3-Attachment_A_MIDGETT_No.2_SSDG_OVERHAUL_FY27_Specification_Rev-0.pdf

USCGC MIDGETT (WMSL 757) - CATERPILLAR® NR2 SSDG

ENGINE OVERHAUL

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2027

Developed By: Akhila K Wijayaratne

(Rev-0, 16 AUG 2026)

Attachment A_ MIDGETT #2 SSDG OVERHAUL FY27 - Specification Rev-0.

ii (Rev-0)

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: Caterpillar (CAT) Ship Service Diesel Generator, Engine Major Overhaul WORK ITEM 2: Caterpillar (CAT) Diesel Engine Hot Lube Oil Flush, Perform WORK ITEM 3: Caterpillar (CAT) Ship Service Diesel Generator, Crankshaft Renewal

USCGC MIDGETT (WMSL-418) CAT SSDG OVERHAUL DOCKSIDE AVAILABILITY FY2027

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

Coast Guard Drawing 418A-WMSL-540-001, Rev D, Fuel Oil Diagram Coast Guard Drawing 418A-WMSL-540-002, Rev A, Diesel Eng And Gas Turb LO Fill, Trans, &

Service Sys Coast Guard Drawing 418A-WMSL-551-001, Rev B, Compressed Air Diagram Coast Guard Drawing 750-WMSL-501-002, Rev H, Machinery Arrangement Coast Guard Drawing 750-WMSL-508-001, Rev C, Piping and Machinery Insulation Schedule and L/M

(ASC508001)

Coast Guard Drawing 750-WMSL-520-001, Rev H, Seawater Cooling System Diagram (ASC520001) Coast Guard Drawing 750-WMSL-635-002, Rev K, Insulation Arr & Details Thermal, Acoustic, & Fire

(ASC635002)

Coast Guard Drawing FL-1204-3, Rev A, Fleet Welded Padeyes And Links

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Coast Guard Technical Publication (TP) 7119, Rev A, SWBS 311, Dec 2023, Ship Service Diesel

Generators Model 3512B Coast Guard Technical Publication (TP) 7368C, SWBS 311, Feb 2022, Ship Service Diesel Generators

(SSDG) Model 3512B Parts Manual Coast Guard Technical Publication (TP) 14025, Rev A, Apr 2025, Ship Service Diesel Generator Sets

Caterpillar 3512B Marine Auxiliary Technical Manual Volume 1 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 v (Rev-0)

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 3041 (SFLC Std Spec 3041), 2022, Shipboard Electrical Cable Test

Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2022, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, and Installation

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2022, Auxiliary Machine Systems

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

OTHER REFERENCES

American National Standards Institute (ANSI/EASA) AR100, 2020, Recommended Practice for the

Repair of Rotating Electrical Apparatus Caterpillar® Marine Model D3512 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) Code of Federal Regulations (CFR) Title 29, Part 1915, Occupational Safety and Health Standards for

Shipyard Employment NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), July 2012, Requirements for

Fabrication, Welding, and Inspection of Submarine Structure The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2016, Solvent 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.

WORK

ITEM

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

1 Y **CRANKSHAFT NSN: 2815-01-511-2837

PN: 128-6786 1 42,164.08

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center 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, paragraph 3.2.6.5 (Inspection report particulars)):

Work Item Title

1 Caterpillar (CAT) Ship Service Diesel Generator, Engine Major Overhaul viii (REV-0)

PRINCIPAL CHARACTERISTICS

418' WMSL

PHYSICAL

Length overall 418' 0" Length between perpendiculars 390' 0" Maximum beam 54' 0" Beam @ 01 level 47' 9-1/8" Depth (01 level @ side to baseline) 39' 2-3/4" 01 deck camber foredeck 1/4" in 1'-0" Minimum berth depth 20' 0" Height of highest projection Approximately 119' Draft, design 14.40' Design displacement 3925 long tons

MACHINERY

Two diesel engines MTU 20V, 20-cylinder 9,730 SHP each One gas turbine General Electric LM2500; 29,500 SHP Type of propulsion CODAG Electrical system 24 Volt DC Two controllable pitch propellers Rolls-Royce 5 blade, 14' 0" diameter; 229 RPM max Two reduction gears RENK One cross connect gear RENK

HULL

Hull material 5086 Aluminum HSLA-80 Steel ABS EH 36 Steel

ABS AH 36

Frame spacing FWD of FR 9 2' 3" FR 9 to FR 10 6' 9" FR 10 to FR 98 4' 1" FR 98 to FR 99 3'-8"

ELECTRICAL

Power Three 1360 kW, 450 V, 60 Hz, 3 Phase, 1800 RPM Caterpillar 3512B diesel engines with Baylor ship service generators Shore tie cable Seven MIL-C-24368/2 (NATO) shore power receptacles, 400 A each

TANK CAPACITIES

Diesel oil 220,359 gal Fresh water 12,454 gal JP-5 Fuel 35,182 gal

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00000_0725_FLT

REC_00000_FLT_Commercial Project @ Contractor’ Facility (0121)

General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed at a commercial contractor’s facility for Coast Guard vessels.

1.2 Term interchangeability. The terms 'Contractor', 'CG Yard', 'NAVSTA EVERETT', 'shipyard', 'Base', and 'Coast Guard Industrial' are used interchangeably in this specification. Where the primary service provider is Coast Guard personnel, references to contractor and other noted descriptors within this specification or within drawings, publications, SFLC Standard Specifications or other commercial and military references are deemed the same as prime service provider.

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), Latest

Version, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Latest

Version, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), Latest

Version, Fire Prevention and Response Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), Latest

Version, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Occupational Safety and Health

Standards for Shipyard Employment NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), July 2012, Requirements for Fabrication, Welding, and Inspection of Submarine Structure

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3. 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 in 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.

3.1.1 The Contractor must conform to all requirements specified in SFLC Std Spec 5550 and in the Fire Protection and Response work item, as applicable, during the performance of this availability.

3.1.1.1 Fire Safety Plan submission. The Contractor must submit a copy of the CFR 1915, Subpart P, Fire Safety Plan with the Contractor’s bid when work will be conducted in a Contractor–owned facility.

Include any MOA(s) with local firefighting facilities.

3.1.1.2 Fire Plan submission. The Contractor must submit a copy of the developed availability specific fire plan, as requested in the Fire Protection and Response work item, seven (7) days before the Arrival Conference.

3.1.2 Safety Certifications. The Contractor must provide the credentials for anyone certifying that a space is safe for workers or hot work in accordance with 3.3.1 of SFLC Std Spec 0000.

NOTE

NAVSEA drawings listed will be available FOR INSPECTION ONLY from the Coast Guard Port Engineer post-award. SFLC will not redistribute NAVSEA documents. Contractors can apply to NAVSEA headquarters directly for copies.

3.2 Fire watch requirements. The Contractor must refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

• Provide fire watch personnel and fire extinguishers for the duration of the availability period.

3.3 Preservation requirements. The Contractor must accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec 6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

3.3.2 Coating colors and system color schemes. The Contractor must obtain a written KO authorization to deviate from any coatings required in SFLC Std Spec 6310 Appendix C before work.

3.3.3 In-process quality control measures. The Contractor must abide by all the safety, preservation, and quality control requirements specified in SFLC Std Spec 0000, paragraph 3.2.4.2 (In-process QC measures for “critical-coated surfaces”).

3.3.3.1 Quality control requirements. The Contractor must abide by the following when performing preservation related inspections. The following measurements must be randomly spaced throughout for the purposes of providing a representation of the entire prepared or coated surface.

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3.3.3.1.1 Surface profile measurements. One surface profile measurement must be taken for every 200 square feet for the first 1000 square feet; for each additional 500 square feet or less, one profile measurement must be taken. Profile measurements must be taken in accordance with SFLC Std Spec 6310, paragraph 3.1.8.3 (Surface profile measurements). A “measurement” for surface profile is defined as follows:

• ASTM D4417, Method B: One profile measurement is the average (mean) of 10 individual readings.

• ASTM D4417, Method C: One profile measurement is the average (mean) of 2 individual readings.

3.3.3.1.2 Soluble salt conductivity measurements. 5 conductivity measurements must be taken every 1000 square feet. For submerged (immersed) applications conductivity measurements must not exceed 30 microsiemens/cm. For non-submerged (non-immersed) applications conductivity measurements must not exceed 70 microsiemens/cm. If a conductivity check fails, clean the surface in accordance with SFLC Std Spec 6310, paragraph 3.1.8.5 (Soluble salt removal).

3.3.3.1.3 Coating thickness measurements. Three area measurements must be taken for the first 1000 square feet; for each additional 1000 square feet, perform an additional area measurement. A “measurement” for coating thickness is defined as follows:

• SSPC-PA 2 defines an area measurement as 5 separate spot measurements randomly spaced throughout a 100 square foot area.

• SSPC-PA 2 defines a spot measurement as 3 gage readings and each new gage reading the probe must be moved to a new location within a 1.5-inch diameter circle defining the spot.

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

NOTE

NAVSEA approval is NOT required for welding procedures submitted but the procedures must be reviewed and shown to satisfy the requirements set forth in NAVSEA TP 1688, by a welding regulatory agency. The requirements for welding Strenx 900 are considered the same as those for welding HY-130.

3.5 Environmental protection requirements. The Contractor must adhere to the following environmental protection requirements in accordance with the SFLC Stand Spec 0000:

3.5.1 Contractor operated (non USCG) facilities. The Contractor must provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix A, Requirements for Environmental Protection at Contractor Operated (Non USCG) Facilities, as applicable, during the performance of this availability. Contractor must plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor must 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 must not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.1.1 Plans and permits. The CG Facility has unit specific permits including the following:

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• Spill Prevention Control and Countermeasures (SPCC) Plan: Unit has a SPCC Plan which requires certain unit-specific procedures be followed for the storage, inspection, and transfer of petroleum products in containers 55 gallons or greater.

• National Pollutant Discharge Elimination System (NPDES) Storm Water (SW) Permit: Unit has an NPDES SW permit which requires unit-specific procedures be followed for the storage and inspection of equipment and materials which may contribute contaminants to storm water discharges.

• Air Emission Permit: Unit has an Air Emission Permit which requires unit-specific procedures be followed for the emissions of VOCs and hazardous air pollutants.

3.5.2 Test and procedures. The Contractor is required to promptly conduct tests and procedures for the purpose of assessing whether operations are in compliance with applicable Environmental Laws.

Analytical work must be done by qualified laboratories; and where required by law, the laboratories must be certified.

3.5.3 Regulatory notifications. The Contractor is responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The Contractor must submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities.

Regulatory notifications must be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

3.5.4 Environmental manager. The Contractor must appoint in writing an Environmental Manager for the project, who is responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager must ensure compliance with Hazardous Waste Program requirements, including hazardous waste handling, storage, manifesting, and disposal;

implement the Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas; ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the Environmental Records binder and required documentation, including environmental permits compliance and close-out.

3.5.5 HW disposal. Contractor must comply with SFLC Std Spec 0000 Appendix A, Requirements For Environmental Protection At Contractor Operated (Non USCG) Facilities for HW disposal.

3.6 Local Policy. The Contractor must refer to site (e.g., Base) Regulations and Instructions for details regarding local policies (e.g., crane services, parking, or facility usage).

3.7 SFLC Standard Specification approved changes. Approved updates to the 2022 SFLC Standard Specifications will appear here.

13 (REV-0)

3.7.1 SFLC Standard Specification 5550: Replace paragraph 3.11.3 to state, “Material supporting imminent work shall be brought on the cutter and stored where the work is being performed. Material that appreciably contributes to fire load shall be removed at the end of each work shift when personnel are not present. Trash, debris, and packaging materials shall be promptly removed from the vessel at the end of each work shift and not allowed to accumulate.” Advance the paragraph numbering of the Fire Prevention and Safety Inspection form to 3.11.4.

3.8 Certified OEM Dealership. The Contractor (awardee) must be an authorized/licensed dealership for Caterpillar Marine diesel engines/generator, to accomplish the following:

• 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.

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

• 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.

3.8.1 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 maintained. The full cost associated with trainee efforts shall be funded by the Contractor and shall not be charged to this contract.

3.8.2 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 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.

3.8.3 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.

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4. NOTES

None.

15 (REV-0)

31100_AKW_0826_WMSL

WORK ITEM 1: Caterpillar (CAT) Ship Service Diesel Generator, Engine Major Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform the Major Overhaul on each of the Ship Service Diesel Generator (SSDG) Caterpillar 3512B Diesel listed in Table 1.

TABLE 1 – NAME PLATE DATA

CATERPILLAR

MODEL NO. DESCRIPTION LOCATION

3512B No.2 Ship Service Diesel Generator,1360 KW, 450 Volt AC, 3 Phase, 60 Hz

Forward Main Machinery Room (5-44-01-E)

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST

($/UNIT)

Y **CRANKSHAFT NSN: 2815-01-511-2837

PN: 128-6786

1 42,164.08

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 418A-WMSL-540-001, Rev D, Fuel Oil Diagram Coast Guard Drawing 418A-WMSL-540-002, Rev A, Diesel Eng And Gas Turb LO Fill, Trans, & Service Sys Coast Guard Drawing 418A-WMSL-551-001, Rev B, Compressed Air Diagram Coast Guard Drawing 750-WMSL-501-002, Rev H, Machinery Arrangement Coast Guard Drawing 750-WMSL-508-001, Rev C, Piping and Machinery Insulation Schedule and L/M (ASC508001) Coast Guard Drawing 750-WMSL-520-001, Rev H, Seawater Cooling System Diagram

(ASC520001)

Coast Guard Drawing 750-WMSL-635-002, Rev K, Insulation Arr & Details Thermal, Acoustic, & Fire (ASC635002) Coast Guard Drawing FL-1204-3, Rev A, Fleet Welded Padeyes And Links

16 (REV-0)

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 7119, Rev B, SWBS 311, May 2025, Ship Service

Diesel Generators Model 3512B Coast Guard Technical Publication (TP) 7368C, Rev A, SWBS 311, Jul 2025, Ship Service

Diesel Generators (SSDG) Model 3512B Parts Manual Coast Guard Technical Publication (TP) 14025, Rev A, Apr 2025, Ship Service Diesel Generator

Sets Caterpillar 3512B Marine Auxiliary Technical Manual Volume 1 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 3041 (SFLC Std Spec 3041), 2022, Shipboard Electrical Cable Test Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2022, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, and Installation Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2022, Auxiliary Machine Systems Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

American National Standards Institute (ANSI/EASA) AR100, 2020, Recommended Practice for the Repair of Rotating Electrical Apparatus Caterpillar® Marine Model D3512 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)

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2016, Solvent Cleaning

3. REQUIREMENTS

3.1 General.

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

• 3.2 Failure Investigative Work.

• 3.5 Additional contractor furnished equipment (CFE)

• 3.5.6 Crankshaft inspection

3.1.2 Tech Rep. The Contractor must provide the services of an authorized/licensed OEM certified Caterpillar marine Tech Rep for the Caterpillar SSDG (Engine Model No. 3512B) to accomplish the following on site:

17 (REV-0)

• Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

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

• Advise on manufacturer's proprietary information pertinent to the system.

• Ensure compliance with manufacturer's procedures and standards during the performance of the work item.

3.1.2.1 Ensure the Tech Rep has a résumé of demonstrated experience with the system/equipment stated above.

3.1.2.2 Submit the Tech Rep’s name and résumé to the COR at the Arrival Conference.

3.1.2.3 The OEM authorized/ licensed Caterpillar Technical Representative must be present, on site, while the following engine work is being performed:

• Disassembly of Engine

• Inspection and Qualification of Parts

• Maintenance Listed in Paragraph 3.6 herein

• Re-assembly of Engine

• Engine Final Preparation for Testing

• Engine Cleaning

• Engine Testing

• Troubleshooting

• System Adjustments

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).

3.1.3.1 Overhead wipe down. Prior to commencing work, the Contractor must protect the open sections of the engine with a drop cloth to prevent contamination of the engine. Wipe down the overheads above the SSDG, including all framework, stiffeners, piping, intake piping, exhaust piping, and other items in the overhead to remove dirt and dust, which could fall into the engine during work.

3.1.4 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

• Insulation

• Electrical wiring

• Overhead lights

• Catwalks will require removing handrails and placing adequate supports/shoring under, if they are intended to be used to hold heavy engine parts

• Exhaust system

• Intake system

18 (REV-0)

3.1.5 Special tools. Overhaul of the engine requires the use of special tools. The Technical Manual describes the tools needed. The Contractor or the OEM authorized/ licensed Caterpillar Technical Representative being supplied by the Contractor is responsible for supplying all of the special tools and any other tools needed to overhaul the engine. The Coast Guard does not have any of the special tools required for overhaul of the engine

3.1.6 Testing plan. The Contractor must submit a plan for final break-in and testing of the SSDGs in Table 1 in accordance with Tech Rep direction, Cutter Operating Procedures, requirements of Paragraph

3.3 herein and TP 7119 (both for prime mover and National Oilwell Varco or Kato generator). The test plan must include a CAMPAR test to be performed by the Tech Rep. Submit the testing plan no later than one week after the Arrival Conference via a CFR.

NOTE

Only refer to Kato Technical Publication for NSC 10.

3.1.6.1 The Contractor must obtain the OEM authorized/ licensed Caterpillar Tech Rep’s approval of the Testing Plan.

3.1.6.2 No testing can commence before COR approval.

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

• Procedures to handle emergencies during the testing process (fire, engine casualty, injury, etc)

• Method of testing E-Stop and automatic safety shutdowns (including high coolant temperature and low oil pressure automatic shutoffs)

• Load bank specification and location (final operational test only)

• Cable locations for load bank

• No-load tests

• Loaded tests

• Parallel load sharing

• All proposed connection, cable and load bank configurations

• Data to be collected during tests. At a minimum, this would include:

o Governor settings/fuel rack position o Cylinder exhaust temperature o Jacket water temperature o Cylinder compression pressure o Cylinder firing pressure o Crank case vacuum o Intake manifold pressure o Exhaust back pressure o Fuel oil consumption (total consumption over the course of the test) o Lube oil consumption (total consumption over the course of the test)

3.1.7 Electrical work. The Contractor must accomplish all electrical work in accordance with SFLC Std Spec 3042, and test cables in accordance with SFLC Std Spec 3041.

19 (REV-0)

Lifting points or padeyes are available in the overhead to assist with lifting engine components.

3.1.8 Rigging. The Contractor is responsible for all rigging with the following considerations:

3.1.8.1 All existing padeyes that will be used for a lift must be pull tested to 1.5 times their Working Load Limit in accordance with SFLC Standard Spec 5000 Paragraph 3.2.7. All testing must occur in the presence of a Coast Guard Inspector.

3.1.8.2 If new padeyes are required, fabricate them in accordance with Coast Guard Drawing FL-1204-3 and SFLC Standard Spec 0740. Newly fabricated padeyes must be pull tested to 2 times their Working Load Limit in accordance with SFLC Standard Spec 5000 Paragraph 3.2.7. All testing must occur in the presence of a Coast Guard Inspector.

3.1.8.3 Upon completion of testing, install a label plate in accordance with SFLC Standard Spec 5000 Paragraph B2.9.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.2 Investigative work. In conjunction with component removal and prior to any component disposal, the Contractor must submit a CIR providing a consolidated failure analysis investigation report of damaged components that caused the engine failure. Report must include, but are not limited to, main bearings, pistons, liners, conrod bearings, crankshaft, turbochargers, cylinder heads, filters, strainers and crankcase ventilation system. Report shall include photos of each component found defective and any future recommendations for operations.

#2 SSDG experienced high crankcase pressure with oil/smoke vapor protruding from lube oil dipstick ports and crankcase vents. Ships Force attempted minor dynamic troubleshooting, but vapor generation was too rapid to continue operation of the engine. The SSDG was tagged out and opened (and remained open) for further investigation work and repairs.

3.3 Structural measurement Before engine disassembly, the Contractor must record crank thrust, web deflection, timing and any gear backlash deemed necessary by the Tech Rep. Submit a CFR with recorded data.

3.4 Additional contractor furnished equipment (CFE). Prior to starting engine overhaul, the Contractor must submit a CIR with a list of all additional required parts that are not supplied as GFE nor explicitly listed for renewal in Table 2. The list must include the part name, part number, and date of delivery (or estimated date, if not currently received) of all CFE to ensure all material arrives on time to support the work schedule.

TABLE 2 – MINIMUM CFE RENEWAL LIST

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ITEM DESCRIPTION PN QTY ITEM DESCRIPTION PN QTY

AUX WATER PUMP GP PN: 4243625 1 SEAL PN: 5328532 4

BEARING-CAMSHAFT PN: 1011198 14 SEAL PN: 9X7523 2

BEARING-CONN ROD PN: 1077330 12 SEAL PN: 1073759 2

BELLOWS AS PN: 2071364 10 SEAL PN: 1782437 2

BELLOWS AS PN: 2071390 2 SEAL PN: 2714926 1

BOLT PN: 0S1594 4 SEAL AS-WATER PN: 4200652 48

BOLT PN: 1653932 2 SEAL AS-WATER PN: 4200653 48

BOLT PN: 1653934 2 SEAL-BONDED PN: 6V0405 4

BOLT PN: 1A5964 4 SEAL-CRANKSHAFT PN: 5697728 1

BOLT PN: 3008579 8 SEAL-CRANKSHAFT PN: 5697729 1

BOLT-HIGH TEMP PN: 5P8880 4 SEAL-INTEGRAL PN: 1272176 12

BOLT-HIGH TEMP PN: 7L6443 80 SEAL-INTEGRAL PN: 2348937 2

BOLT-HIGH TEMP PN: 9L7373 52 SEAL-O-RING PN: 0336031 3

BOLT-HIGH TEMP PN: 6V1943 12 SEAL-O-RING PN: 1092332 8

BOLT-HIGH TEMP PN: 6V6753 8 SEAL-O-RING PN: 1097411 2

BOLT-LOCKING PN: 9X8872 48 SEAL-O-RING PN: 1123102 4

BRIDGE FLOAT PN: 2657537 12 SEAL-O-RING PN: 1367227 6

BRIDGE FLOAT PN: 2657538 12 SEAL-O-RING PN: 1H9696 1

BUSHING PN: 1011372 1 SEAL-O-RING PN: 2147566 12

BUSHING PN: 1259751 2 SEAL-O-RING PN: 2147568 40

BUSHING PN: 1275400 2 SEAL-O-RING PN: 2287090 2

BUSHING PN: 1409597 2 SEAL-O-RING PN: 2287097 1

BUTTON PN: 1546389 36 SEAL-O-RING PN: 2353546 4

CAMSHAFT AS PN: 4522501 1 SEAL-O-RING PN: 2385080 3

CAMSHAFT AS PN: 4522502 1 SEAL-O-RING PN: 2385081 13

CAMSHAFT AS PN: 4522503 1 SEAL-O-RING PN: 2986387 1

CAMSHAFT AS PN: 4522504 1 SEAL-O-RING PN: 3J1907 3

CORE AFTERCOOLER PN: 2828217 1 SEAL-O-RING PN: 3J7354 2

CORE GP-O CLR PN: 4W4980 1 SEAL-O-RING PN: 3K0360 5

CYLINDER PACK PN: 10R-4343 12 SEAL-O-RING PN: 4F7387 1

DAMPER GP-BASIC PN: 1463740 1 SEAL-O-RING PN: 4S5898 12

GASKET PN: 1228856 2 SEAL-O-RING PN: 5B4399 1

GASKET PN: 1637826 1 SEAL-O-RING PN: 5D5957 9

GASKET PN: 2301072 2 SEAL-O-RING PN: 5P0840 27

GASKET PN: 2415928 12 SEAL-O-RING PN: 5P4892 7

GASKET PN: 2416236 1 SEAL-O-RING PN: 5P5846 1

GASKET PN: 2432288 4 SEAL-O-RING PN: 5P7530 12

GASKET PN: 2W0752 2 SEAL-O-RING PN: 5P7818 1

GASKET PN: 3094550 1 SEAL-O-RING PN: 5P8210 2

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GASKET PN: 3P6061 1 SEAL-O-RING PN: 6J2680 7

GASKET PN: 4289129 12 SEAL-O-RING PN: 6K6307 1

GASKET PN: 4289130 20 SEAL-O-RING PN: 6V1454 2

GASKET PN: 4973911 2 SEAL-O-RING PN: 6V3348 12

GASKET PN: 4H7869 3 SEAL-O-RING PN: 6V3907 6

GASKET PN: 4N1320 2 SEAL-O-RING PN: 6V3908 1

GASKET PN: 6F4868 2 SEAL-O-RING PN: 6V3917 4

GASKET PN: 7N3049 1 SEAL-O-RING PN: 6V5048 9

GASKET PN: 7N4320 2 SEAL-O-RING PN: 6V5064 3

GASKET PN: 7N4932 1 SEAL-O-RING PN: 6V5066 5

GASKET PN: 7N4945 3 SEAL-O-RING PN: 6V5101 13

GASKET PN: 8N2559 1 SEAL-O-RING PN: 6V5103 4

GASKET PN: 9L1480 2 SEAL-O-RING PN: 6V6228 36

GASKET PN: 9Y8389 2 SEAL-O-RING PN: 6V8001 1

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GASKET PN: 2473796 2 SEAL-O-RING PN: 6V8002 1

GASKET PN: 2528374 2 SEAL-O-RING PN: 6V8260 1

GASKET PN: 3419211 8 SEAL-O-RING PN: 6V9769 12

GASKET PN: 4P4460 2 SEAL-O-RING PN: 7X4805 3

GASKET PN: 7N3368 2 SEAL-O-RING PN: 8C0562 3

GASKET PN: 7N7559 2 SEAL-O-RING PN: 8T1919 14

GASKET PN: 5N1940 1 SEAL-O-RING PN: 8T2928 3

GASKET-COPPER PN: 4B8407 8 SEAL-O-RING PN: 8T2929 3

GASKET-CYL HEAD PN: 3628264 12 SEAL-O-RING PN: 9M2610 1

GASKET-EXHAUST PN: 4537800 4 SEAL-O-RING PN: 6V9027 2

GASKET-HEAT EXCH PN: 3H5939 1 SEAL-O-RING PN: 3103954 3

GASKET-MANIFOLD PN: 7N5080 12 SEAL-O-RING PN: 5P8872 1

GASKET-PLATE PN: 1445692 12 SEAL-O-RING PN: 1808424 3

GEAR-FLYWHEEL PN: 2330643 1 SEAL-O-RING PN: 6V6609 9

HARNESS AS-WIRING PN: 1326469 12 SEAL-O-RING PN: 8L2786 2

HEAD GP-CYL BSC PN: 3356220 12 SEAL-O-RING PN: 5H6734 1

HOSE PN: 2693129 1 SEAL-O-RING PN: 2594598 1

HOSE PN: 5P1469 5 SEAL-O-RING PN: 2594600 3

HOSE AS PN: 1874606 1 SEAL-O-RING PN: 2697885 3

HOSE AS PN: 3095088 1 SEAL-O-RING PN: 3237347 12

HOSE AS PN: 5755643 2 SEAL-O-RING PN: 4477206 4

HOSE AS PN: 2525658 2 SEAL-O-RING PN: 1123540 4

HOSE AS PN: 3836859 1 SEAL-PLATE PN: 1492209 65

HOSE AS PN: 5326587 1 SEAL-RECTANGULAR PN: 7N6806 4

HOSE-ELBOW PN: 1417143 1 SEAL-RING PN: 1515257 2

HOSE-TEE PN: 2176692 1 SEAL-THREAD PN: 8J6775 2

INJECTOR GP-FUEL PN: 3920217 12 SEAL-VALVE COVER PN: 2720760 12

LIFTER AS PN: 2827944 12 SENSOR GP-TEMP PN: 2639597 12

LIFTER AS-VALVE PN: 5744543 24 SHAFT AS PN: 2302633 12

LOCKNUT PN: 2K4973 4 SHIELD PN: 2843920 2

LOCKNUT PN: 2N2766 4 SHIELD AS-EXHAUST PN: 1406468 1

MAIN BEARING PN: 1496031 7 SHIELD AS-EXHAUST PN: 1406469 1

NUT-FLANGE PN: 3102233 8 SHIELD AS-EXHAUST PN: 5051567 1

PLATE-SPACER PN: 5197297 12 SHIELD AS-EXHAUST PN: 5051568 1

PLATE-THRUST PN: 1011365 1 SPRING-INJECTOR PN: 1003878 12

PUMP FUEL PRIMING PN: 1623906 1 THRUST PLATE PN: 7C6209 2

PUMP GP-ENG OIL PN: 4P5638 1 TURBOCHARGER PN: 5091016 2

PUMP GP-F XFR PN: 3137770 1 VALVE-CHECK PN: 7E3921 1

PUMP GP-WATER PN: 4160610 1 WASHER AS-THRUST PN: 7C3258 2

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RING-RETAINING PN: 9F7707 36 WASHER-THRUST PN: 1011368 2

ROCKER ARM AS PN: 2816159 12 WASHER-THRUST PN: 7N3218 2

ROCKER ARM AS PN: 2302621 24 WASHER-THRUST PN: 7N5246 2

ROD END PN: 7X7875 2 WASHER-THRUST PN: 7N7539 2

SEAL PN: 2407032 12 WIRING HARNESS PN: 4457604 1

SEAL PN: 2720758 12 WIRING HARNESS PN: 4457605 1

SEAL PN: 2720759 12 WIRING HARNESS PN: 2600003 1

Equivalent Caterpillar Remanufactured (ReMan) part may be substituted for any part listed above.

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3.5 SSDG Overhaul (Major). The contractor must execute the Major Overhaul listed in TP 14025 (SMCS Code 7595-020-MJ).

3.5.1 The Contractor is responsible for all engine disassembly and reassembly necessary to complete these repairs and inspections.

3.5.2 The Contractor must drain and disconnect the SSDG engine assembly fluid systems including, but not limited to, fuel oil supply and return, jacket water, sea water, and lube oil systems (Approximately 200-gallons jacket water, 165-gallons lube oil, and 5-gallons fuel oil, per engine assembly). Remove the fluid systems from the Cutter and dispose of in accordance with all applicable federal, state, and local laws and regulations. The Contractor must submit a CFR for an initial wiring diagram of the pre-lube pump prior to unwiring the pump. Contractor shall not proceed to unwire the pump without COR approval.

3.5.3. The Contractor is responsible for all engine cleaning required to accomplish these repairs and inspections, as well as for any debris that migrates into the engine during work. Dispose of all residual fluids in accordance with Federal, State and Local laws and SFLC Std Spec 0000.

3.5.4 The Contractor must furnish all tools, equipment, consumable and parts required to perform the Major Overhaul. The mandatory parts that require renewal are listed in Table 2. Equivalent Caterpillar Remanufactured (ReMan) part may be substituted for any part listed if authorized by the OEM.

3.5.5. The Contractor must submit a CFR with the inspection results for all components in the “Inspection, Reconditioning or Exchanging of Components” or “Inspection of Components” section. For bidding purposes, assume that all GFP provided material and CFE furnished material in Table 2 will be renewed as a minimum. Note clearly in the CFR when any components fail their inspections in accordance with the Caterpillar Publication Reusability Manual SEBF8029 (series).

3.5.6 The Contractor must inspection the crankshaft condition in accordance with the Caterpillar Publication Reusability Manual SEBF8029 (series). Submit a CIR with inspection results.

3.5.6.1 The Contractor may be directed to renew the Crankshaft in accordance with Work Item “Caterpillar (CAT) Ship Service Diesel Generator, Crankshaft Renewal.”

3.5.7 When reassembling the engine, components must be torqued to values given in Coast Guard TP 7119. If no torque value is given in the TP, rely on directions from the OEM authorized/ licensed Caterpillar Technical Representative.

3.5.8 The Contractor is responsible for disconnecting and reconnecting services to the engine as required to overhaul the engine (further delineated by the full content of this specification), all associated service systems including, but not limited to, exhaust, ventilation, fuel oil, sea water, and lube oil. Reference Section 2 for more information about these systems

3.5.9 Engine components, which require removal for performance of this work item, must be labeled, and stored in a covered and protected location off-ship for reuse. If necessary, cables attached to such items may also be disconnected and pulled back per SFLC Std Spec 3042. Ensure that all reused items have been thoroughly cleaned of excess lubricants and soot.

3.5.10 Any items listed as MTI must be cleaned of excess lubricants and soot and packed in the containers that had the new components.

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3.5.11 Table 3 provides information about the SMCS code for various pieces of equipment as shown in TP 7119. This is NOT an exhaustive list of all the work that must be done in the scope of this work item.

3.5.12

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TABLE 3 – MAINTENANCE ITEMS

ITEM SMCS

CODE ITEM SMCS

CODE

Aftercooler 1063-040 Front Gear Group 1064-571 Fuel Filter Elements and Filter Housing 1260

Air Cleaner Housing 1051 Fuel Injection Control Linkage 1290

Air Inlet Shutoff / Damper 1078-081 Fuel Injectors 1290 1078-535 Fuel Lines 1290 1078-011 Fuel Pressure Regulating Valve 1250-081

Air Starting Motor/Electric Starting Motor

1451-040 Fuel Transfer and Priming Pump 1256 1451-535 Heat Exchanger 1350 1451-070 Intake Manifold

Camshaft 1210 Lube Oil Filter Bypass Valve Cooling System 1371 Lube Oil Filter Elements

Crankshaft 1202 Lube Oil Valves Crankcase Breather 1317 Oil Sequencing Valves

Crankshaft Front Seal 1160 Oil Pan and Oil Pan Screen Crankshaft Rear Seal 1160 Oil Pump 1304

Crankshaft Main Bearing 1201 Piston and Connecting Rod Assemblies and Cylinder Liners

Cylinder Heads 1100 1218

Electrical Components

1063/1395 Piston Cooling Jets 1214 1924 Pressure and Temperature Gauges and RPM

Indicators on Local Control Panel 1907-070 1052/1919 Rear Gear Group 1202

Engine Mount 1152-535 Turbocharger 1052-040 Engine Oil Cooler 1300 Valve Covers, Rocker Shaft Assy, and Push Rods 1102

Engine Oil Filter Housing 1318 Valve Lifters and Guides 1102 Exhaust Manifolds 1059 Vibration Damper 1205

Flywheel & Flywheel Housing

1156 VULKAN Coupling 1157 Water Temperature Regulators 1408

Fresh Water Pump 1361-040 Zinc Rods

1388-040 Front Drive Housing 1207 1388-510

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3.5.11 Driven equipment will be addressed in Paragraph 3.8 herein.

3.6 Diesel engine final cleaning. After completion of engine repairs and overhaul, the Contractor must open and clean the engine crankcase. Wipe out the crankcase using lint free rags. After cleaning, inspect the crankcase in the presence of the OEM authorized/ licensed Caterpillar Technical Representative and the Coast Guard Inspector. Verify no foreign objects are in the crankcase. Submit a CFR.

3.6.1 Hot Lube Oil Flush. Following crankcase obstruction verification, the Contractor may be directed to perform a Hot Lube Oil Flush of the engine and ancillary equipment in accordance with Work Item “Caterpillar (CAT) Diesel Engine Hot Lube Oil Flush, Perform.”

3.7 Alignment. Upon completion of the overhaul, the Contractor must prepare the engine for final alignment.

NOTE

Final alignment will be completed by USCG personnel. Once the engine overhaul is complete, provide written notice to the Contracting Officer Representative (COR). The Coast Guard will require three (3) calendar days from the time of receipt of written notification to mobilize personnel and execute the final shaft alignment and gerenator pinning. The Contractor must not perform any work that interferes with alignment operations without prior written approval from the COR.

3.7.1 In the presence of the CG Inspector, fill the engine’s jacket water with contractor furnished Caterpillar Extended Life Coolant (CAT ELC).

3.7.2 In the presence of the CG Inspector, fill the engine’s lube oil sump. Lube oil will be furnished from ship's lube oil storage tanks.

NOTE

Final filling of engine sumps with lube oil will be performed by the Coast Guard using onboard piping, valves, and lube oil storage tanks.

3.7.3 Check engine timing in accordance with CG TP, and the OEM authorized/ licensed Caterpillar Technical Representative’s guidance.

3.7.4 The Contractor must replenish the lube oil storage tanks with approximately 165-gallons used to refill each engine. Exact quantity and type of lube oil shall be verified by Coast Guard Inspector prior to scheduling this operation.

3.8 Perform the following checks in accordance with instructions provided in the manufacturer's Technical Manual. These checks are described in the technical manual under the section on System Operation Testing and Adjusting, Section 7, TP 14025.

• Fuel System Inspection

• Fuel Injector Testing

• Engine Rotation

• Camshaft Timing

• Set Valve Clearances

28 (REV-0)

• Cooling System Pressure Test

• Safety Switch Operation

3.8.1 Prior to the performance of engine testing, conduct a comparison of all gages and pyrometers that will be used to record the engine’s performance against a certified standard to ensure accuracy of reporting. Provide a CFR listing the gage readings between local and remote gages. Take final crankshaft web deflection readings and thrust measurements. Record on a CFR. Show the post overhaul readings to the COR and to the OEM authorized/ licensed Caterpillar Technical Representative for final approval.

3.8.2 Prior to operational testing, set and adjust the engine overspeed trip in the presence of the OEM authorized/ licensed Caterpillar Technical Representative and the Coast Guard Inspector. Document successful testing with a CFR before proceeding with the rest of the test.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

Ensure a person is standing by the emergency shutdown when starting the engine after maintenance.

3.9 Operational test, post repairs. After completion of work, the Contractor must thoroughly test, in the presence of the Coast Guard Inspector 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.

3.9.1 All system adjustments must be performed by the Contractor in accordance with TP 7119 and OEM authorized/ licensed Caterpillar Technical Representative’s guidance, to provide satisfactory operation of the SSDG engines throughout the range of operation.

3.9.2 The Contractor must provide at least one (1) person to attend the ship during engine testing to record test data, and require the Tech Rep to attend the ship during engine testing and break-in.

NOTE

Machinery Control and Monitoring System (MCMS) setup will be performed by Coast Guard Personnel.

3.9.3 The Contractor must execute the final test plan.

3.9.3.1 The Contractor must provide a resistive load bank (i.e. 450 Volt, 1500 KW) with cabling (approximately 300 ft.) and accessories to test the SSDG listed in Table 1. The load bank must be placed on the pier or the cutter at the discretion of the COR. The Contractor must provide any additional labor or crane services for the setup, operation, and disassembly of the load bank and associated cabling or accessories.

3.9.3.2 The Contractor must check all piping system joints for tightness and correct, as required.

3.9.3.3 In addition to measurements taken in the test plan, the Contractor must operate the engine at no load and low idle at approximately 900 RPM. Run for 15 minutes, or until temperatures and pressures stabilize, whichever comes soonest. Stop the engine, remove crankcase covers and measure and record conrod and main bearing temperatures. Any unusual operating conditions must be corrected by the Contractor. Submit a CFR with test results.

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3.9.3.4 In addition to measurements taken in the test plan, the Contractor must operate the engine at no load at 1800 RPM. Run for 15 minutes, or until temperatures and pressures stabilize, whichever comes soonest. Stop the engine, remove crankcase covers and measure and record conrod and main bearing temperatures.