J2 STATEMENT OF WORK MACKINAW CAT.pdf

USCGC MACKINAW (WLBB 30)

SPECIFICATION FOR MAINTENANCE AND SUPPORT OF THE MAIN PROPULSION/AUX

DIESEL ENGINE AND GENERATOR

Developed By: LT Michael Dougall

(Rev-0, 16 October 2023) ii (Rev-0)

USCGC MACKINAW (WLBB-30) MAINTENANCE AND SUPPORT OF THE MAIN

PROPULSION/AUX DIESEL ENGINE AND GENERATOR

TABLE OF CONTENTS

Revisions Record ....................................................................................................................................... iii Consolidated List of References ................................................................................................................ iv Consolidated List of Government-furnished Property .............................................................................. vi Consolidated List of Critical Inspection Items ......................................................................................... vii Principal Characteristics .......................................................................................................................... viii General Requirements WORK ITEM 1: Maintenance and Support Service for the Main Diesel Engine and Generator - Annual WORK ITEM 2: Maintenance and Support Service for the Main Diesel Engine and Generator - Periodic WORK ITEM 3: Main Diesel Engine Overhaul (Top End and Major) WORK ITEM 4: Maintenance and Support Service for the Auxiliary Diesel Engine and Generator - Annual WORK ITEM 5: Maintenance and Support Service for the Auxiliary Diesel Engine and Generator - Periodic WORK ITEM 6: Auxiliary Diesel Engine Overhaul (Top End and Major) WORK ITEM 7: Provide Technical Remote or On-Site Support and Diagnostics 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

• Surface Forces Logistics Center Standard Specifications: https://www.dcms.uscg.mil/Our- Organization/Assistant-Commandant-for-Engineering-Logistics-CG-4-/Logistic-Centers/Surface-Forces- Logistics-Center/Contracting-Links/Standard-Specifications/

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

Coast Guard Drawing 240 WLBB 180-310, Rev A, Emergency Aux Generator Foundation A&D DWG Coast Guard Drawing 240 WLBB 201-001, Rev E, Machinery Spaces Arrangement Coast Guard Drawing 240 WLBB 201-002, Rev B, Equipment Access and Removal Plan Coast Guard Drawing 240 WLBB 202-001, Rev F, Mchry Plant Control and Monitoring System Block & Deck Plan Coast Guard Drawing 240 WLBB 235-001, Rev A, Propulsion Generator Installation Drawing Coast Guard Drawing 240 WLBB 256-001, Rev D, Main Engine Freshwater Cooling System Diagram Coast Guard Drawing 240 WLBB 256-003, Rev B, Main Engine Cooling System A/D

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3D, Jan 2014, Coatings and Color Manual Coast Guard Technical Publication (TP) 3813, SWBS 312A, Apr 2005, Emergency Diesel Generator – Model Coast Guard Technical Publication (TP) 3814, SWBS 312A, Nov 2006, Emergency Diesel Generator – Engine Parts Coast Guard Technical Publication (TP) 3815, SWBS 312A, Nov 2009, Emergency Diesel Generator – Generator Parts Coast Guard Technical Publication (TP) 3858, SWBS 235A, Dec 2006, Main Diesel Generator – Engine Service Coast Guard Technical Publication (TP) 3859, SWBS 235A, Dec 2006, Main Diesel Generator – Monitoring System and Drawing http://www.assistdocs.com/search/search_basic.cfm http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.techstreet.com/ http://www.nfpa.org/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace http://shopping.netsuite.com/sspcmarketplace v (Rev-0)

Coast Guard Technical Publication (TP) 3860, SWBS 235A, Dec 2006, Main Diesel Generator – Engine Parts Coast Guard Technical Publication (TP) 3861, SWBS 235A, Feb 2009, Main Diesel Generator – Generator Service and Parts – Model AA2741700 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

OTHER REFERENCES

ASTM International (ASTM) D4417, 2003, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department of Transportation Commercial Item Description (CID) A-A-59316, Nov 2003, Abrasive Materials for Blasting MIL-A-22262, Mar 1996, Abrasive Blasting Media Ship Hull Blast Cleaning NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), May 1997, Requirements for Fabrication, Welding, and Inspection of Submarine Structure The Society for Protective Coatings (SSPC) VIS 1, 2004, Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning vi (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.

This section is not applicable to this package.

vii (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_STD, paragraph

3.2.6.5 (Inspection report particulars)):

Work Item Title 3 Main Diesel Engine Overhaul (Top End and Major) 6 Auxiliary Diesel Engine Overhaul (Top End and Major) viii (Rev-0)

PC_240_WLBB_1011

Principal Characteristics

240' WLBB (30 CGC MACKINAW)

PHYSICAL CHARACTERISTICS

Length Overall 240’ 0” Depth (main deck at side to baseline) 24' 0" Maximum Beam 58’ 0” Height of Highest Projection (above DWL) 95' 6" Full Load Draft 16’ 0” Full Load Displacement (Icebreaking) 3426.73 LT Freshwater Shore Tie Voltage Requirements 1,200 Amp total

3EA 400A 450VAC 3PH

Ungrounded forward/aft stations

HULL CHARACTERISTICS

Frame Spacing FR 19-25 = 19"

FR 33-39 = 21"

ALL Else = 20"

MACHINERY CHARACTERISTICS

Number of Propellers 2 Number of Blades per Propeller 4

Diameter of Propeller 10.25' Pitch 96.98" Revolutions per Minute (RPM) 226 rated 270 max Shafting/Propulsion System Azipod

TANK CAPACITIES

Diesel Oil 115,538 gallons Fresh Water Capacity 27,948 gallons Hydraulic Oil Capacity 696 gallons Lube Oil Storage 1,159 gallons Grey Water Tank 27, 080 gallons Sewage Holding Tank 5,313 gallons

1 (Rev-0)

00000_PWB_1111_FLT REC_0000_FLT_ Commercial Project @ CG Facility (0211)

General Requirements

1. SCOPE

1.1 Intent. This item describes the general requirements to be followed by the Contractor while conducting tasks specified in this specification.

2. REFERENCES

2.1 COAST GUARD DRAWINGS

None.

2.2 COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3D, Jan 2014, Coatings and Color

Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General

Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and

Allied Processes

2.3 OTHER REFERENCES

Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety

Administration, Department of Transportation

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 also to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.2 Work. The Contractor shall provide all qualified personnel, labor, materials, parts, tools, test equipment, test fittings, supplies, consumables, and equipment required to maintain and support the main propulsion/auxiliary diesel engines, generator, and controls as defined in this specification.

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.

2 (Rev-0)

3.2.1 Travel. The Contractor shall provide all travel to support tasks onboard the vessel at the vessel’s homeport (Cheboygan, MI), for Work Item One (Maintenance and Support Services for the Main Diesel Engine and Generator – Annual) and Work Item Four (Maintenance and Support Service for the Auxiliary Diesel Engine and Generator – Annual). As such Work Items One and Four should incorporate travel and per diem. All other Work Items under this specification should only include per diem, if additional travel is required outside the annual groom period specified by the KO the Contractor shall submit a CFR/CR.

3.2.2 Parts. The Contractor shall use only Original Equipment Manufacturer (OEM)-approved parts for all work.

3.2.3 System and equipment information. The following are the core system components and shall be referred to as “system” throughout the body of this specification.

• Main Diesel Engine (MDE): Caterpillar Model 3612 - Direct Injected, Turbocharged, Aftercooled (DITA) (3 each)

• Main Generator: KATO Model 3130 KW (3 each)

• Generator Monitoring System (GMS): Caterpillar Model 3612 generator set (3 each)

• Auxiliary Diesel Generator (ADG) Engine: Caterpillar Model 3508 - Direct Injected, Turbocharged, Aftercooled (DITA) (1 each)

• Auxiliary Diesel Generator: KATO Model 750 KW (1 each)

• Generator Monitoring System (GMS): Caterpillar Model 3508 generator set (1 each)

3.3 Contractor qualifications. The Contractor shall provide qualified personnel to perform all contract work and services within specified time frames. Qualification requirements are as follow:

3.3.1 The Contractor shall provide a Caterpillar certified Tech Rep knowledgeable and competent with performance of mechanical and electrical tasks / troubleshooting for the Caterpillar Model 3612 and 3508 diesel engines and ancillary support equipment to accomplish the following tasks – on site:

• Ensure proper repair methods and compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

• Conduct Marine Engine Performance diagnostic testing (CAMPAR or load bank testing), ensuring compliance with manufacturer's, U.S. Coast Guard, and other pertinent procedures and standards.

• Generate a Computer Aided Marine Performance Analysis Report (CAMPAR) with the diagnostic test data and recommendations for the diesel engines. (Reports shall be submitted to COR within 90 days of test completion).

• Provide genuine, OEM-approved parts

3.3.2 Contractor’s personnel in training. The Contractor may not use trainees to perform any of the required services unless each trainee performs all work under the close supervision of a technical representative. At least a (1:1) technical representative to trainee ratio shall be strictly

3 (Rev-0) maintained. The full cost associated with trainee efforts shall be funded by the Contractor and shall not be charged to this contract.

3.3.3 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 COR. In the case of a ship visit as a result of a casualty, the list of all employees who will be performing the work shall be submitted within 8 hours after the ship visit is authorized by the Contracting Officer. 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.

3.3.4 Security clearances. No special security clearances are normally required to perform any work under this specification. The Contractor shall supply a list of all employees who may be required to perform work under this specification and periodically update that list. Should the cutter be berthed at a Department of Defense or foreign government military facility, the Contacting Officer 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.

3.3.5 Government facility regulations. The Contractor shall observe and comply with all USCGC MACKINAW (WLBB-30) and Homeport Facility policy/instructions that might affect work performance under this specification.

3.4 Documentation and reporting.

3.4.1 The Contractor shall attend a Post Contract Award Orientation Conference with the Contracting Officer and/or COR no later than two weeks after contract award at a location to be designated by the Contracting Officer. The purpose of this meeting is to discuss contract requirements, task order procedures and objectives, and to ensure that all Government and Contractor representatives understand contract clauses and procedures. Thereafter, the Contractor Contracting Officer and/or COR shall meet twice each year to discuss performance problems and review Contractor’s corrective actions, to address Contractor or Government concerns, and to plan future contract tasks and events. Additional meetings may be held, if requested by the Government or Contractor.

3.4.2 The Contractor shall submit a trip report summarizing all work accomplished for each ship visit.

The Contractor shall submit the report to the COR no later than seven (7) calendar days after each visit departure. The report shall include the following:

• List of all work accomplished;

• List of all Critical Inspection Reports (CIR) and Condition Found Reports (CFR) submitted;

• List of all pending work and current status;

• Log of all requested technical assistance (remote and on-site), including description of requested support and resolution; and,

• List of any parts resulting from work accomplished required for dealer turn-in.

4 (Rev-0)

3.4.4 The Contractor shall submit a quarterly report summarizing all work accomplished for the fiscal quarter. The Contractor shall submit the report to the COR no later than thirty (30) calendar days after the end of each fiscal year quarter The report shall include the following:

• List of all trip reports provided to the Coast Guard;

• List of all CIRs and CFRs submitted;

• List of all pending work and current status;

• Log of all requested technical assistance (remote and on-site), including description of requested support and resolution;

• List of any parts resulting from work accomplished required for dealer turn-in;

• Any technical bulletins or service updates issued for applicable equipment under this contract;

• List of any components being investigated by OEM for engineering defects or suspected issues;

• List of any system or equipment modifications performed by request of the USCG; and,

• List of any recommended component , equipment, or software upgrades recommended by OEM to applicable equipment.

3.5 General administrative support. The Contractor shall provide administrative services in support of the activities outlined in this specification, including but not be limited to the following.

3.5.1 The Contractor shall prepare and provide written reports, briefing materials and other documentation.

3.5.2 The Contractor shall provide all written reports in electronic format with read/write capability using applications that are compatible with Coast Guard Standard Workstation (Windows Vista, Microsoft Office, and Adobe Acrobat applications).

3.5 Government quality assurance. The Government has the right to inspect, test, and audit all services and quality records called for by this specification at all times during the performance of the contract. The Government will perform inspections and tests in a manner that will not unduly delay work. When on-the-spot action to correct observed defects cannot be taken, the Government will use a Contract Deficiency Report (CDR) to advise the Contractor of the problem and to indicate to the Contractor the requirement for response or corrective action. The Contractor shall respond within 24 hours to the COR with a copy to the Contracting Officer.

3.6 Government furnished property and services.

3.6.1 Government furnished information. The Government will provide a copy of the ship’s Allowance Parts Lists (APL’s) to the Contractor within (30) days after contract award. The Contractor may make use of any of the equipment technical manuals, ship’s drawings, Engineering Logs and records available on the ship. However, the Contractor shall be responsible for ensuring that the documents covering these systems are up to date with the latest technical information from the OEM prior to their use.

3.6.2 Government’s right for changing out parts. The Contractor shall be aware that the Government reserves the right to furnish new replacement parts for installation in-place of contractor removed parts.

The Coast Guard will provide the parts in a timely manner that is agreed upon by both parties. When the

5 (Rev-0)

Government exercises this right, the Contractor shall turn over the removed part to the Coast Guard as a Mandatory Turn-In (MTI) item.

3.6.3 MACKINAW will provide crane services while in homeport. If MACKINAW’s Crane is not available due to a casualty or otherwise, the contractor shall submit a CFR to provide a crane to facilitate any and all onloads and offloads of equipment, machinery, and parts. The Contractor shall provide notification of requested MACKINAW crane services at minimum 24 hrs prior to usage.

3.7 Engineering support services. The Government may require engineering analyses to include but not limited to support system/component design changes, hardware and software modifications, or related efforts. Such analyses may include, but are not limited to feasibility studies, inspection reports, reports of onboard technical surveys, specification development, failure analyses, etc. The Contractor shall submit a proposal to provide such services, when requested by the Contracting Officer. The Contractor shall perform those services only when approved by the Contracting Officer.

3.8 Contractor-provided fire watch personnel. The Contractor shall provide fire watch personnel and equipment when required when hotwork is to be performed.

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

3.10 Hazardous Waste (HW) disposal. The Contractor shall be responsible for all hazardous wastes generated by work under this contract. Contractor shall label and package all hazardous wastes in 49 CFR-171-177 approved containers and in accordance with all other applicable Federal, state, and local laws and regulations. In addition, the Contractor shall comply with applicable parts of 40 CFR 262, applicable to handling of hazardous wastes.

3.10.1 Along with the Government, the Contractor shall be contractually considered the co-generator of all hazardous wastes; be aware that the Government will make available its facility’s EPA Generator Identification (ID) Number for manifesting of hazardous wastes.

3.10.2 The Contractor shall identify, arrange, and be responsible for the turnover of all hazardous wastes, within the confines of the Coast Guard shore facility, to the facility’s HM/HW Coordinator. The Contractor shall notify the ship’s HW Coordinator prior to any transfers of HW from ship to shore.

3.10.3 The Contractor shall prepare a manifest of hazardous waste to be reviewed and signed by the HM/HW Coordinator. The Contractor shall contact the HM/HW Coordinator for turnover of any hazardous waste and notify the COR in writing 24 hours prior to any waste removals. Waste removals shall be conducted during normal business hours (0800-1600), Monday through Friday (excluding holidays).

3.10.4 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 Contracting Officer approval.

3.10.5 Local environmental regulations at the Government facilities may be more stringent than in many jurisdictions. As with all environmental regulations, it is the Contractor's responsibility to research, prepare for, and comply with local and state regulations.

3.10.6 Coast Guard facilities do not have Facilities Response Plans (see 33 CFR 154 Subpart F). It is the Contractor’s responsibility to furnish the Facility Response Plan (FRP) when required for over-the-

6 (Rev-0) water liquid transfers to and from vessels. This requirement is applicable to transfers to/from vessels with an oil/fuel capacity of 250 barrels or more.

3.11 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed exterior and interior surfaces to match existing adjacent surfaces, in accordance with COMDTINST M10360.3, Appendix A (Cutter and Boat Exterior Painting Systems) and Appendix B (Cutter and Boat Interior Painting Systems), respectively, and as applicable. The Contractor shall abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

3.11 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove protective material and inspect for the presence of contamination. The Contractor shall lean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

7 (Rev-0)

23500_CAT Maint IDIQ_MWC_1011_30

WORK ITEM 1: Maintenance and Support Service for the Main Diesel Engine and Generator - Annual

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to provide annual support and service for three Caterpillar Model 3612 main propulsion diesel engine and generator.

1.2 Government-furnished property. None.

2. REFERENCES

2.1 COAST GUARD DRAWINGS

None.

2.2 COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3858, SWBS 235A, Dec 2006, Main Diesel Generator – Engine

Service Coast Guard Technical Publication (TP) 3859, SWBS 235A, Dec 2006, Main Diesel Generator –

Monitoring System and Drawing Coast Guard Technical Publication (TP) 3860, SWBS 235A, Dec 2006, Main Diesel Generator – Engine

Parts Coast Guard Technical Publication (TP) 3861, SWBS 235A, Feb 2009, Main Diesel Generator –

Generator Service and Parts – Model AA2741700

2.3 OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Refer to “General Requirements”.

3.1.3 Protective measures.

Refer to “General Requirements”.

3.1.4 Interferences.

None.

8 (Rev-0)

3.1.5 Maintenance prerequisites. Prior to a maintenance interval being performed, the Contractor shall verify that all maintenance requirements from the previous interval have been completed.

NOTE

Ship’s Force will be performing routine maintenance in support of equipment operations. The Contractor shall coordinate with the COR to ensure all prerequisites have been accomplished prior to conduct of scheduled work.

3.2 Scope of work. The Contractor shall perform the following annually in accordance with TP 3858, TP 3859, TP 3860, TP 3861, and manufacturer’s instructions. Submit CFR and recommendations for all inspection items.

3.2.1 Diesel engine.

• CAMPAR test.

• Aftercooler Condensation - Drain.

• Engine Timing Synchronization, Valve Lash Inspect & Adjust.

• Engine valve rotators - Inspect.

• Oil Mist Detector – Clean / Replace.

• Cooling System Supplemental Coolant Additive (SCA) – Test / Add.

• Aftercooler Core – Clean / Test.

o Document air side differential pressures via CFR. Complete cleaning and testing, in accordance with TP 3858, when air side differential pressure reaches 7kPa (1.0 psi) at full rated power, not to exceed three (3) years (last completed in October 2022).

• Air Starting Motor Lubricator Bowl - Clean.

• Starting Motor – Inspect

• Water Temperature Regulator – Replace

• Engine Protection Devices - Calibrate.

3.2.2 Generator and Generator Monitoring System.

• Perform MPC E-A-8993

• Generator Monitoring System – Clean & Inspect.

• Clearance and spacing of lead wires and electrical connections – Inspect.

• Outlet box, air screens, bearing housings, and air baffles – Clean & Inspect.

4. NOTES

4.1 “As-Built” engine configuration. Specific as-built engine configuration parts group data is available upon request.

9 (Rev-0)

23501_CAT Maint IDIQ_MWC_1011_30

WORK ITEM 2: Maintenance and Support Service for the Main Diesel Engine and Generator - Periodic

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to provide periodic support and service for the Caterpillar Model 3612 main propulsion diesel engine and generator.

1.2 Government-furnished property.

None.

2. REFERENCES

2.1 COAST GUARD DRAWINGS

None.

2.2 COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3858, SWBS 235A, Dec 2006, Main Diesel Generator – Engine

Service Coast Guard Technical Publication (TP) 3859, SWBS 235A, Dec 2006, Main Diesel Generator –

Monitoring System and Drawing Coast Guard Technical Publication (TP) 3860, SWBS 235A, Dec 2006, Main Diesel Generator – Engine

Parts Coast Guard Technical Publication (TP) 3861, SWBS 235A, Feb 2009, Main Diesel Generator –

Generator Service and Parts – Model AA2741700

2.3 OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Refer to “General Requirements”. 3.1.3

Protective measures.

Refer to “General Requirements”.

10 (Rev-0)

3.1.5 Maintenance prerequisites. Prior to a maintenance interval being performed, the Contractor shall verify that all maintenance requirements from the previous interval have been completed.

NOTE

Ship’s Force will be performing routine maintenance in support of equipment operations. The Contractor shall coordinate with the COR to ensure all prerequisites have been accomplished prior to conduct of scheduled work.

3.2 Scope of work. The Contractor shall perform the following at the given time intervals in accordance with TP 3858, TP 3859, TP 3860, TP 3861, and manufacturer’s instructions. Submit CFR and recommendations for all inspection items.

3.2.1 Diesel Engine.

3.2.1.1 8,000 Hour Service or 3 Years.

• Camshaft Roller Followers – Inspect.

• Cooling System Coolant (DEAC) – Change.

• Cooling System Coolant Extender (ELC) – Add.

• Crankshaft Vibration Dampener – Inspect.

• Driven Equipment - Check.

• Engine Oil Temperature Regulator - Replace.

• Exhaust Shields – Inspect.

• Governor Actuator Oil – Replace.

• Turbocharger – Inspect.

• Water Pump – Inspect.

3.2.1.2 16,000 Hour Service or 6 Years.

• Cooling System Coolant (ELC) – Change.

3.2.1.3 Vibration Analysis (As-Required).

• Vibration Analysis – Conduct.

3.2.2 Generator and Generator Monitoring System.

3.2.2.1 20,000 Hour Service or 3 Years.

• Sleeve bearing, liner, shaft journal, and seal surfaces – Inspect.

• Generator windings – Clean and Inspect.

3.2.2.2 40,000 Hour Service or 6 Years.

11 (Rev-0)

• Generator – Overhaul per TP 3861.

3.2.2.3 Generator Balancing (As-Required).

• Generator Balancing – Conduct.

3.2.2.4 Infrared Scan (As-Required).

• Infrared Scan – Conduct.

4. NOTES

4.1 “As-Built” engine configuration. Specific as-built engine configuration parts group data is available upon

12 (Rev-0)

23503_CAT Maint IDIQ_MWC_1211_30

WORK ITEM 3: Main Diesel Engine Overhaul (Top End and Major)

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to disassemble, clean, inspect, repair and reassemble (Top End and Major Overhaul) for the Caterpillar Model 3612 main propulsion diesel engine.

1.2 Government-furnished property.

None.

2. REFERENCES

2.1 COAST GUARD DRAWINGS

None.

2.2 COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3858, SWBS 235A, Dec 2006, Main Diesel Generator – Engine

Service Coast Guard Technical Publication (TP) 3859, SWBS 235A, Dec 2006, Main Diesel Generator –

Monitoring System and Drawing Coast Guard Technical Publication (TP) 3860, SWBS 235A, Dec 2006, Main Diesel Generator – Engine

Parts Coast Guard Technical Publication (TP) 3861, SWBS 235A, Feb 2009, Main Diesel Generator –

Generator Service and Parts – Model AA2741700

2.3 OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

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

• 3.3.1 (Engine component cleaning and inspections).

• 3.4.1 (Engine component cleaning and inspections).

3.1.2 Tech Rep.

Refer to “General Requirements”.

3.1.3 Protective measures.

13 (Rev-0)

3.1.5 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.

3.1.6 Authority to proceed. The Contractor/technicians shall not proceed with any work on the engine units or accessories described in this specification, until specific instructions are given by the Contracting Officer on what 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.

3.1.7 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. 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.

3.1.8 Report. The Contractor shall record the appropriate inspection findings on a CFR (clearance and tolerance readings of the cylinder block and related components). The Contractor shall submit a written report of all findings and recommendations to the Coast Guard Inspector (CGI) within 24 hours after inspection. A copy shall be provided to the Contracting Officer.

3.1.9 Government’s right for furnishing various components and parts. 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 Coast Guard as Mandatory Turn-In (MTI) items.

3.2 Operational test – initial. Prior to commencement of work, the Contractor shall witness an operational pretest (by Coast Guard personnel) of the Auxiliary Diesel Engine to demonstrate existing operational condition. Submit a CFR.

3.3 Top End Overhaul.

3.3.1 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 2.1 and

2.2 as guidance. The Contractor shall provide a CIR of these components to the Contracting Officer for disposition.

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

COMPONENT

Aftercooler

Exhaust Manifold Rocker Shaft Assembly and Push Rods

Turbocharger

14 (Rev-0)

Water Manifold

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

Table 2 - Engine Components shall be disassembled and automatically renewed during the performance of a Top End Overhaul

COMPONENT

Complete Cylinder Head Assemblies

Cylinder Head Gaskets and Seals Inlet Air Line Seals

Turbocharger Bearings, Bushings and Seals Valve Lubricator (If Equipped) Water Pump Bearings and Seals

Water Temperature Regulators and Seals

3.3.3 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).

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

COMPONENT

Aftercooler Exhaust Manifold

Rocker Shaft Assembly and Push Rods Turbocharger

Water Manifold

3.4 Major Overhaul (Including Top End).

3.4.1 Clean and Inspect Engine Components. The Contractor shall disassemble, clean, inspect and test the engine components listed below, (Refer to Table 4) utilizing the appropriate publications as outlined in Section 2.1 and

2.2 as guidance. The Contractor shall provide a CIR of these components to the Contracting Officer for disposition.

Table 4 - Engine Components shall be disassembled, cleaned, inspected or tested during the performance of a Major Overhaul

COMPONENT

Camshaft Camshaft Lifters Connecting Rods

Crankshaft Crankshaft Vibration Damper

Cylinder Block Cylinder Liners

Driven Equipment (alignment) Engine Mounts

Flywheel

15 (Rev-0)

Front Gear Train (Gears) Fuel Injection Pump Fuel Transfer Pump

Governor Oil Cooler Core

Oil Suction Screen Pistons (Crowns/Skirts) Rear Gear Train (Gears)

3.4.2 Automatic renewal. The Contractor shall perform the following engine component renewals with genuine, remanufactured (or new) OEM components, (Refer to Table 5).

Table 5 - Engine Components shall be disassembled and automatically renewed during the performance of Major Overhaul

COMPONENT

Camshaft Bearings Con Rod Bearings Crankshaft Seals

Crankshaft Thrust Plates Exhaust Manifold (Seals and Bellows)

Fuel Group Fuel Injectors

Fuel Transfer Pump Gear Train Bushings

Inlet Manifold (Gaskets and Seals) Jacket Water Pump

Lube Oil Cooler Lubricating Oil Pump

Main Bearings Piston rings

Sea Water Pump Software (Install new software when a new ECM is installed) Valve Rotators

3.4.3 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 6).

Table 6 - Engine Components to be renewed upon inspection and with KO authorization

COMPONENT

Crankshaft Camshaft

Connecting Rods Crankshaft Vibration Damper

16 (Rev-0)

Cylinder Block Cylinder Liners

Driven Equipment (alignment) Engine Mounts

Flywheel Front Gear Train (Gears)

Fuel Injection Pump Fuel Transfer Pump

Governor Oil Cooler Core

Oil Suction Screen Pistons (Crowns/Skirts) Rear Gear Train (Gears)

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

3.6 Fluids. The Contractor shall furnish and renew all fluids and filters associated with the engine reassembly.

3.7 Reassemble Engine Units and Accessories. After any authorized repairs and renewals, the Contractor 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 Operational test – post repairs. After completion of work, the Contractor shall perform an operational test to be witnessed by Coast Guard personnel. The Contractor shall conduct engine test run (break-in) in accordance with applicable Caterpillar and Coast Guard standards. Upon successful operational testing, the Contractor shall perform the applicable CAMPAR test requirement.

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

3.10 Acceptance. Acceptance of the work shall be discontinued until corrective actions, acceptable to the Government, have been taken. Any testing shall be repeated after correction of any deficiencies, unless waived by the Contracting Officer.

3.11 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.

4. NOTES

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

4.2 “As-Built” engine configuration. Specific as-built engine configuration parts group data is available upon

17 (Rev-0)

4.3 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 shall:

4.3.1 Monitor the assigned work items to keep informed of progress and ensure compliance with specification requirements.

4.3.2 Witness all testing as required by the specification.

4.3.3 Immediately notify the Contracting Officer of any work which appears to be contrary to specification requirements.

4.3.4 Document all work performed in the Machinery History Log.

18 (Rev-0)

31200_CAT Maint IDIQ_MWC_1211_30

WORK ITEM 4: Maintenance and Support Service for the Auxiliary Diesel Engine and Generator - Annual

1.1 Intent. This work item describes the requirements for the Contractor to provide annual support and service for the Caterpillar Model 3508 auxiliary diesel engine and generator.

1.2 Government-furnished property.

None.

2. REFERENCES

2.1 COAST GUARD DRAWINGS

None.

2.2 COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3813, SWBS 312A, Apr 2005, Emergency Diesel Generator –

Model 3508 Coast Guard Technical Publication (TP) 3814, SWBS 312A, Nov 2006, Emergency Diesel Generator –

Engine Parts Coast Guard Technical Publication (TP) 3815, SWBS 312A, Nov 2009, Emergency Diesel Generator –

Generator Parts

2.3 OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Refer to “General Requirements”.

3.1.3 Protective measures.

19 (Rev-0)

3.1.5 Maintenance prerequisites. Prior to a maintenance interval being performed, the Contractor shall verify that all maintenance requirements from the previous interval have been completed.

NOTE

Ship’s Force will be performing routine maintenance in support of equipment operations. The Contractor shall coordinate with the COR to ensure all prerequisites have been accomplished prior to conduct of scheduled work.

3.2 Scope of work. The Contractor shall perform the following annually in accordance with TP 3813, TP 3814, TP 3815, and manufacturer’s instructions. Submit CFR and recommendations for all inspection items.

3.2.1 Diesel engine.

• CAMPAR test.

• Cooling System Coolant Analysis (Level II) – Obtain.

• Engine – Clean.

• Engine Crankcase Breather – Clean.

• Engine and Oil Filter – Change.

• Engine Protective Devices – Check.

• Fuel System Primary Filter – Clean / Inspect / Replace.

• Fuel System Secondary Filter – Replace.

• Air Starting Motor Lubricator Bowl - Clean.

• Crankshaft Vibration Dampener – Inspect.

• Engine Mounts – Check.

• Turbocharger - Inspect.

• Engine Valve Lash – Inspect / Adjust.

• Fuel Injector – Inspect / Adjust.

3.2.2 Generator and Generator Monitoring System.

• Generator Monitoring System – Clean & Inspect.

• Stator output leads, protective sleeving and insulation - Inspect.

• Tightness of electrical connections - Inspect.

• Transformers, fuses, capacitors, and lightning arrestors – Inspect.

• Clearance and spacing of lead wires and electrical connections – Inspect.

• Outlet box, air screens, bearing housings, and air baffles – Clean & Inspect.

• Insulation resistance to ground on all generator windings – Check.

• Space heater operations - Check.

20 (Rev-0)

• Exciter armature for proper rotating rectifier connection tightness – Check.

4. NOTES

4.1 “As-Built” engine configuration. Specific as-built engine configuration parts group data is available upon

21 (Rev-0)

31201_CAT Maint IDIQ_MWC_1211_30

WORK ITEM 5: Maintenance and Support Service for the Auxiliary Diesel Engine and Generator - Periodic

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to provide periodic support and service for the Caterpillar Model 3508 auxiliary diesel engine and generator.

1.2 Government-furnished property.

None.

2. REFERENCES

2.1 COAST GUARD DRAWINGS

None.

2.2 COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3813, SWBS 312A, Apr 2005, Emergency Diesel Generator –

Model 3508 Coast Guard Technical Publication (TP) 3814, SWBS 312A, Nov 2006, Emergency Diesel Generator –

Engine Parts Coast Guard Technical Publication (TP) 3815, SWBS 312A, Nov 2009, Emergency Diesel Generator –

Generator Parts

2.3 OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep.

Refer to “General Requirements”.

3.1.3 Protective measures.

22 (Rev-0)

3.1.5 Maintenance prerequisites. Prior to a maintenance interval being performed, the Contractor shall verify that all maintenance requirements from the previous interval have been completed.

NOTE

Ship’s Force will be performing routine maintenance in support of equipment operations. The Contractor shall coordinate with the COR to ensure all prerequisites have been accomplished prior to conduct of scheduled work.

3.2 Scope of work. The Contractor shall perform the following at the given time intervals in accordance with TP 3813, TP 3814, TP 3815, and manufacturer’s instructions. Submit CFR and recommendations for all inspection items.

3.2.1 Diesel Engine.

3.2.1.1 3,000 Hour Service or 3 Years.

• Cooling System Coolant (DEAC) – Change.

• Cooling System Coolant Extender (ELC) – Add.

3.2.1.2 6,000 Hour Service or 6 Years.

• Cooling System Water Temperature Regulator – Replace.

• Prelube Pump – Inspect.

• Starting Motor – Inspect.

• Water Pump – Inspect.

3.2.2 Generator and Generator Monitoring System.

3.2.2.1 20,000 Hour Service or 3 Years.

• Sleeve bearing, liner, shaft journal, and seal surfaces – Inspect.

• Generator windings – Clean and Inspect.

3.2.2.2 40,000 Hour Service or 6 Years.

• Generator – Overhaul per TP 3861.

4. NOTES

4.1 “As-Built” engine configuration. Specific as-built engine configuration parts group data is available upon

23 (Rev-0)

31202_CAT Maint IDIQ_MWC_1011_30

WORK ITEM 6: Auxiliary Diesel Engine Overhaul (Top End and Major)

1.1 Intent. This work item describes the requirements for the Contractor to disassemble, clean, inspect, repair and reassemble (Top End and Major Overhaul) for the Caterpillar Model 3508 auxiliary diesel engine.

1.2 Government-furnished property.

None.

2. REFERENCES

2.1 COAST GUARD DRAWINGS

None.

2.2 COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3813, SWBS 312A, Apr 2005, Emergency Diesel Generator –

Model 3508 Coast Guard Technical Publication (TP) 3814, SWBS 312A, Nov 2006, Emergency Diesel Generator –

Engine Parts Coast Guard Technical Publication (TP) 3815, SWBS 312A, Nov 2009, Emergency Diesel Generator –

Generator Parts

2.3 OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

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

• 3.3.1 (Engine component cleaning and inspections).

• 3.4.1 (Engine component cleaning and inspections).

3.1.2 Tech Rep.

Refer to “General Requirements”.

3.1.3 Protective measures.

24 (Rev-0)

3.1.5 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.

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

3.1.7 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.

3.1.8 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) within 24 hours after inspection.

3.1.9 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 Coast Guard PA as Mandatory Turn-In (MTI) items.

3.2 Operational test – initial. Prior to commencement of work, the Contractor shall witness an operational pretest (by Coast Guard personnel) of the Auxiliary Diesel Engine to demonstrate existing operational condition. Submit a CFR.

3.3 Top End Overhaul.

3.3.1 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 2.1 and

2.2 as guidance. Provide a CIR 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 Overhaul

COMPONENT

Aftercooler

Exhaust Manifold Rocker Shaft Assembly and Push Rods

Turbocharger Water Manifold

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

25 (Rev-0)

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

COMPONENT

Complete Cylinder Head Assemblies

Cylinder Head Gaskets and Seals Inlet Air Line Seals

Turbocharger Bearings, Bushings and Seals Valve Lubricator (If Equipped) Water Pump Bearings and Seals

Water Temperature Regulators and Seals

3.3.3 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).

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

COMPONENT

Aftercooler Exhaust Manifold

Rocker Shaft Assembly and Push Rods Turbocharger

Water Manifold

3.4 Major Overhaul (Including Top End).

3.4.1 Clean and Inspect Engine Components. The Contractor shall disassemble, clean, inspect and test the engine components listed below, (Refer to Table 4) utilizing the appropriate publications as outlined in Section 2.1 and

2.2 as guidance. Provide a CIR of these components to the KO for potential reuse determination.

Table 4 - Engine Components to be disassembled, cleaned, inspected or tested during the performance of a Major Overhaul

COMPONENT

Camshaft Camshaft Lifters Connecting Rods

Crank…