Attachment_2_FIR_CAT_Ovhl_SOW_19OCT2017.docx

DOCX document 102 KB Posted

Attached to
CGC_FIR-ENGINE_OVERHUAL
Solicitation number
70Z08518QP4500800
Issued by

About this file

Spec SOW CGC FIR engine overhaul

View the file

Other files

File Type Posted
Amendment_A0001_CGC_BARBARA_MABRITY_ENGINE_OVERHAUL.pdf PDF
Solicitation_70Z08518QP4500800.doc DOC document
Attachment_3_Past_Performance_Information_Form__FIR.doc DOC document
Attachement_1_FIR_BLANK_SOS_FY17.xlsx XLSX spreadsheet
Attachment_4_Request_for_Clarification.docx DOCX document
Attachment_5_Ombudsman.docx DOCX document

On GovTribe

Work with this file

  • Download the original file
  • Contacts named in this file
  • Similar government files
  • Ask GovTribe AI about this file

Text version

WLB 225’ SEA GOING BUOY TENDER ENGINE OVERHAUL

SPECIFICATION FOR DOCKSIDE MAINTENANCE

FY2017

Developed By: LCDR George Fulenwider (Rev-0 13 February 2017)

TABLE OF CONTENTS

Revisions Recordiii
Consolidated List of Referencesiv
Consolidated List of Government-furnished Propertyv
Consolidated List of Critical Inspection Itemsvi
Principal Characteristicsvii
General Requirements8
WORK ITEM 1: Ships Service Diesel Generator Center Section Overhaul, Main Diesel Engine Top End Overhaul13

USCG WLB 225 ENGINE OVERHAUL DOCKSIDE MAINTENANCE 2018

ii
(Rev-1)

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.

DATE
REV#
WORK ITEM#
CHANGES MADE

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.

USCG CATERPILLAR ENGINE OVERHAUL DOCKSIDE MAINTENANCE 2017

iii
(Rev-1)

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 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

Caterpillar Marine Model D3508, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance Caterpillar Guidelines for Reusability, “Index of Publications on Reusability or Salvage of Used Parts”, Caterpillar Publication SEBF8029 (series)

USCG CATERPILLAR ENGINE OVERHAUL DOCKSIDE MAINTENANCE 2017

iv
(Rev-1)

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.

None

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)):

Work Item
Title Main Diesel Engines, #2 SSDG Center Section Overhaul, #2 MDE Top End Overhaul

3.1.1 Disassemble, Clean, Inspect, Repair or Renew and Reassemble Engine Units and Accessories.

Principal Characteristics

225' WLB (A-CLASS)

Physical

Length overall
225' 0"
Length between perpendiculars
206' 0"
Maximum beam
46'
Designed draft
13' 0"
Full load displacement
1905.6 Long Tons SW
Light ship displacement
1500.7 Long Tons SW
Minimum operating displacement
1869.2 Long Tons SW
Mast height (above 12' waterline)
67' 5"
Anchor
Two 4000 lb standard Navy stockless anchors, 8 shots each, port and starboard, 1-3/8 die lock chain

Hull

Bilge keels (port & starboard)
Frames 42-79

Frame spacing

FR 0 to 12
21"
FR 12 to 30
22"
FR 30 to 102
24"

Machinery

Main propulsion
Diesel Reduction
Diesel engines
Two Caterpillar 3608, TA, 3100 BHP each @ 900 RPM
Number of propellers
1
Number of blades
4
Diameter
10'
Pitch
Controllable
RPM
254
Ship's service diesel generators
Two Caterpillar 3508 TA, 450 KW
Emergency diesel generator
One Caterpillar 3406 DITA, 280 KW
Shore tie
Two 450 VAC, 400 Amp, 3-wire
Shaft bearing, forward
Cooper Bearing 01-BCP-1400-EX-TL
Shaft bearing, aft
Water Lubricated Cutless Bearing

Tank CAPACITIES

Diesel oil
76,498 gal.
Fresh water capacity
8056 gal.
Hydraulic oil capacity
2785 gal.
Lube oil storage
764 gal.
Grey water tank
2700 gal.
Sewage holding tank
1700 gal.

USCG ENGINE OVERHAUL DOCKSIDE MAINTENANCE 2018

19
(Rev-1)

00000_1215_FLT

REC_00000_FLT_Commercial Project @ CG Facility (1212) 00000_CAT Engine Ovhl IDIQ_MWC_0116_IBCT General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for accomplishment of tasks specified in this specification by commercial contractors at various geographically dispersed Coast Guard facilities for Coast Guard vessels in the continental United States and in OCONUS states and territories.

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 Caterpillar Marine Model D3508, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance Caterpillar Marine Model D3608, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance Caterpillar Guidelines for Reusability, “Index of Publications on Reusability or Salvage of Used Parts”, Caterpillar Publication SEBF8029 (series)

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 Personnel.

3.2.1 Tech Rep. The Contractor shall provide the services of a Tech Rep or equivalent, who is familiar with the Caterpillar marine diesel engine models listed in Para 3.3.4, to accomplish the following tasks :

· Accessing Original Equipment Manufacturer (OEM) proprietary information, software, and tools pertinent to tasking in accordance with the specification.

· Execute proper repair methods, with minimal Coast Guard assistance and ensuring compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

· Generating a Computer Aided Marine Performance Analysis Report (CAMPAR) with the diagnostic test data and recommendations for the diesel engines.

· Conducting Marine Engine Performance diagnostic testing (CAMPAR or load bank testing), ensuring compliance with OEM, U.S. Coast Guard, OSHA, and other pertinent procedures and standards.

· Providing genuine, OEM-approved parts or equivalent

3.2.1.1 Ensure that the Tech Rep is a Certified Representative of Caterpillar, Inc. or equivalent.

3.2.1.2 Ensure that Tech Rep is certified and authorized by Caterpillar or equivalent to perform work on the applicable Caterpillar model marine diesel engine.

3.2.2 Employee identification and access. At least seventy two (72) hours prior to each ship visit to perform work under this contract, the Contractor shall submit a list of all employees who shall be performing that work to the specific overhaul project COR. To gain access to the ship or other Government facilities to perform any work under this contract, each Contractor employee shall carry a picture identification card furnished by the Contractor, or other servicing agent authorized by the Contractor/Manufacturer. The employee shall prominently display this card on their person in the chest area at all times when on any Government facility, except when actively engaged in labor wherein the card might get caught in tools or operating machinery and represent a hazard to the employee.

3.2.3 Security clearances. Special security clearances are normally not required to perform any work under this contract. The Contractor shall supply a list of all employees who may be required to perform work and periodically update that list. Prior to each ship visit to perform work, the Contractor shall submit information on visiting employees. In event the cutter be berthed at a Department of Defense or foreign government military facility, the KO will provide instructions on the method by which the cutter crew will assist the Contractor’s representatives in meeting facility access requirements at the time the Contractor is tasked.

3.3 Scope of work.

3.3.1 Work. The Contractor shall provide all personnel, labor, materials, parts, tools (standard and special), test equipment, test fittings, supplies, consumables, and equipment required to accomplish tasking in accordance with the scope of work.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment, perform electrical tag-outs in support of maintenance, and be available to advise on rigging safety procedures as necessary. All other labor associated with maintenance tasks (i.e. rigging, parts delivery, repairs, etc) shall be provided by the Contractor.

3.3.2 Travel. The Contractor shall provide all travel necessary to support tasks onboard the vessel at the vessel’s homeport.

3.3.3 Engine parts.

3.3.3.1 New parts. The Contractor shall use only new, OEM-approved parts or equivalent for accomplishments of tasks.

3.3.3.2 Reused parts. The Contractor shall ensure all parts qualified for “reuse” meet the reusability guidelines specified in the appropriate documents listed in the latest published version of Caterpillar Publication SEBF8029 “Index of Publications on Reusability or Salvage of Used Parts”.

3.3.4 Engine applicability. The Contractor shall be advised that tasking will include work associated with the following Caterpillar® engine models (serial number prefixes included in parenthesis):

· D3508 #2 SSDG Center Section Overhaul Serial Number *BAG00017, Arrangement Number 180-0452.

· D3608 #2 MDE Top End Overhaul Serial Number *8LL00026, Arrangement Number 109-3839.

3.4 Documentation.

3.4.1 Inspections. For visual inspections and condition assessments (i.e. pass/fail) during the requested overhaul, the use of digital pictures attesting to condition of components inspected is required. These, in conjunction with a narrative, will be used to document acceptability. Visual inspections shall be accomplished using the following guidelines and included in all CFR submissions:

· OEM’s relevant guidance and reference documents for inspection and assessment shall be utilized and referenced accordingly (including Publication Number, Publication Date, and Title). For Caterpillar applications, this would include the appropriate documents listed in the latest published version of Caterpillar Media SEBF8029 “Index of Publications on Reusability or Salvage of Used Parts”.

· List of all instruments (make and model) of equipment used in support.

· List of all parts and components inspected, including part numbers and serial numbers (as applicable) for machinery history and configuration tracking purposes.

· All readings and measurements (clearances, tolerances, etc) recorded and used in support of OEM-reusability determinations.

· Recommendations for re-use, replacement, repair, or renewal of inspected components per OEM-reusability guidelines.

3.4.2 Parts list. Upon completion of work, the Contractor shall submit an itemized parts list (including part number information and nomenclature) detailing any parts replaced during overhaul. This list shall be attached to a CFR.

3.5 Compliance. All work shall meet the requirements of this work specification. The inspections set forth shall become part of the Contractor's overall Inspection System or Quality Program. The absence of any inspection requirements shall not relieve the Contractor of the responsibility of ensuring that all work submitted to the Government for acceptance complies with all requirements of the contract.

3.5.1 Noncompliance. If any work fails to pass a test or inspection, the Contractor shall take action to correct the work.

3.6 Acceptance. Acceptance of the work shall be discontinued until corrective actions, acceptable to the Government, have been taken. After taking corrective action, repeat the inspection on the corrected work.

3.7 Final acceptance. Final acceptance shall be withheld until re-inspection shows the corrective action to be successful. In the event of failure after re-inspection, the Contractor shall submit to the Coast Guard Inspector a written report concerning the failure with recommended corrective actions.

3.8 Conformance. Quality conformance tests and inspections shall be the minimum test and inspection methods used to demonstrate compliance to the requirements set forth in this work specification.

3.9 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:

· 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.

3.10 Preservation requirements. The Contractor shall accomplish all preservation tasks, including touch-ups of affected engine components, in accordance with SFLC Std Spec 6310. All new parts replaced shall be preserved in accordance with OEM-standards (i.e. new blocks, cylinder heads, etc).

3.11 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740.

3.12 Environmental protection requirements. The Contractor shall adhere to the following environmental protection requirements in accordance with the SFLC Std Spec 0000:

3.12.1 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.

3.12.2 HW disposal. The 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).

3.13 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:

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

3.13.1.1 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%".

3.13.1.2 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”

3.13.2 SFLC Standard Specification 0000 General Requirements.

3.13.2 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.”

3.14 Rigging. Contractor is responsible for rigging all machinery parts on and off the vessel. Assistance with rigging engine parts on and off vessel, or use of buoy deck for temporary tool and parts storage must be confirmed with vessel at least seventy two (72) hours prior to start of contract or the Friday before the contract start date.

4. NOTES

4.1 Access to COMDTINST M10360.3. The COMDTINST M10360.3 may be accessed at the following URL address: http://www.uscg.mil/directives/cim.asp

00000_0116_FLT

00000_CAT Engine Ovhl IDIQ_PJM_0116_IBCT WORK ITEM 1: Ships Service Diesel Generator Center Section Overhaul, Main Diesel Engine Top End Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to disassemble, clean, inspect, repair and reassemble (Center Section Overhaul) Caterpillar Diesel Engine Units and Accessories, to include engine models D3508 and D3608 Marine Diesel Engine and provide genuine CAT OEM approved parts or equivalent as necessary for repairs aboard WLB.

Table 1 – Generator Data

Quantity
Characteristics
Manufacturer
Location
1
#2 SSDG Center Section Overhaul Serial Number *BAG00017, Arrangement Number 180-0452
Caterpillar 3508 Type Engine
Engine Room
1
#2 MDE Top End Overhaul

Serial Number *8LL00026, Arrangement Number 109-3839

Caterpillar 3608 Type Engine
Engine Room

1.2 Government-furnished property.

None

2. REFERNCES

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 Caterpillar® Marine Model D3508, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance Guidelines for “Index of Publications on Reusability or Salvage of Used Parts”, Publication, SEBF8029 (series).

3. REQUIREMENTS

3.1 General. The Contractor shall provide all parts, labor, tools required which includes but is not limited to (standard tools/special tools/Test Equipment/Consumables). Additionally, Contractor shall cover all core charges and ensure cores are returned to distributor.

NOTE

The Contracting Officer (KO) will identify the engine serial and arrangement numbers of engine units and accessories to be completed under this contract.

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

· 3.3 (Engine component cleaning and inspections).

3.1.2 Protective measures.

3.1.2.1 Ensure protective measures are in place IAW General Requirements,

3.1.3 Interferences.

3.1.3.1 Contractor shall be responsible for reinstalling all interferences.

3.1.3.2 Contractor shall be responsible for rigging engine parts into and out of vessel. CG assistance provided at discretion of each vessel’s command.

3.1.4 References. The Contractor/technicians shall disassemble, clean, inspect, repair or renew and reassemble the Caterpillar engine units and accessories in accordance with the references listed in Section 2 herein.

3.1.5 Authority to proceed. The Contractor/technicians shall not proceed with any additional growth work on the engine units or accessories described in this specification, until specific instructions are given by the KO on what additional work is to be accomplished.

NOTE

The Contracting Officer (KO) will provide a written response to the Contractor, after receipt of the CIR, regarding all work to be completed for repairs. Work may not proceed until this authorization is received.

3.1.6 Responsibility for inspection. The Contractor/technicians shall be responsible for all inspections and test requirements specified herein. The Contractor shall provide the necessary calibrated test equipment to conduct all of the inspection requirements. Be aware that the Government reserves the right to verify or perform any of the inspections or tests set forth in this specification where such inspections are deemed necessary to assure that supplies or services conform to the prescribed requirements.

3.2 Operational test – initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of the Caterpillar Engine to demonstrate existing operational condition. Submit a CFR documenting operational condition of engine.

3.2.1 Operational test – initial – Center Section Overhaul When conducting a CSO, submit CFR to include web deflection readings and thrust measurements of engine in pre-overhaul condition

3.3 Clean and Inspect Engine Components. The Contractor shall disassemble, clean, inspect and test the engine components listed below, (Refer to Table 1) utilizing the appropriate publications as outlined in Section 2 as guidance. Provide a CIR/CFR of these components to the KO for potential reuse determination.

Table 1 - Engine Components to be disassembled, cleaned, inspected or tested during the performance of a Top End/Center Section Overhaul

TOP END
CENTER SECTION (includes Top End)
Aftercooler
Camshaft
Exhaust Manifold
Camshaft Lifters
Rocker Shaft Assembly and Push Rods
Crankshaft
Turbocharger Housing and any other components not renewed in Table 2.
Crankshaft Vibration Damper (all models except 3608)
Water Manifold
Cylinder Block
Jacket Water Pump
Driven Equipment (alignment)
Salt Water Pump
Engine Mounts
Heat Exchanger – All.
Flywheel
Cylinder Head Spacer Plate (3508 only)
Front Gear Train (Gears)
Governor Fuel Linkage
Oil Cooler Core
Oil Supply Lines
Oil Suction Screen

Rear Gear Train (Gears)

Spacer Plates

3.3.1 Report. The Contractor shall record the appropriate inspection findings on a CFR (clearance and tolerance readings of the cylinder block and related components). Submit a written report of all findings and recommendations to the Coast Guard Inspector (CGI) and COR within 24 hours after inspection.

3.3.2 Government’s right for furnishing various components and parts. The Contractor shall be aware that the Government reserves the right, to furnish new or rebuilt components or parts for installation, in place of the existing parts, at no additional cost to the Government. If the Government exercises this right, the Contractor shall turn over all existing components or parts to the CGI or COR as Mandatory Turn-In (MTI) items.

3.4 Automatic renewal. The Contractor shall perform the following engine component renewals with genuine, remanufactured (or new) OEM components or equivalent, (Refer to Table 2).

Table 2 - Engine Components to be disassembled and automatically renewed during the performance of a Top End/Center Section Overhaul

TOP END
CENTER SECTION (includes Top End)
Complete Cylinder Head Assemblies
Camshaft Bearings
Cylinder Head Gaskets and Seals
Connecting Rod Bearings and Hardware (bolt and caps)
Inlet Air Line Seals
Crankshaft Seals
Turbocharger Bearings, Bushings and Seals
Crankshaft Thrust Plates
Valve Lubricator (If Equipped)
Exhaust Manifold (Seals and Bellows)
Water Pump Bearings and Seals
Fuel Injection Pumps
Water Temperature Regulators /thermostats and Seals
Fuel Transfer Pump
Fuel Injectors
Gear Train Bushings
Turbocharger Cartridge
Inlet Manifold (Gaskets and Seals)
Head Studs
Jacket Water Pump
Fuel System (Primary and secondary filters)
Lubricating Oil Pump
Air Filters
Main Bearings
Valve and injector Lifters (3608 ONLY)
Piston rings

Sea Water Pump

Software (Install new software when a new ECM is installed)

Front Gear Trains (Gears)

Rear Gear Trains (Gears)

Crankshaft Vibration Damper (3608 model engine ) including hardware

Lifter Roller Assemblies

Connecting Rods

Cylinder Liners

Piston Assembly

Crankshaft Counterweights hardware (bolts)

Spacer Plates

3.5 Discretionary renewal. If a modification has been authorized and released by the KO, the Contractor shall renew the specified engine components with genuine, remanufactured (or new) OEM components. (Refer to Table 3).

3.5.1 Exceptional Circumstances. If the Coast Guard or the servicing element determines a long block or short block is required to return the ship to operational condition, the KO may authorize the contractor to complete repairs utilizing a long block or short block vice in place overhaul of engine. KO may authorize assembly of long block offsite to accomplish repair.

Table 3 - Engine Components to be renewed upon inspection and with KO authorization

TOP END
CENTER SECTION (includes Top End)
Aftercooler
Crankshaft
Exhaust Manifold
Camshaft
Rocker Shaft Assembly and Push Rods
Cylinder Block
Turbocharger
Driven Equipment (alignment)
Water Manifold
Engine Mounts (Caterpillar)

Flywheel

Oil Cooler Core

Oil Suction Screen

Governor (Overhaul by authorized governor dealer)

Table 4 - Optional Services to BE completed during an engine overhaul with KO Authorization Optional Services

Machining of Engine Block

Cooler Clean

Line bore

Renew Long Block

3.6 Gaskets and seal. The Contractor shall furnish and renew all gaskets and seals (consumables) associated with the engine reassembly in this contract.

3.7 Fluids and Filters. The Contractor shall furnish and renew all fluids and filters associated with the engine reassembly. Contractor will be advised of Coast Guard desired engine oil preference prior to arrival conference.

3.8 Reassemble Engine Units and Accessories. After any authorized repairs and renewals, the authorized Caterpillar Contractor/technician’s shall reassemble the engine units and accessories to its original configuration utilizing the appropriate publications as outlined in Section 2.1 as guidance.

3.8.1 Alignment Check. Contractor shall perform alignment check post engine to include but not limited to SSDG generator decoupling, engine mount repair, rear gear work, or disconnecting engine from shaft and/ or red gear 3..9 Operational testing – post overhaul.

NOTE

The USCG considers the testing below to be separate testing evolutions. The Contractor and Ship’s Force should coordinate scheduling of the three to ensure optimum use of schedule.

3.9.1 Operational "light-off" test. After completion of work, the Contractor shall witness an operational "light-off" test (by Coast Guard personnel) of the diesel engine unit and accessories to prove satisfactory operating condition.

3.9.2 Engine break-in. Upon successful completion of operational "light-off testing", the Contractor shall conduct an engine test run (break-in), under various loads, in accordance with applicable Caterpillar and Coast Guard standards. This is to ensure all internal engine components have been properly tested (seating of piston rings, proper oil flow to internal parts, temperatures) and any discrepancies are resolved. The contractor shall provide and utilize an external load bank to accomplish the proper engine break-in

3.9.2.1 For MDEs, this will include both pier-side and underway testing to ensure proper engine break-in.

3.9.2.2 For SSDGs and EDGs, the Contractor shall provide and utilize an external load bank to accomplish the proper engine break-in.

3.9.3 Computer Aided Marine Performance Analysis Report (CAMPAR) testing. Upon successful operational testing and engine break-in, the Contractor shall perform a CAMPAR diagnostic test for the engine in accordance with Caterpillar’s instructions. The CAMPAR testing shall include all data points required by the CAMPAR program and includes the installation of external meters and gauges in support. The Contractor shall provide all diagnostic equipment, test fittings, test measurement devices, and any additional tooling required in support of CAMPAR testing (Refer to General Requirements – Paragraph 3.3.1 “Work”).

NOTES

1. The intent of the CAMPAR testing is to establish overall condition of the engine “post-overhaul” in support of engine performance-tracking initiatives. CAMPAR testing shall be conducted in accordance with Caterpillar standards and include all data elements recorded on the complete program (i.e. fuel rates, boost pressures, etc).

2. Historically, the CAMPAR test results provided to the USCG have omitted specifications (i.e. acceptable data ranges for recorded parameters, units of measure, and recorded data). Contractor shall annotate the submitted test data as necessary to provide this information.

3. Ship’s Force may assist in data collection efforts as requested by the Contractor. Additionally, data collection can be accomplished using installed ship’s instrumentation (i.e. local meters, gauges, MPCMS displays, etc) provided locations are in agreement with PAR testing requirements. The Contractor shall be aware that all PAR testing locations are not monitored by the USCG and will require the Contractor to install additional gauges and/or meters (and associated test fittings) to accomplish tasking.

3.9.4 Adjustments. Based on the results of the operational testing, perform any additional adjustments (or readjustments) as required to ensure proper operation of the engine.

3.9.5 Testing data submittal. Upon completion of testing, the Contractor shall submit (as attachment to CFR) all data recorded during testing. This shall include the following:

· .Operational logs during engine break-in

· Complete CAMPAR report, including fuel demand curves and findings

4. NOTES

4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests.

4.2 Coast Guard Inspector responsibilities. Although the Contractor is responsible for applying appropriate quality assurance measures, the Coast Guard will witness the accomplishment of these measures. Therefore, a Coast Guard Inspector will:

4.2.1 Monitor the assigned work items to keep informed of progress and to ensure that the specifications are being followed.

4.2.2 Witness all test as required by the specification.

4.2.3 Be guided by the work item and seek immediate clarification when necessary.

4.2.4 Immediately bring to the attention of the Contracting Officer any work which appears to be contrary to the work item requirements.

4.2.5 Document all work performed in the Machinery History Log.

4.2.6 Ship’s force is responsible for post-overhaul verifications per Coast Guard instructions.

NOTE

When there is overwhelming documentation to record. The Engineer Officer/Engineer Petty officer may state in the Machinery History Log, “All overhaul documentation is located (indicate where) for reference.

4.3 Definitions.

4.3.1 Tools - Common tools normally contained in a standard toolbox (screwdrivers, wrenches, pliers) etc.

4.3.2 Special Tools/Test Equipment - Such as torque wrenches, calibrated electronic meters, computer devices etc not normally found in a standard toolbox.

4.3.3 Consumables - A non-reusable item such as a rag, disposable gloves, paint, oil, grease, solvent, adhesive, sealant, corrosion preventive product, cleaner, jacket water, etc.

image1.jpeg

File details come from the government source that posted it. Updated .