CGC JAMES Ship Service Diesel Generator (SSDG) Service

1. SCOPE

1.1 Intent. This specification invokes general requirements for conducting vessel repairs performed by commercial contractors on Coast Guard Cutter JAMES. Repairs are for the Ship Service Diesel Generator (SSDG) listed in Table 1.

TABLE 1– SSDG NAME PLATE DATA

1.2 Work Items. This specification contains three Work Items:

#1. Ship Service Diesel Generator 1 and 2, Perform Alignment

#2. Ship’s Service Diesel Generator (SSDG) 1 and 2, Heat Exchanger, Perform Commercial Cleaning

#3. Ship Service Diesel Generator, 1 and 2 Load Test, Perform

1.2.1 Sequence. Work Item #1 and Work Item #2 must be completed prior to commencing Work Item #3.

1.3 Location. CGC JAMES is located at 1050 Register St. North Charleston, SC 29405

1.4 Ship Orientation: CGC JAMES is moored Starboard side.

1.5 FLETC Base Access Requirements. Contractors must have a valid REAL ID. Form 121 will be provided via email by the Port Engineer and must be submitted for a background check 5 business days prior to the start of the period of performance.

1.7 Firm Fixed Price. This is a Firm Fixed Price contract.

2. GENERAL REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

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

Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), 2022, Fire Prevention and Response

3. GENERAL REQUIREMENTS

3.1 General. The Contractor must conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability. The requirements of this WI applies to all work under the scope of this contract, whether explicitly stated in all following work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.2 Contractor-provided fire watch personnel. The Contractor must provide fire watch personnel and equipment.

3.3 Welding and brazing requirements. The Contractor must perform all welding and allied processes, and NDE in accordance with SFLC Std Spec 0740.

3.4 Fire Prevention Specification. The Contractor must submit a Fire Prevention Plan in accordance with paragraph 3.1 of SFLC Standard Spec 5550

1100_BEC_0126_418

Work Item 1: Ship Service Diesel Generator, Perform Alignment

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform alignment of the Ship Service Generators (SSDG) listed in Table 1.

TABLE 1– SSDG NAME PLATE DATA

CATERPILLAR MODEL

NO.

DESCRIPTION

LOCATION

3512B No.1 Ship Service Diesel Generator, 1360 KW, 450

Volt AC, 3 Phase, 60 Hz Aft Machinery Room (5-84-01-

E)

3512B No.2 Ship Service Diesel Generator, 1360 KW, 450

Volt AC, 3 Phase, 60 Hz Foward Main Machinery Room

(5-44-01-E)

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 7119, SWBS 311, Section B, FEB 2023, Ship Service Diesel Generator (SSDG) Model 3512B

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

Surface Forces Logistics Center Standard Specification 3100 (SFLC Std Spec 3100), 2022, Inspect, Test, and Recondition AC Synchronous Machines In-Place

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

American Society of Mechanical Engineers (ASME) Standard B18.8.2 Taper Pins, Dowel Pins, Straight Pins, Grooved Pins, and Spring Pins, 2020 (ASME B18.8.2)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor must be OEM authorized and licensed, and provide the services of a Technical Representative for CATERPILLAR 3512B marine diesel generator set to accomplish the following on site:

Provide manufacturer's proprietary system/equipment information, software, and tools.

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

Direct the alignment and pinning process for the generator set in accordance with OEM technical guidance.

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

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.1.5 Special tools. The Contractor must provide all special tools required to perform work on this item.

3.1.5.1 The Contractor must provide tools to conduct alignment according to either the Dial Indicator Alignment Procedure or the Laser Tool Alignment Procedure as described in TP 7119, Section 20, CAT Special Instruction REHS7485-02.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.2 Air-Gap Measurements. Following replacement of the generator bearing, the Contractor must take air-gap measurements of the main rotor and exciter in accordance with SFLC Std Spec 3100. Complete Data Sheet 1 and submit via CFR.

3.3 Inspect Vulkan coupling. The Contactor, under guidance of the Tech Rep, must inspect the Engine to Generator coupling. Inspect for any damage or defects according to TP 7119, Section 15, Vulkan Couplings Vulastik L Operating Manual. Submit a CFR.

3.4 Generator-engine alignment. Under guidance of the Tech Rep, following all engine and/or generator maintenance and repairs, measure shaft alignment as described in TP 7119, Section 20, CAT Special Instruction REHS7485-02 (May 2016). Adjust the alignment as necessary to achieve a satisfactory alignment measurement. All measurements must be checked under supervision of the Coast Guard Inspector. Submit a CFR.

3.4.1 Applicable sections of CAT Special Instruction REHS7485-02 include those marked S/N: NSC.

3.4.2 Measure crankshaft and generator end play.

3.4.3 Measure shaft alignment using the Dial Indicator method or Laser Shaft Alignment as described in TP 7119, Section 20. Make adjustments and add shims as needed to bring alignment within tolerance stated on the “Generator Set Alignment Data Sheet.” (copy provided in section 4).

3.4.4 Perform the Soft Foot Check Procedure, and use shims to correct out of tolerance measurements.

3.4.5 Install Tapered pins. After alignment has been confirmed, the Contractor must install the alignment tapered pins.

NOTE

The alignment pins are used to preserve Generator to engine alignment. The pins are tapered; the holes pass through both the generator foundation pads and the foundation bedplate. Holes are concentric and reamed after alignment using a tapered drill. After installation, the pins extend 1”-3” above the generator foundation and a minimum of ½” below the foundation bedplate.

3.4.6 Measure diameter of existing holes for pins on Generator foundation pad. Use tapered drill to ream for alignment tapered pins at existing locations, ensure the reamed holes will allow for full contact of the alignment pins with Generator foundation pads and foundation bedplate. Maintain existing angle towards centerline of generator.

3.4.7 Contractor must provide tapered pins per ASME B18.8.2 to fit the reamed holes. Pin material low carbon steel. Taper on pins ¼” per foot. Pins must have interior threads SAE on the large diameter end to facilitate removal. Installed pins must extend 1”-3” above the generator foundation and a minimum of ½” below the foundation bedplate.

3.4.8 Perform alignment readings again and document in the “Final Readings” column of the Generator Set Alignment Data Sheet.

3.4.9 After alignment is accomplished with acceptable readings, the Contractor must reconnect the coupling, and install coupling guard in accordance with the instruction in TP 7119 Crankshaft End Play procedure.

3.4.8 The Contractor must complete and submit the Generator Set Alignment Data Sheet provided in Section 4 of this work item via CFR.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.5 Operational test, post repairs. After completion of work, the Contractor must thoroughly test, under Coast Guard Inspector oversight, and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

3.5.1 When this work item is conducted in connection with load test, separate operational test is not required.

3.6 Touch-up preservation. The Contractor must prepare and coat all new and disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.)

4. NOTES

4.1 Generator Set Alignment Data Sheet. Reprinted from TP 7119.

4.2 Completed pin installation (upper view).

4.3 Completed pin installation (lower view).

31100_BEC_0126_418

Work Item 2: Ship’s Service Diesel Generator (SSDG), Heat Exchanger, Perform Commercial Cleaning

6. SCOPE

6.1 Intent. This work item describes the requirements for the Contractor to perform commercial cleaning of the SSDG heat exchangers.

TABLE 1– SSDG NAME PLATE DATA

CATERPILLAR MODEL

NO.

DESCRIPTION

LOCATION

3512B No.1 Ship Service Diesel Generator, 1360 KW, 450

Volt AC, 3 Phase, 60 Hz Aft Machinery Room (5-84-01-E)

3512B No.2 Ship Service Diesel Generator, 1360 KW, 450

Volt AC, 3 Phase, 60 Hz

6.2 Government-furnished property.

7. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements

Coast Guard Technical Publication (TP) 7119, SWBS 311, Section B, FEB 2023, Ship Service Diesel Generator (SSDG) Model 3512B

OTHER REFERENCES

None

8. REQUIREMENTS

8.1 General.

8.1.1 CIR.

None.

8.1.2 Tech Rep.

None.

8.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

8.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following:

Engine piping

Engine wiring

Fuel lines

8.2 Special tools. The Contractor must provide the required service tools listed in TP 7119, section 11, table 2, CAT Special Instruction REHS2599-091. Specifically, part numbers:

248-6745, Bars (x2)

162-7120, Pins (x2)

8.3 System preparation. The Contractor must ensure the heat exchanger is isolated and drained prior to removal, in accordance with the procedure for heat exchanger removal TP 7119, section 11. Precautions regarding cleanliness of the interconnected systems must be observed. The engine must be configured to be incapable of starting before starting this procedure.

8.3.1 Drain the cooling system. Open vent valves or expansion tank filler cap for ventilation and complete draining of the system.

8.3.2 Shut the fuel supply valve to the engine. Open the fuel purge valve.

8.4 Cooler removal. The Contractor must remove the cooler in accordance with TP 7119, section 11.

8.4.1 Support cooler with a suitable lifting device.

8.4.2 Loosen and remove bolts on elbows at all four piping connections.

8.4.3 Remove heat exchanger mounting bolts, and remove the heat exchanger.

8.4.4 Transport the heat exchanger to a suitable shop location for disassembly and cleaning.

8.5 Disassembly and cleaning. The Contractor must disassemble the cooler in a shop, conduct cleaning, and seal and o-ring replacement. Conduct disassembly and cleaning in accordance with the procedures and precautions required by TP 7119, section 11.

8.5.1 Mark the outside of the plates diagonally, and ensure plates removed for cleaning are kept in order throughout the process of cleaning.

8.5.2 Clean plates and inspect sealing surfaces and in accordance with the tech manual.

8.5.2.1 Clean the plates and gaskets with OEM approved solvents, and do not exceed soaking times noted in the technical guidance which are known to cause damage to plates or gaskets. Recommended solvents are listed below. CAT technical support may provide an updated list.

Paraffinic based solvent

Naphtha based solvent

8.5.2.2 Solvents listed below prohibited by TP 7119 must not be used.

Ketones (acetone, methylketone, or methylisobutyketone)

Esters (ethlacetate or butylacetate)

Halogenated hydrocarbons (chlorothene, carbon tetrachloride, or freons)

Aromatics (benzens, or toluene).

8.5.3 Document cleanliness of the inspected plates, seals, and gaskets, the solvents used, and any parts replaced. Submit a CFR.

8.6 Reassembly. The Contractor must reassemble the heat exchanger in accordance with TP 7119, section 11.

8.6.1 Press the plates together, remove the bars, and install and torque bolts to 160 ft-lb (+/- 30 ft-lb) in accordance with the OEM torque specifications. Mark torqued bolts.

8.6.2 Replace all collars and liners – items 6 and 8, respectively, in illustration from TP 7119, section 11.

8.6.3 Transport to ship for reinstallation on the engine.

8.7 Installation. The Contractor must reinstall the heat exchanger in accordance with TP 7119, section 11.

8.7.1 Install new liners and o-rings on the heat exchanger connections – items 14 and 16, respectively, on illustration 5 from TP 7119, section 11.

8.7.2 Use a suitable lifting device to move the heat exchanger into position.

8.7.3 Install and tighten mounting bolts. Reinstall and tighten fuel lines and all heat exchanger connections.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

8.8 Operational test, post repairs. After completion of work and under oversight of the Coast Guard Inspector, the Contractor must thoroughly test and demonstrate the SSDG to be in satisfactory operating condition. Submit a CFR.

8.8.1 Test the SSDG for a minimum of 2 hours at variable load, record engine temperatures throughout the test and include in the CFR.

8.8.2 If this WI is completed in connection with load testing, separate operational test is not required.

8.9 Restoration. Ensure configuration and alignment of the SSDG is restored to normal operating condition.

9. NOTES

9.1 Caterpillar references. This procedure relies heavily on Coast Guard Tech Pub 7119, section 11, which is a copy of CAT Special Procedure REHS2599-091 dated 7 May 2014. If the contractor obtains a newer version of this procedure relevant to the specified engine, it will be permitted, but a copy of the new procedure must be provided to the Asset Manager and the Port Engineer.

31100_BEC_0126_418

WORK ITEM 3: Ship Service Diesel Generator, Load Test, perform

10. SCOPE

10.1 Intent. This work item describes the requirements for the Contractor to conduct load test of designated Ship Service Diesel Generator (SSDG). Table 1 provides basic technical specifications and locations of the SSDG.

TABLE 1– SSDG NAME PLATE DATA

CATERPILLAR MODEL

NO.

DESCRIPTION

LOCATION

3512B No.1 Ship Service Diesel Generator, 1360 KW, 450

Volt AC, 3 Phase, 60 Hz Aft Machinery Room (5-84-01-E)

3512B No.2 Ship Service Diesel Generator, 1360 KW, 450

Volt AC, 3 Phase, 60 Hz

10.2 Government-furnished property.

11. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangements (ASC501001)

Coast Guard Drawing 418A-WMSL-801-001, Rev A, Booklet of General Plans

COAST GUARD PUBLICATIONS

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

Coast Guard Technical Publication (TP) 7119, SWBS 311, Section B, FEB 2023, Ship Service Diesel Generator (SSDG) Model 3512B

Coast Guard Technical Publication (TP) 7165B, Ship Service Switchboards 1S, 2S, 3S & 1SP Shore Power – Operation, Maintenance & Installation – Volume 1

Coast Guard Technical Publication (TP) 7166B, Ship Service Switchboards 1S, 2S, 3S & 1SP Shore Power – Operation, Maintenance & Installation – Volume 2 & 4

Coast Guard Technical Publication (TP) 7167, Ship Service Switchboards 1S, 2S, 3S & 1SP Shore Power – Operation, Maintenance & Installation – Volume 3

OTHER REFERENCES

COMDTINST 9077.1 (series) Equipment Lockout-Tags-Plus Instruction

MIL-STD-1310 (series), Sep 2009, Shipboard Bonding, Grounding, and Other Techniques for Electromagnetic Compatibility and Safety

Underwriter’s Laboratories (UL) 508

12. REQUIREMENTS

12.1 General.

12.1.1 CIR.

None.

12.1.2 Tech Rep. The Contractor must be OEM authorized and licensed, and provide the services of a Technical Representative for CATERPILLAR 3512B marine diesel generator set to accomplish the following on site:

Provide manufacturer's proprietary system/equipment information, software, and tools.

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

Direct the alignment and pinning process for the generator set in accordance with OEM technical guidance.

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

12.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

12.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following:

Piping

Electrical Cables

Switchboard Enclosure

Vent Ducting

Motor Operated Valves

12.1.5 Background information. Prior to the start of this work item, SSDG #1 and SSDG#2 will have preventive maintenance work completed by the Coast Guard, including the following tasks.

Generator Bearing Replacement

12.2 Generator set locations and cable routing. The generator sets are located in spaces according to Table

1. Refer to drawings 750-WMSL-501-002 and 418A-WMSL-801-001 for understanding of locations of equipment and to develop cable routing.

12.2.1 Proposed temporary cable routing must be developed using USCG Dwg 418A-WMSL-801-001.

Submit a CFR.

12.2.1.1 Temporary load bank cables must be routed from the switchboard to the load bank via a single route, and must not be routed separately by any method which would lead to unbalanced phase cables to transit through hull or bulkhead openings.

12.2.1.2 In this case, the ship will be moored starboard-side to the pier.

12.2.1.3 One suggested cable routing is to pass the cables past the at-sea refueling station, along the walkway toward the starboard-side davit, down the starboard side, and into the ship at the starboard-side rescue station door.

12.3 Grounding. The Contractor must ensure conductive surfaces of the load bank enclosure are appropriately bonded and grounded for protection of personnel in accordance with requirements for UL listing or other Nationally-Recognized Testing Laboratory (NRTL).

12.4 Contractor Furnished Materials (CFM). The Contractor must provide the load bank and cables of sufficient length, according to the specifications of this paragraph.

12.4.1 The load bank must meet these minimum technical characteristics: 1500 kW, 1900 A, resistive, 450VAC, 3-phase, 60 Hz, NRTL approval.

12.4.2 The connection cable must be single conductor 4/0, minimum 90 deg C rating, 8 cables per phase, 300 feet long. Alternate cable configurations of equivalent electrical characteristics are permitted.

12.4.3 The contractor must provide miscellaneous hardware required for electrical installation (i.e. Nylon Stuffing Tubes, Chafing Gear, Box Connectors, Lugs, Fasteners, Wire Nuts, Tapes, Cable ties & Cable Mounting Brackets, etc) of the electrical equipment.

12.5 Testing plan. The Contractor must submit a plan for load testing of the 1 and 2 SSDG in accordance with TP 7119. Submit the load testing plan no later than one week after the Arrival Conference via CFR.

12.5.1 The plan must cover the following topics at a minimum:

Load bank operator and installation technician qualifications

Emergency shutdown procedures

Load bank specification sheet and location

Cable locations for load bank

No-load operational checks

All proposed connections, cable and load bank configurations – specifically note variations from suggested methods or configurations provided in this specification

Data collection capabilities at the load bank

12.5.1.1 The Contractor must start testing of the SSDG after Approval of submitted Test Plan..

12.5.1.2 The test procedure must follow the loading and time steps of Table 3.

12.5.2 After placing load bank at suitable location, the Contractor must install the cables from the load bank to associated switchboard bus connection, according to the agreed upon cable routing.

CAUTION

THE SWITCHBOARD SHOULD BE ROPED OFF AS A PERSONNEL

EXCLUSION AREA (APPROXIMATELY 10 FOOT RADIUS FROM

ANY VISIBLE LIVE BUS

12.5.2.1 The Contractor must route the cables from designated SSDG to load bank through hatches and passageway. The Contractor must run cables in overheads as much as possible to avoid trip hazards.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

SAFETY

At any point in the load test or operational testing period if the need presents itself the engine – Prime mover may be shut down by the Tech rep with communication to the USCG operational Engineer utilizing the local EOS, E stop or shut down from the switch gear. Any of the three options will automatically open the SSDG buss breaker

12.5.3 After warmup of SSDG until coolant temperature reaching 140 Degree F, the Contractor must perform the load testing of designated SSDG listed in Table 1 at following load condition.

TABLE 3 – LOAD TESTING

LOAD HOURS

No Load 0.5

25 % Load 0.5 50 % Load 0.5 75 % Load 0.5

100 % Load 2.0 No Load 0.5

12.5.3.1 Running no load testing. No load testing will consist of running the engine at idle rpm until the engine coolant temperature reaches 140 deg. F during that warmup time safety testing will be performed for oil pressure, temp warning, emergency shut down conditions, and coolant temp. warning and shutdown. Shipboard alarm verification will be observed at that time as well.

12.5.3.1 Engine parameter readings during the load bank test must be taken every 15 minutes including, but not limited to the bullet points in this paragraph. Submit a CFR.

Engine temp, Coolant temp, oil pressure, boost pressure, intake air temp after the aftercooler, exhaust stack temp, left and right bank exhaust temperatures.

In addition to the generator load test form, a Caterpillar steady state engine performance file shall be recorded on the engine ECM all related available information.

Generator information, voltage reading per phase, amperage readings per phase, HZ, bearing and winding temps.

Pre and post-test project status report from CAT ET must be saved on the ECM to provide verification of all available diagnostic codes and events.

All electronic files and reports must be submitted via CFR.

12.6 Load test documentation. After completion of testing, the Contractor must provide all collected data sheets to the Contracting Officer.

13. NOTES

13.1 Suggested generator set load test data sheet, for recording data during testing.

14.1 Submit all questions via email to the Technical Points of Contact (TPOC) identified below.

14.1.1 Asset Manager- Temple, Matthew C CWO-2 USCG SFLC (USA) Matthew.Temple@uscg.mil

14.1.2 Port Engineer- Burzycki, Christian F LT USCG SFLC (USA) Christian.F.Burzycki@uscg.mil

14.1.3 JAMES Engineering Officer- Moeller, Andrew W LCDR USCG CGC JAMES (USA) Andrew.W.Moeller@uscg.mil