins/Onan marine generator set – #2 SSDG Model MDKAF S/N: E973688159, Kubota diesel engine Model 2803B, S/N F2803-141835.

1.2 Government-furnished property.

None.

2. REFERENCES

Coast Guard Drawings

None

Coast Guard Publications

Coast Guard Technical Publication (TP) 3973, SWBS 311, Sections A thru G, Jun 2005, Ship Service Diesel Generator (Model MDKAF)

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2014, Auxiliary Machine Systems

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.

3.1.1 Performance Periods: The overall period of performance is from 03 Sep, 2018 to 04 Oct, 2018. This period of performance is broken down into two separate schedules, for the purposes of overhauling Shackle’s B/SSDG engines.

3.1.1.1 Schedule 1: Immediately upon award of contract, the contractor shall begin the ordering of all parts to ensure availability to reduce any long lead time items that include but are not limited to, crankshafts and fuel injection pumps. Additionally make preparations for travel as necessary for the purposes of this project.

3.1.1.2 Schedule 2: The Contractor shall pickup gen-sets at the point of origin (South Portland , ME 04679-4414 ). The contractor shall overhaul B/SSDG engines in accordance with this Statement of Work and return gen-sets to the point of origin, NLT, 1000, 09/28/2018. Exact pick up and return dates for each SSDG will be coordinated with the CG PE and shall be determined based on the completion of the first overhauled SSDG. Only one SSDG can be removed, overhauled, and installed before removing the other SSDG. Satisfactory final acceptance testing after installation must be completed prior to removal of the second SSDG.

3.1.2 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph(s):

3.1.2.1 Tech Rep. The Contractor shall provide the services of a qualified Tech Rep who is familiar with the Cummins Onan Marine Generator Set – Model MDKAF to perform the following:

WORK ITEM 1: Advise on manufacturer's proprietary information pertinent to the system.

WORK ITEM 1: Ensure compliance with manufacturer's procedures and standards during disassembly, inspection, reassembly, and testing.

3.1.2.2 Ensure the Tech Rep has a résumé of demonstrated experience with the system/equipment stated above.

3.1.2.3 Submit a copy of the Tech Rep’s résumé and a list of references to the COR at the Arrival Conference.

3.1.3 Protective measures - general.

Not applicable.

3.1.4 Interferences.

Not applicable.

3.1.5 Tools and supplies. The Contractor shall provide all personnel, labor, materials, parts, tools (including special tooling), test equipment, test fittings, supplies, consumables, and equipment for accomplishment of tasks.

3.1.6 Parts. The Contractor shall use only new, Original Equipment Manufacturer (OEM)-approved parts for accomplishments of tasks. “Remanufactured” parts are acceptable if provided by OEM-authorized parts supplier certifying that the remanufactured parts have met the OEM-guidelines for reusability. The Contractor shall cover all core charges and ensure the cores are returned to the distributor.

3.1.7 References. The Contractor shall perform all tasking in accordance with manufacturer’s instructions, using Coast Guard TP-3973 as guidance.

3.1.8 Operational test – prior to overhaul. Prior to commencement of work, the Contractor shall witness Coast Guard Personnel perform an initial operational test of the SSDG (s), to demonstrate existing operational condition. Submit a CFR.

3.2 Overhaul guidance.

3.2.1 Disassembly and inspection. The Contractor shall disassemble, clean, and inspect the following engine components (refer to Table 1) for reuse determination.

TABLE 1 – Engine components to be inspected

Component / Part

Cylinder block (including cylinder bore and bearing saddle)

Crankshaft and associated components (bearings and connecting rods)

Main bearing housing

Generator (armature, commutator, diode pack, bearings, bearing end bell)

Fuel camshaft assembly

Flywheel

Oil pan

Fuel camshaft assembly

3.2.1.1 Upon completion of inspections, the Contractor shall provide a written report (CIR) to the Coast Guard Inspector (within 24 hours after inspection) reporting all findings. The CIR shall include (at a minimum) the following information:

· Visual condition assessment.

· All readings (clearances, tolerances, etc) recorded.

· OEM reusability specifications for inspected components.

· Recommendations for repair or renewal of inspected components

NOTE

The Contracting Officer (KO) or Contracting Specialist (KS) will provide a written response to the Contractor after receipt of the CIR regarding all authorized repair work. Work shall not proceed until this authorization is received.

3.2.2 Automatic renewal. In addition to the repairs and/or renewals authorized in paragraph 3.2.1, the Contractor shall renew the following engine components (refer to Table 2).

TABLE 2 – Engine components to be renewed

Component / Part

Cylinder head assembly (including valves, tappets, and springs, glow plugs, intake and exhaust manifold fasteners)

Engine block core plugs

Piston assemblies

Pistons

Piston ring assemblies

Connecting rod bearings

Crankshafts

Crankshaft bearings and seals, (front & rear)

Idler gear bushings

Camshaft assembly

Fuel injectors

Fuel injection nozzle assemblies

Fuel injection pump

Electric fuel pump

Lube oil pump w/suction screen

Starter 24vdc

Raw water pump

K9 relay

Stop solenoid 24vdc

Coolant pump

Thermostat and Sensor(s)

All Hoses and attachments

Oil & fuel filters

3.2.3 Heat exchanger. The Contractor shall clean, inspect, and pressure test the heat exchanger in the presence of the COR, in accordance with SFLC Std Spec 5000, Appendix C, Paragraph C2.7 (Heat exchangers and fluid coolers). Ensure no leakage from or permanent deformation of pressure-containing parts by repairing all leaks and discrepancies. Submit a CFR.

3.2.4 Reassembly. After completion of all authorized work, the Contractor shall reassemble the engine and accessories to its original configuration using new gaskets and seals.

3.3 Engine acceptance (shop break-in) testing. After reassembly, the Contractor shall accomplish the following to demonstrate satisfactory operation of the SSDG in accordance with Para 3.3.1 or 3.3.2.

NOTE

The Contractor shall provide all consumables (filters, fluids, etc) in support of acceptance testing.

3.3.1 Manufacturer’s schedule for overhauled engine (recommended). The Contractor shall thoroughly test and demonstrate, under the direction of the Tech Rep, the SSDG to be in satisfactory operating condition in accordance with manufacturer’s recommendations, as follows:

3.3.1.1 Submit a written plan to the COR (attached to a CFR) at least 48 hours prior to acceptance testing with the Contractor’s proposed plan for SSDG testing and run-in schedule for an overhauled engine. The test plan shall be based upon manufacturer’s recommended procedures and include information pertaining to parameters monitored, durations, and acceptance specifications.

NOTE

The proposed plan shall include the manufacturer’ recommended plan for run-in of a “light loaded” diesel engine and include all the elements (i.e. no load testing, incremental load testing, loads, etc) addressed in Paragraph 3.3.2.

3.3.1.2 Upon Coast Guard approval of the plan submitted in Paragraph 3.3.1.1, demonstrate satisfactory operation of the SSDG in the presence of the Coast Guard Inspector in accordance with the approved test plan. Inspect and correct any abnormal noise, vibration, leaks, or out of specification parameters. Submit a CFR documenting the results of the testing.

NOTE

All testing shall be coordinated with and performed in the presence of the CG Inspector. Coast Guard personnel will operate all machinery.

3.3.2 Coast Guard’s recommended schedule for overhauled engine. In the event the manufacturer’s schedule is not available or does not provide the details necessary to ensure proper run-in of the engine, the Contractor shall thoroughly test and demonstrate, under the direction of the Tech Rep, the SSDG to be in satisfactory operating condition in accordance with Table 1. Inspect and correct any abnormal noise, vibration, leaks, or out of specification parameters. Submit a CFR documenting the results of the testing.

TABLE 1 – Run-IN Schedule

NOTE

Step’s **4 and **12 indicate no load to cool down and then shut down.

a. Recheck all hoses & component connections/external engine.

b. Check and adjust all valve settings.

c. Re-torque cylinder head bolts per Mfg specifications.

The use of a load bank will be required in support of load testing. Load banks shall be provided by the Contractor.

3.3.2.1 During performance of testing, monitor all engine parameters for signs of misalignment or overheating (i.e. abnormal noises, vibrations, pressures, and temperatures). If any unusual readings are experienced, immediately secure the engine and troubleshoot to determine the cause

3.3.2.2 Obtain oil samples prior to operation (Step 1), prior to applying load (Step 9), and upon completion of successful load testing (Step 16). Submit all oil samples for lab analysis of wear particles.

3.3.2.3 Record all engine and generator parameters on a log sheet for each Run-In Schedule step (Steps 1 thru 5) and every 15 minutes after (Steps 6 thru 16).

NOTE

In the event testing cannot be completed in a single day, the run-in may be continued the following day if necessary. Operate the engine until all temperatures are stabilized (consistent with the last recorded readings) and continue the run-in. Annotate the log sheet to indicate test resumption.

3.4 Engine preparation. After engine acceptance, the Contractor shall accomplish the following to prepare the engine for shipment.

3.4.1 Touch-up preservation, general. Prepare and coat all new and disturbed engine surfaces, as applicable, to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.)

3.4.2 Fluids. Drain and dispose of all fluids in accordance with federal, state, and local regulations.

3.4.3 System cleanliness protection. Take all necessary precautions to prevent the introduction of contaminants. Piping systems interface points shall be sealed with commercial grade plastic or metallic caps, plastic or metallic plugs, mating blanked covers, or with blank flanges attached with bolts. Plastic bags and duct tape are not acceptable.

3.4.4 Wrapping. The engine shall be shrink-wrapped in 6 mil or heavier polyethylene sheeting or otherwise covered and sealed to prevent water damage. To prevent adhesion between protective coverings and painted surfaces, protective coverings shall not be applied until the paint has cured (if applicable).

3.4.5 Crating. The wrapped engine shall be placed in a sturdy wooden shipping crate with the skid securely anchored to the crate bottom with bolts or lag screws. The crate shall be designed for movement with a forklift.

3.4.6 Transportation. The Contractor shall Transport the gen-sets to the contractor overhaul facility. Upon completion of work, the Contractor shall transport the gen-sets back to the cutter.

3.5 Documentation. The Contractor shall submit a CFR that provides an itemized list of all new and remanufactured parts used in support of overhaul. This shall include OEM part names and part numbers for configuration management tracking.

3.6 Operational test – post installation. After completion of installation, the Contractor shall be present to witness Coast Guard operational testing onboard the vessel. The equipment will be operated through its full range of capabilities in all configurations and operating modes (including maximum available loading using ship’s load). Submit a CFR.

4. NOTES

This section is not applicable to this work item.