Attachment_1_Work_Specification_PAMLICO_CAT_3304_CSO_BSSDG_REV0_FY19.pdf

CATERPILLAR® ENGINE OVERHAUL

SPECIFICATION FOR DOCKSIDE MAINTENANCE

FY2019

(Rev-0)

USCGC PAMLICO CATERPILLAR ENGINE OVERHAUL DOCKSIDE MAINTENANCE 2019

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property Consolidated List of Critical Inspection Items Principal Characteristics .............................................................................. Error! Bookmark not defined.

General Requirements WORK ITEM 1: Ships Service Diesel Engines, Center Section Overhaul

USCG PAMLICO CATERPILLAR ENGINE OVERHAUL DOCKSIDE MAINTENANCE 2019

iii (Rev-0)

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.

iv (Rev-0)

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 D3304B, 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) http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace

5 (Rev-0)

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

6 (Rev-0)

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 Ships Service Diesel Engines, Center Section Overhaul

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

Accessories.

7 (Rev-0)

PRINCIPAL CHARACTERISTICS - TENDER

75’ WLR (E-CLASS: CGC PAMLICO), INLAND RIVER BUOY TENDER

PHYSICAL

Length overall 75' 5-1/2"

Depth 7' 8-1/2"

Maximum beam 22' 5"

Height of highest projection N/A

Full load draft 4' 0” LCF Draft

Full load displacement 118.15 Long Tons Fresh Water

Shore tie voltage requirements N/A

Frame spacing 1' 6"

MACHINERY

Number of propellers 2

Number of blades 4

Diameter of propeller 48"

Pitch 43" fixed

RPM 410

8 (Rev-0)

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 D3304B, 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.

9 (Rev-0)

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 Caterpillar Tech Rep. The Contractor shall provide the services of a certified Tech Rep, 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

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

3.2.1.2 Ensure that Tech Rep is certified and authorized by Caterpillar 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.

10 (Rev-0)

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 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):

(#1 SSDG D3304B Serial Number 83Z11292 Arrangement Number 1W3874)

(#2 SSDG D3304B Serial Number 83Z11293 Arrangement Number 1W3874)

NOTE

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

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.

11 (Rev-0)

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.

12 (Rev-0)

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”

3.13.1.3 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’.

3.13.1.4 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)".

3.13.2 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 http://www.uscg.mil/directives/cim.asp

13 (Rev-0)

00000_0116_FLT

00000_CAT Engine Ovhl IDIQ_PJM_0116_IBCT

WORK ITEM 1: #1 Ships Service Diesel Engines, Center Section 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 D3304 Marine Diesel Engine and provide genuine CAT OEM approved parts as necessary for repairs aboard WLB.

TABLE 1 – GENERATOR DATA

QUANTITY CHARACTERISTICS MANUFACTURER LOCATION

#1 SSDG Center Section Overhaul

Serial Number *83Z11292, Arrangement Number 1W3874

Caterpillar 3304 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 D3304B, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance

14 (Rev-0)

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.

15 (Rev-0)

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 (3304B 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, (Refer to Table 2).

16 (Rev-0)

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 Dampner (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 determine 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.

17 (Rev-0)

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.

18 (Rev-0)

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.

19 (Rev-0)

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.

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WORK ITEM 2: #2 Ships Service Diesel Engines, Center Section 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 D3304BB Marine Diesel Engine and provide genuine CAT OEM approved parts as necessary for repairs aboard WLB.

TABLE 1 – GENERATOR DATA

QUANTITY CHARACTERISTICS MANUFACTURER LOCATION

#2 SSDG Center Section Overhaul

Serial Number *83Z11293, Arrangement Number 1W3874

Caterpillar 3304 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 D3304B, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance

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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.

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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 (3304B 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, (Refer to Table 2).

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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 Dampner (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 determine 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.

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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.

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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.

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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.