70Z08527QLRE0004_SOW.pdf

PERFORMANCE WORK STATEMENT (PWS)

USCGC HEALY (WAGB-20) – Main Propulsion Diesel Generator (MPDG) – Governor, Overspeed CorrecƟve Maintenance & Cylinder Head Replacement.

LocaƟon:

USCGC Healy (WAGB 20) 1519 Alaskan Way South SeaƩle, WA 98134 Phone: (206) 217-6815

Period of Performance:

Coordinate days onsite between: 13 Oct 2026 – 31 Oct 2026

References:

Core ConsulƟng Group Doc CGC-20260801-260901, USCG Healy InvesƟgaƟon, Rev 0

(03SEP2026)

USCG Technical PublicaƟon (TP) 5016, SWBS 233, SecƟon A, Main Diesel Engine (MDE) –

Model 12ZAV40S – Technical Manual Supplement (Vol 1), Rev - (01SEP2022) USCG Technical PublicaƟon (TP) 5017, SWBS 233, SecƟon A, Main Diesel Engine (MDE) –

Model 12ZAV40S – OperaƟonal Manual (Vol 2), Rev - (01OCT2022) USCG Technical PublicaƟon (TP) 5018, SWBS 233, SecƟon A, Main Diesel Engine (MDE) –

Model 12ZAV40S – Maintenance Manual (Vol 3), Rev - (01OCT2022) USCG Technical PublicaƟon (TP) 5019, SWBS 233, SecƟon A, Main Diesel Engine (MDE) –

Model 12ZAV40S – Spare Parts Code Book (Vol 4), Rev A (01OCT2022) USCG Technical PublicaƟon (TP) 5020, SWBS 233, SecƟon A, Main Diesel Engine (MDE) –

Model 12ZAV40S – Auxiliary Equipment Manual (Vol 5, Part 1), Rev A (01DEC2022)

ObjecƟve 1: Mechanical Overspeed Cutout Maintenance Provide a Qualified Service Technician, familiar with Wärtsilä New Sulzer Diesel (NSD) Model ZAV40 engines/gensets, to disassemble, remove, clean/inspect, repair, recalibrate, bench test and reinstall the mechanical overspeed shutdown for the #1 and #3 MPDGs.

ObjecƟve 2: Electro-pneumaƟc Overspeed Limiter Maintenance Provide a Qualified Service Technician, familiar with Wärtsilä New Sulzer Diesel (NSD) Model ZAV40 engines/gensets, to disassemble, remove, clean/inspect, repair, recalibrate, bench test and reinstall the electro-pneumaƟc overspeed safety cut-out for the #1 and #3 MPDGs.

ObjecƟve 3: Woodward Governor and Booster Overhaul Provide a Qualified Service Technician, familiar with Wärtsilä New Sulzer Diesel (NSD) Model ZAV40 engines/gensets and Woodward Model PGG-EG-58 governors to disassemble, remove, clean/inspect, overhaul, recalibrate, bench test and reinstall the Electro-Hydraulic Governor/Actuator assemblies and their respecƟve booster for the #1 and #3 MPDGs. The governors and boosters appeared to be operaƟng properly but there is no record of service or overhaul. These engines have 40K+ operaƟng hours.

Governor/booster inspecƟon, overhaul and bench tesƟng must be conducted by an authorized service facility for Woodward governors.

* The government reserves the right to provide spare boosters in inventory for inspecƟon, overhaul and bench tesƟng in lieu of exisƟng aƩached boosters.

ObjecƟve 4: Governor Lube Oil Cooler Maintenance Provide a Qualified Service Technician, familiar with Wärtsilä New Sulzer Diesel (NSD) Model ZAV40 engines/gensets to remove, clean/inspect, hydrostaƟcally test, and reinstall the governor oil coolers for the for the #1 and #3 MPDGs.

Engine Cooler Make Model Part Number #1 MPDG Young HF-201-HY-1P 307008 #3 MPDG Young HF-201-HY-1P 307008

ObjecƟve 5: Governor Drive Maintenance Provide a Qualified Service Technician, familiar with Wärtsilä New Sulzer Diesel (NSD) Model ZAV40 engines/gensets to disassemble, remove, clean/inspect, overhaul, and reinstall the Governor Drive Assemblies for the #1 and #3 MPDGs & A2 Cylinder Head on #3 MDE.

ObjecƟve 6: MDE #3 Cylinder Head Replacement (A2) Replace the Unit A2 cylinder head due to damage to the dummy valve seaƟng surface and dummy valve body.

Engine Governor Type Part Number Serial Number #1 MPDG Woodward PGG-EG 58 8576-957 13620732 #3 MPDG Woodward PGG-EG 58 8576-351 2667353

Engine Booster Make Model #1 MPDG* Woodward 8901-067 #3 MPDG* Woodward 8901-067

* The government reserves the right to provide spare boosters in inventory for inspecƟon, overhaul and bench tesƟng in lieu of exisƟng aƩached boosters.

Background:

CGC HEALY suffered a catastrophic overspeed failure of its #2 MPDG. The RCFA report (CGC 20260801-260901) for the event idenƟfied immediate correcƟve acƟon is required for the #1 and #3 MPDG, with respect to maintenance of the overspeed devices and governor equipment.

Scope:

The Contractor shall provide all labor, equipment and parts necessary to perform the maintenance tasks specified herein. The Contractor shall also possess knowledge and/or have access to all OEM documentaƟon and proprietary system informaƟon as well as industry/regulatory standards. The Contractor shall addiƟonally account for all personnel travel costs and shipping of tools/equipment related expenses, as needed.

CLIN 0001 - Mechanical Overspeed Cutout Maintenance The Contractor must remove, disassemble, clean, inspect, and overhaul (or renew) all components of the mechanical overspeed from the #1 and #3 MPDGs, in accordance with SecƟon 5303-1 of USCG TP 5018.

The inspecƟon should include the springs, pistons, sealing elements, moving components, and associated actuaƟng mechanisms to idenƟfy any evidence of wear, corrosion, seizure, contaminaƟon, mechanical damage, or deterioraƟon.

Any component found defecƟve, damaged, or outside the specified tolerances should be repaired or replaced as applicable.

At minimum CFM Renewal parts should include:

Minimum CFM renewal list

PN DESCRIPTION

KS53077 Sealing for KS 53076

KS53075 Sealing for KS 53074

KS 53078 Compression spring for KS 53052 KS 53079 Compression spring for KS 53052 KS53032 Cyl. pin for KS 53031

KS53035 Sealing for KS 53034

KS 53012 Shaft

KS 53013 Shut-off piston for KS 53011

KS 53014 Spindle for KS 53011

KS 53015 Spring plate for KS 53013

KS 53016 Adjusting screw for KS 53011

KS 53018 Clamping piece for KS 53014

KS 53019 Spring plate for KS 53011

KS 53022 Spring for KS 53013

KS 53023 Spring for KS 53011

KS 53024 Spring for KS 53011

KS 53026 Circlip type J for KS 53013

KS 53027 Circlip type J for KS 53011

KS 53029 Ball for KS 53011

KS 53030 Ball for KS 53011

KS 53050 Latch

KS 53051 Pin for KS 53050

KS 53054 Rod

KS 53094 Screw for KS 53001

KS 53101 Joint ring for KS 53094

Contractor may renew complete ShaŌ assembly (PN KS 53011) in lieu of parts KS 53012- KS

53030, if renewal adds no addiƟonal cost to the government.

Upon compleƟon of the inspecƟon and recondiƟoning, device should be properly reassembled, adjusted, and calibrated in accordance with the Original Equipment Manufacturer (OEM) specificaƟons. FuncƟonal bench tesƟng should then be performed to verify proper operaƟon and confirm that the devices operate reliably within the established engine safety parameters.

The Contract shall reassemble all components of the mechanical overspeed, on to each of the affected MPDGs, in accordance with OEM instrucƟons.

1.1 - Electro-pneumaƟc Overspeed Limiter Maintenance The Contractor must idenƟfy the speed sensing source, set point, output/solenoid and pneumaƟc path for any independent electro-pneumaƟc overspeed funcƟon.

Contractor must remove, clean, and inspect the pneumaƟc safety cut-out valve and all associated components on the MPDGs. Renew any worn, corroded, or damaged parts.

Perform a funcƟonal bench test of electro-pneumaƟc valves to confirm that the devices operate reliably within the established engine safety parameters as per USCG TP 5017. Simulate electrical trip signals and calibrate trip setpoints to engine specs.

Reassemble components onto the original MPDGs; rewire and connect all pneumaƟc piping.

1.2 - Woodward Governor and Booster Overhaul The Contractor must remove, overhaul, calibrate, bench test and reinstall each governor and booster in accordance with USCG TP 5020 and OEM specificaƟons.

During removal, the contractor must drain all oil from the governor, disconnect all linkages, electrical connectors and piping. Plug all piping and protect connectors upon removal to prevent contaminaƟon.

The overhaul facility must conduct the following on the governor and booster.

Document serial numbers, model designaƟons, part numbers, and as-received physical condiƟons.

Inspect all external surfaces for housing cracks and mechanical damage.

Completely disassemble all components to piece-part level in accordance with OEM disassembly procedures.

Clean all components using OEM approved cleaning methods.

Inspect, measure, and document all components against OEM wear limits.

Inspect and test all electrical components against OEM standards.

At a minimum, renew all o-rings, oil seals, gaskets, crush washers, filter screens, roll pins, and bearings with OEM parts during reassembly.

Bench test each governor and booster in accordance with OEM procedures.

Provide full inspection and testing report with the overhauled governor and booster.

Prior to reinstallation, clean and inspect all linkages, bushings, and connectors.

Reinstall the governors and boosters, refill oil, verify all linkage is attached and operates freely and properly.

1.3 Governor Lube Oil Cooler Maintenance

The Contractor must remove, clean, inspect, pressure test and reinstall each governor oil cooler.

During removal the contractor must drain all fluids and cap/plug all piping to prevent contaminaƟon.

Mechanically and chemically clean each cooler as required to descale the cooler.

Flush/neutralize all cleaning fluids and dry thoroughly.

Perform a pressure test of the shell side and tube side of each cooler. Zero pressure drop and zero tube joint or casing leakage is allowed.

Apply test pressure to the exterior tube walls equaling 125 percent of the working design operaƟng pressure of the tubes and hold for a minimum of 15 minutes. Visually inspect tubes for leaks.

Apply test pressure to the interior tube walls equaling 125 percent of the working design operaƟng pressure of the tubes and hold for a minimum of 15 minutes. Visually inspect tubes for leaks.

While maintaining the test pressure on the interior of the tubes, apply a test pressure of 125 percent of the shell's working design operaƟng pressure for a minimum of 15 minutes.

Visually inspect shell for leaks.

Reinstall each cooler on the engine using new seals.

1.4 Governor Drive Maintenance

The Contractor must remove, overhaul, and reinstall each governor drive assembly in accordance with USCG TP 5018 and USCG TP 5019.

AŌer removal the contractor must blank plate the engine casing to prevent contaminaƟon and foreign objects from entering the engine.

Conduct and record axial clearance and backlash prior to disassembly.

Disassemble each governor drive components, down to the piece part level, in accordance with USCG TP 5018. Thoroughly clean and inspect all components for damage and wear.

Reassemble each governor drive using all new bushings and locking wire.

Check/record axial clearances and backlash aŌer reassembly to ensure it meets OEM tolerance.

Reinstall each governor drive on the engine using new gaskets.

CLIN 0002 - Replace MDE#3 Cylinder Head A2 Replace the Unit A2 cylinder head due to damage to the dummy valve seaƟng surface and dummy valve body. Send the removed cylinder head and dummy valve to the machine shop for inspecƟon and recondiƟoning in accordance with OEM specificaƟons.

• Remove the Unit A2 cylinder head and associated components/connecƟons.

• Clean and inspect the cylinder block and cylinder head maƟng surfaces.

• Install the replacement/serviceable cylinder head with a new cylinder head gasket set and Ɵghten in accordance with OEM specificaƟons.

• Reinstall the dummy valve with a new sealing ring and verify correct seaƟng.

• Reinstall The injector valve with new sealing ring.

• Reinstall the rocker arms and adjust the valve clearance.

At minimum Contractor Furnished Material (CFM) renewal parts should include:

PN QUANTITY DESCRIPTION

107.122.903.200

NIIN:014652075

1 CYLINDER HEAD

KS 27290 2 Set of O-rings and joints (KS 27266 and KS 27271) KS 27025 1 O-ring for KS 27201 KS 21451 1 Set of O-rings and joints (KS 21420, 21421, 21425, 21426)

KS 27029 3 O-ring

KS 27030 2 O-ring

KS 27016 1 Joint for KS 27400

KS 44119 2 Sealing for KS 44118

KS 44130 4 O-ring for KS 44118

2.1 Service Report Deliverable

The contractor shall provide a wriƩen service report documenƟng maintenance acƟons performed for the #1 and #3 MPDGs no later than 5 working days aŌer compleƟon of onsite work performance.

The report shall include:

Summary of maintenance acƟons performed for mechanical overspeed cutout.

Summary of maintenance acƟons performed for electro-pneumaƟc overspeed limiter.

Summary of maintenance acƟons performed for the Woodward governor and booster.

Summary of maintenance acƟons performed for the governor lube oil cooler.

Summary of maintenance acƟons performed for the governor drive.

CLIN 0003 –PotenƟal Repairs Based on CFRs (not to exceed $60,000) Pricing for any addiƟonal travel costs, material, or field service days will be requested and handled by the KO under the terms of the contract. Any repairs beyond the base scope idenƟfied because of the troubleshooƟng shall be documented in a CondiƟon Found Report (CFR) with a technical descripƟon of the recommended repairs. The CFR shall be provided to the Technical POCs and the ContracƟng Officer.

Any addiƟonal work will be authorized only by the KO through a wriƩen contract modificaƟon.

The contractor shall not perform any repairs beyond the base scope unƟl specifically authorized in wriƟng by the KO. If the Government elects to proceed with addiƟonal repairs, the KO will issue a wriƩen contract modificaƟon that idenƟfies the authorized addiƟonal work and associated firm fixed price. The contractor shall base any proposal for addiƟonal repairs on the findings in the CFR.

Vendor QualificaƟons:

Engine Technicians shall be Qualified Service Technicians to perform inspecƟons and repairs of New Sulzer Diesel (NSD) Model ZAV40 engines/gensets and/or other large marine engines/gensets with rotaƟng piston design. Technicians must have a minimum of 5 yrs of demonstrable experience, via resume, in diesel engine inspecƟons and assessment. Submit the resume of each Technician at the Ɵme of proposal.

Governor Technicians shall be Qualified Service Technicians to perform inspecƟons, repair and calibraƟon of Woodward Model PGG governors and/or related ancillary equipment.

Technicians must have a minimum of 5 yrs of demonstrable experience, via resume, in diesel engine inspecƟons and assessment. Submit the resume of each Technician at the Ɵme of proposal.

Government Furnished Support:

The government will provide access to the cuƩer, escort as required, access to each MPDG and the related spaces as operaƟonally available.

Ships Force will provide available operaƟonal logs, maintenance history, casualty informaƟon, and equipment idenƟficaƟon data as available.

Points of Contact:

Asset Manager – MKCM Armando Perez – Armando.Perez@uscg.mil Supervisor – LCDR Andrew Constant – Andrew.S.Constant@uscg.mil Port Engineer – LCDR Joshua MarƟn - Joshua.A.MarƟn@uscg.mil

Acceptance Criteria:

The services below will be considered complete upon:

USCG inspector review and acceptance of the Mechanical Overspeed Cutout Maintenance performed.

USCG inspector review and acceptance of the Electro-pneumaƟc Overspeed Limiter

Maintenance performed.

USCG inspector review and acceptance of the Woodward Governor and Booster

Maintenance performed.

USCG inspector review and acceptance of the Governor Lube Oil Cooler Maintenance performed.

USCG inspector review and acceptance of the Governor Drive Maintenance performed.

USCG inspector review and acceptance of #3 MDE A2 Cylinder Head replacement performed.

CompleƟon of a verbal out-brief to the onsite designated USCG representaƟve summarizing the onsite maintenance acƟons accomplished and any follow-on recommended acƟons.

Delivery of the wriƩen service report within 5 working days aŌer compleƟon of the onsite maintenance acƟons.