Attachment 1- PWS Dated 31JUL2025.pdf

PERFORMANCE WORK STATEMENT (PWS)

Maritime Security Cutter Large (WMSL) Main Propulsion Diesel Engine (MPDE) Dockside (DS) Scheduled Maintenance and Emergent Repairs

(31 July 2025)

1 General: This is a non-personal services contract to provide all labor, materials, services, equipment, supplies, power, accessories and facilities to perform scheduled maintenance and emergent repairs to the Main Propulsion Diesel Engines (MPDEs) on the United States Coast Guard (USCG) 418’ Maritime Security Cutter Large (WMSL) Class of USCG Cutters.

Performance shall take place in Alameda, CA, Charleston, SC, Honolulu, HI, and worldwide as required for emergent repairs. The Government shall not exercise any supervision or control over the Contractor employees performing the services herein. The Contractor’s employees shall be accountable solely to the Contractor who, in turn, is responsible to the Government.

1.1. Description of Services/Introduction: The Contractor must furnish all labor, materials, services, equipment, supplies, power, accessories and facilities to perform scheduled maintenance and emergent repairs to the MPDEs on the USCG 418’ WMSL Class of USCG Cutters in accordance with the solicitation, schedule and specifications, except for those items specified as Government furnished property and services.

1.2. Background: It is anticipated that the USCG will require maintenance and repair services for the MTU 20V1163 TB93 MPDE, installed on the 418’ WMSL Class of USCG Cutters.

2 Objectives/Scope - Technical and Engineering Services: The Contractor must furnish all labor, materials, services, equipment, supplies, power, accessories and facilities to provide technical and engineering services for the MPDEs on the USCG 418’ WMSL Class of USCG Cutters in accordance with the solicitation, schedule and specifications as follows. For each task, the Contractor must conduct initial and post-repair operational tests of the equipment/system and submit a Condition Found Report (CFR).

2.1 Technical Services, Provide (one hour). The Contractor must provide on-site services of a

Technical Representative for work on the MPDE. The Contractor must provide manufacturer's proprietary information, software, and tools pertinent to the MPDE, be present and assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly. The Contractor must prepare reports with summaries of services provided.

2.2 Technical Services, Provide (one hour “overtime”). The Contractor must provide on-site services of a Technical Representative for work on the MPDE. The Contractor must provide manufacturer's proprietary information, software, and tools pertinent to the MPDE, be present and assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly. The Contractor must prepare reports with summaries of services provided.

2.3 Technical Services, Provide (one hour “Holiday”). The Contractor must provide on-site services of a Technical Representative for work on the MPDE. The Contractor must provide manufacturer's proprietary information, software, and tools pertinent to the MPDE, be present and assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly. The Contractor must prepare reports with summaries of services provided.

2.4 Engineering Services, Provide. The Contractor must provide engineering services via in-person visits, phone calls, and or emails, to support the development and modification of maintenance programs and procedures pertinent to the MPDE and provide technical engineering services to support maintenance, troubleshooting, and repair of the MPDE and its interface with the propulsion gas turbine, main reduction gears, control systems, and running gear. The Contractor must prepare reports with summaries of services provided at the end of each month.

2.5 MPDE, Commission/Cold and Hot Checks of ADEC-UNI Governor. The Contractor must complete MPDE complete Hot and Cold check IAW RRSA document USCG NSC 20V1163 Cold Checks, to include dockside and sea trials. During sea trials, the Contractor must ensure correct break-in operations and make any required adjustments.

Following completion of sea trials, the Contractor must perform the 50-hour service on the MPDE.

2.6 Dock Trial Performance Support, Provide. The Contractor must provide Technical Representatives on board the cutter while inport for performance of dock trials following maintenance and repairs.

2.7 Sea Trial Performance Support, Provide. The Contractor must provide Technical

Representatives on board the cutter while underway for the performance of sea trials for a 72-hour period.

2.8 Miscellaneous Parts and Consumables, Provide. The Contractor must provide miscellaneous parts and consumables associated with the performance of technical services not encompassed under defined maintenance and emergent repair actions. The Contractor must submit pricing for miscellaneous parts and consumables, including shipping, to the Contracting Officer’s Representative.

2.9 Travel. The Contractor must submit travel expense claims to the Contracting Officer’s Representative monthly, to encompass all travel completed in the previous month. Any direct labor expenses incurred by the Contractor for travel time must be burdened as part of the Contractor’s indirect rates and cannot be billed directly as technical services.

3 Objectives/Scope - Maintenance and Emergent Repairs: The Contractor must furnish all labor, materials, services, equipment, supplies, power, accessories and facilities to perform scheduled maintenance and emergent repairs to the MPDEs on the USCG 418’ WMSL Class of USCG Cutters in accordance with the solicitation, schedule and specifications as follows. For each task, the Contractor must conduct initial and post-repair operational tests of the equipment/system and submit a Condition Found Report (CFR).

3.1 MPDE, Inspect. The Contractor must perform a MPDE Diesel Engine Inspection (DEI).

Include in the CFR any discrepancies, defects or unexpected wear discovered during visual inspections, cylinder compression readings, valve clearance readings, turbocharger inspections, gear case inspections, cylinder liner inspections, air bank inspections, and filter element inspection and replacement. Submit a separate final report noting the condition of the engine, inspection results, and LOS data plots. The following GFE will be provided:

MTI Item NSN/Part No. Qty/Engine Note

N Parts Kit, Diesel Engine NSN: 2815-01-628-0945

P/N: 584-DEI-KIT

3.2 Long Term Lay-Up Preservation, Perform. The Contractor must perform long term preservation and re-activation of the MPDE.

3.3 Cofferdam, Install. The Contractor must install a cofferdam over the sea chest of the raw water pump and overboard discharge location.

3.4 Set Up and Tear Down, Perform. The Contractor must remove and reinstall interferences and drain and refill fluids to facilitate performance of intercooler and cylinder component maintenance.

3.5 Engine Oil Flush, Perform. The Contractor must flush the engine oil of the MPDE.

3.6 Engine Coolant, Flush and Replace. The Contractor must drain, flush and refill engine coolant system of the MPDE.

3.7 Coolant Pumps, Renew. The Contractor must renew the right and left coolant pumps of the MPDE. The following GFE will be provided:

Y Jacket Water Pump Replacement Kit NSN: 4320-01-619-2545

PN: 584-JWPMP-RPLM

3.8 Crankshaft Thrust Bearing Clearance, Check. The Contractor complete Thrust Bearing

Clearance Check. Submit report.

3.9 Engine Mounts, Inspect and Adjust. The Contractor must perform an inspection of the MPDE engine mounts and readjust the engine mounts as required by the USCG.

3.10 Injectors, Renew. The Contractor must renew the injectors of the MPDE. The following GFE will be provided:

Y Injector Replacement Kit NSN: 2910-01-621-1898

PN: 584-INJ-SWAP-KIT

3.11 Injector Pumps, Renew. The Contractor must renew the injector pumps of the MPDE.

Y Fuel Injection Pump Kit NSN: 2910-01-619-2228

PN: 584-FL-INJ-PMP-KIT

3.12 Oil Thermostat, Renew. The Contractor must renew the oil thermostat of the MPDE. The following GFE will be provided:

N Oil Thermostat NSN: 6685-12-347-9909

PN: 5841404818

3.13 Turbocharger Controls, Renew. The Contractor must inspect and overhaul the turbocharger controls of the MPDE. The following GFE will be provided:

N Valve Assembly NSN: 4810-12-360-4998

PN: 0005342732

N Actuating Cylinder NSN: Pending Assignment

PN: X57799100039

3.14 Exhaust Manifold, Renew. The Contractor must renew the exhaust manifold of the

MPDE. The following GFE will be provided:

Y Exhaust Manifold NSN: 2815-01-F19-5828

PN: 5841404818

3.15 Start Air System, Clean and Inspect. The Contractor must clean and inspect the start air system of the MPDE.

3.16 Alignment, Check. The Contractor must check the alignment of the MPDE to the Reduction Gear using laser alignment equipment. Prior to taking alignment readings, verify that the ship is at approximately 80% fuel load, that engine room temperature is at least 20°C, that engines have not been operated for at least 48 hours, and that alignment readings will be taken between 12:00 AM and 8:00 AM. Include in the CFR the date and time of alignment readings, a copy of the ship’s liquid loading, a record of the engine room and external temperatures, the axial position and radial and axial alignment of the MPDE to the Reduction Gear, and measurements of alignment over the distance between the MPDE output flange and Reduction Gear input flange.

3.17 Raw Water Pump, Renew. The Contractor must renew the raw water pump of the MPDE.

The following GFE will be provided:

Y Sea Water Pump Replacement Kit NSN: 4320-01-619-2264

PN: 584-SWPMP-RPLM

3.18 Lube Oil Pumps, Renew. The Contractor must renew the Lube Oil Pumps of the MPDE.

Y Lube Oil Pump Kit NSN: 4320-01-619-2729

PN: 584-LO-PMP-KIT

3.19 Lube Oil Coolers, Inspect and Pressure Test. The Contractor must inspect and pressure test the lube oil coolers of the MPDE. Include in the CFR borescope pictures showing the condition of the coolers before and after cleaning. Label pictures with the date, Cutter name, engine serial number, and cooler identification.

3.20 Lube Oil Cooler, Renew. The Contractor must renew the lube oil cooler of the MPDE.

Y Lube Oil Cooler NSN: 2930-12-384-6858 PN: 5841800665/32 (left)

NSN: 4420-12-384-2697

PN: 5841800765/32 (right)

1 *Confirm which side (right/left) is needed

3.21 High Pressure Intercoolers, Air Side, Chemical Clean and Inspect. The Contractor must chemically clean and inspect the air sides of the high pressure intercoolers and associated pre-heaters of the MPDE. Include in the CFR borescope pictures showing the condition of the intercoolers before and after cleaning. Label pictures with the date, Cutter name, engine serial number, and intercooler identification before and after cleaning.

3.22 High Pressure Intercoolers, Saltwater Side, Chemical Clean and Inspect. The Contractor must remove, chemically clean, inspect, and conduct leakage test of the salt water sides of the high pressure intercoolers and associated pre-heaters of the MPDE. Include in the CFR borescope pictures showing the condition of the intercoolers before and after cleaning. Label pictures with the date, Cutter name, engine serial number, and intercooler identification before and after cleaning. The Contractor must reinstall the high pressure intercoolers and associated pre-heaters of the MPDE.

3.23 High Pressure Intercoolers, Renew. The Contractor must renew the high pressure intercoolers and associated pre-heaters of the MPDE. The following GFE will be provided:

Y Cooler, Charge Air NSN: 2950-12-384-7694

PN: 0020984020/32

Y Preheater, Insert Heat Exchange NSN: 2815-12-384-3754

PN: 0020984220/87

3.24 Camshaft, Inspect. The Contractor must inspect the camshaft (one side) of the MPDE.

Include in the CFR borescope pictures showing the condition of the camshaft. Label pictures with the date, Cutter name, and engine serial number.

3.25 Camshaft, Renew (Furthest Segment). The Contractor must renew the furthest camshaft segment of the MPDE. The following GFE will be provided:

N Bushing, Size 0-0 NSN: 3120-12-360-5916

PN: 5840510150

Y Camshaft, A-Bank, Drive End NSN: 2815-12-384-5520

PN: 5840515401

Y Camshaft Kit, A-Bank, Center Section NSN: 2815-12-385-0947

PN: 5840504001

Y Camshaft Kit, A-Bank, Non-Drive End NSN: 2815-12-385-0964

PN: 5840504101

Y Camshaft, B-Bank, Drive End NSN: 2815-12-385-0965

PN: 5840504201

Y Camshaft Kit, B-Bank, Center Section NSN: 2815-12-385-0988

PN: 5840504301

Y Camshaft Kit, B-Bank, Non-Drive End NSN: 2815-12-384-5403

PN: 5840515901

N Pin, Straight, Headless NSN: 5315-12-355-6744

PN: 5809910162

N Nut, Plain, Dodecagon NSN: 5310-12-384-5538

PN: 5849900751

N Gasket NSN: 5330-12-335-0415

PN: 5810110380

N Gasket NSN: 5330-12-335-0238

PN: 5810110480

N Gasket NSN: 5330-123350085

PN: 5810110580

3.26 Exhaust Turbochargers, Renew. The Contractor must renew all exhaust turbochargers and remove, inspect, and reseal all lower turbocharger carrier housings. The following GFE will be provided:

Y LP Turbocharger Replacement Kit NSN: 2990-01-619-4969

PN: 584-LPTURBO-RPLM

Y HP Turbocharger Replacement Kit NSN: 2950-01-620-0381

PN: 584-HPTURBO-RPLM

3.27 Geislinger Coupling, Clean and Inspect. The Contractor must remove disassemble, clean, and inspect the MPDE Geislinger coupling. Once the coupling is inspected and any discrepancies are corrected, the Contractor must assemble and reinstall the coupling on the MPDE.

3.28 Geislinger Coupling, Renew. The Contractor must renew the MPDE Geislinger coupling.

MTI Item NSN/Part No. Qty Note

Y Coupling, Power Take Off NSN: 3010-01-682-7264

PN: X58425100019/32

3.29 Low Pressure Intercoolers, Air Side, Chemical Clean and Inspect. The Contractor must chemically clean and inspect the air sides of the low pressure intercoolers of the MPDE.

Include in the CFR borescope pictures showing the condition of the intercoolers before and after cleaning. Label pictures with the date, Cutter name, engine serial number, and intercooler identification before and after cleaning.

3.30 Low Pressure Intercoolers, Saltwater Side, Chemical Clean and Inspect. The Contractor must remove, chemically clean, inspect, and conduct leakage test of the salt water sides of the low pressure intercoolers of the MPDE. Include in the CFR borescope pictures showing the condition of the intercoolers before and after cleaning. Label pictures with the date, Cutter name, engine serial number, and intercooler identification before and after cleaning. The Contractor must reinstall the low pressure intercoolers of the MPDE.

3.31 Low Pressure Intercoolers, Renew. The Contractor must renew the low pressure coolers of the MPDE. The following GFE will be provided:

Y Radiator, Engine Coolant NSN: 2930-12-384-2070

PN: 5840900114/32

3.32 Coolant Plate-Core Heat Exchangers, Clean and Inspect. The Contractor must remove, clean, inspect, reassemble, and reinstall the MPDE coolant plate-core heat exchangers.

3.33 Coolant Thermostats, Renew. The Contractor must renew the coolant thermostats of the MPDE. The following GFE will be provided:

N Jacket Water Thermostat (LS) NSN: 6685-01-193-3818

PN: 584-THERMLS-RPLM

N Jacket Water Thermostat (RS) NSN: 6685-01-619-2848

PN: 584-THERMRS-RPLM

3.34 Air and Exhaust Flap, Inspect. The Contractor must preform inspection of the air and exhaust flaps of the MPDE. Include in the CFR visual inspection results of sealing, mating, and contact faces, dye penetrant inspection results of exhaust flap housing, shaft, and bearing bushes, and inspection results of thread freedom of movement.

3.35 Cylinder Heads, Renew. The Contractor must renew cylinder heads of the MPDE. The

Y Cylinder Head Replacement Kit NSN: 2815-01-619-2838

PN: 584-CYL-HD-RPLM

3.36 Cylinder Heads, Renew (one cylinder). The Contractor must renew one cylinder head of

3.37 Cylinder Heads, Renew (two or more cylinders). The Contractor must renew one cylinder head of the MPDE. The following GFE will be provided:

3.38 Piston and Connecting Rod Assemblies, Clean and Inspect. The Contractor must clean and inspect the piston and connecting rod assemblies of the MPDE.

3.39 Cylinder Liners, Renew. The Contractor must renew the cylinder liners of the MPDE.

N Cylinder Liner Kit NSN: 2815-01-619-2672

PN: 584-CYL-LNR-KIT

3.40 Cylinder Liners, Renew (one cylinder). The Contractor must renew the one cylinder liner, clean and inspect one piston and connecting rod assembly, and replace one connecting rod bearing of the MPDE. The following GFE will be provided:

PN: 584-CYL-LNR-KIT

N Conrod Bearing NSN: 3120-12-358-7417

PN: 5840301960

3.41 Cylinder Liners, Renew (two or more cylinders). The Contractor must renew the one cylinder liner, clean and inspect one piston and connecting rod assembly, and replace one connecting rod bearing of the MPDE. The following GFE will be provided:

PN: 584-CYL-LNR-KIT

N Conrod Bearing NSN: 3120-12-358-7417

3.42 Connecting Rod Bearings, Renew. The Contractor must renew the connecting bearings of

N Conrod Bearing NSN: 3120-12-358-7417

3.43 Engine Block Cylinder Bore, Machine. The Contractor must machine the Maine

Propulsion Diesel Engine block cylinder bore(s) to accommodate oversize cylinder liner(s).

3.44 Engine Block Cylinder Bore Machine/Install Set Rings to Return to Stage Zero: The Contractor must machine the engine block cylinders and install set rings to return the engine block to stage zero.

3.45 Crankshaft, Renew. The Contractor must renew the crankshaft of the MPDE. The

Y Crankshaft NSN: 3950-01-F20-6038 P/N: X51403100006/32

Y Engine Rotation Tool NSN: 2815-01-619-2838

PN: 584-1163RTN-TLN

3.46 MPDE Flexible Hoses, Renew. The Contractor must renew the hose assemblies and expansion joints of the MPDE in accordance with SFLC Std Spec 5000, Appendix C, Paragraph C2.2 (Hose assemblies).

4 Objectives/Scope - MPDE Overhauls: The Contractor must furnish all labor, materials, services, equipment, supplies, power, accessories and facilities to perform the following MPDE overhauls on the USCG 418’ WMSL Class of USCG Cutters in accordance with the solicitation, schedule and specifications as follows. For each task, the Contractor must conduct initial and post-repair operational tests of the equipment/system and submit a Condition Found Report (CFR). Each overhaul encompasses all applicable tasks from Sections 2 and 3 of this PWS (e.g.

long term layup preservation, dockside trials, and sea trials).

4.1 MPDE, 8,000 Hour Overhaul. The Contractor must accomplish the 8,000-hour overhaul in accordance with the MTU hourly maintenance schedule. The 8,000-hour overhaul encompasses cylinder component renewal (to include rings, liners, heads, fuel pumps, injectors, and connecting rod bearings), turbocharger renewal, turbocharger switching system overhaul, intercooler air-side and saltwater-side cleaning, vibration damper/torsional coupling inspection, jacket water pump renewal, salt water pump renewal, lube oil pump renewal, and cooler cleaning and inspection. The Contractor must provide new engine oil and engine fluids. Following completion of work, the Contractor must perform bilge clean-up in accordance with SSPC-SP-1 solvent clean. During sea trials, the Contractor must ensure correct break-in operations and make any required adjustments. After completion of sea trials, the Contractor must perform the 50-hour service on the MPDE. The 8,000-hour overhaul includes the following specific tasks:

Item Task Description Task #

Centrifugal Oil Filter Check thickness of residue layer, Clean. Fit new sleeve.

W1009

Emergency Air Shut-Off Check operation of emergency shut-off flaps

W1024

Valve Gear Check valve clearance, adjust if necessary

W1002

Level Monitors Check coolant level monitor for correct operation, check oil level monitor for correct operation.

W1023

Fuel Filter Fit new filter or new filter insert W1001

Lubrication Points Lubricate W1053

Intercooler (High And Low Pressure)

Clean interior and inspect for leakage

Fuel Injectors Renew all injectors

Engine Mounts Check buffer clearance of resilient mounts. Check proper seating of securing screws.

W1026

Raw Water Pump Inspect pump impeller in place

Engine Coolant Pump Renew seals

Cylinder Head Replace 20 cylinder heads

Cylinder Liner Fit new ones as appropriate. Fit new seals. Inspect fits and coolant chambers.

W1101

Turbo Charger Renew Turbo Charger W1038

Turbo Charger Switching System

Overhaul Exhaust Flaps, Air Flaps, Actuating Cylinders and Solenoids

W1131

Piston Remove Pistons, Skirts and Crowns, Fit new Piston Rings and replace with new

W2044

Component Maintenance Renew Engine Coolant Thermostat

W2038

Component Maintenance Check Rockers, roller tappets, pushrods, and pushrod ball heads for wear.

W2084

Charge-air preheating Remove, clean, replace seal on the valve face of the chair air cooler temperature control (TC) valve

P/N: 584-DEI-KIT

Y Cylinder Head Replacement Kit NSN: 2815-01-619-2838

PN: 584-CYL-HD-RPLM

N Cylinder Liner Kit NSN: 2815-01-619-2672

PN: 584-CYL-LNR-KIT

20 *

Y Piston Skirt NSN: 2815-12-381-5442

PN: 5840300615

10 *

Y LP Turbocharger Replacement Kit NSN: 2990-01-619-4969

PN: 584-LPTURBO-RPLM

Y HP Turbocharger Replacement Kit NSN: 2950-01-620-0381

PN: 584-HPTURBO-RPLM

Y Injector Replacement Kit NSN: 2910-01-621-1898

PN: 584-INJ-SWAP-KIT

Y Fuel Injection Pump Kit NSN: 2910-01-619-2228

PN: 584-FL-INJ-PMP-KIT

Y Jacket Water Pump Replacement Kit NSN: 4320-01-619-2545

PN: 584-JWPMP-RPLM

Y Sea Water Pump Replacement Kit NSN: 4320-01-619-2264

PN: 584-SWPMP-RPLM

Y Lube Oil Pump Kit NSN: 4320-01-619-2729

PN: 584-LO-PMP-KIT

N Preheater Pump Replacement Kit NSN: 2815-01-619-2234

PN: 584-PREHTRPMP-

RPLM

N Conrod Bearing NSN: 3120-12-358-7417

PN: 5840301960

N Jacket Water Thermostat (LS) NSN: 6685-01-193-3818

PN: 584-THERMLS-RPLM

N Jacket Water Thermostat (RS) NSN: 6685-01-619-2848 1

PN: 584-THERMRS-RPLM

N Piston NSN: 5815-12-334-9610

PN: 5840301117

N Turbo Charger Exhaust, Outlet Elbow NSN: 2950-12-360-6215

PN: 5110800468

N Turbo Charger Exhaust, Floating Exhaust Pipe Joint

NSN: 3120-12-360-5719

PN: 5841400265

N Sealing Ring NSN: 5330-12-315-3724

PN: 5841420857

N Sealing Ring NSN: 5330-12-165-6459

PN: 114C62033-1

*Not required, but provided and available if needed based on inspections.

4.2 MPDE, 16,000 Hour Overhaul. The Contractor must accomplish the 16,000-hour overhaul in accordance with the MTU hourly maintenance schedule. The 16,000-hour overhaul encompasses cylinder component renewal (to include rings, liners, heads, fuel pumps, injectors, and connecting rod bearings), turbocharger renewal, turbocharger switching system overhaul, intercooler air-side and saltwater-side cleaning, vibration damper/torsional coupling inspection, jacket water pump renewal, salt water pump renewal, lube oil pump renewal, and cooler cleaning and inspection. The Contractor must provide new engine oil and engine fluids. Following completion of work, the Contractor must perform bilge clean-up in accordance with SSPC-SP-1 solvent clean. During sea trials, the Contractor must ensure correct break-in operations and make any required adjustments. After completion of sea trials, the Contractor must perform the 50-hour service on the MPDE. The 16,000-hour overhaul includes the following specific tasks:

Item Task Description Task #

Lubrication points Lubricate W1053

Oil filters Inspect, Renew W1096

High pressure cooler Inspect W2068

Air filters Inspect X7650

Emergency air shut-off flaps Inspection Only W1024

Jacket water thermostat Renew W2038

Centrifugal oil filter Check and replace elements W1009

Fuel filter Replace element W1001

Valve gear Check valve clearance W1002

Engine mounts Check Buffer clearance W1026

Fuel injectors Inspect, Renew W1017

Engine coolant pump Inspect, Renew W1384

Raw water pump Renew W1383

Turbochargers Renew W1038

Cylinder heads Inspect W1063

Cylinder liners Renew W1101

Fuel pre filter Replace filter element X5900

Preheater / Jacket water heater Inspect for leaks X5602

Preheater Renew X5601

Level probes (Expansion Tank) Inspect X5501

Lube-oil tank Inspect W2040

Auxiliary priming unit Inspect

Cooler installation Clean cooler and replace seals

(PCHE)

W2068

Pressure reducing station Clean air filter, renew if necessary. Renew diaphragm (Block)

X7650 X7651

Torsional resilient coupling Inspect X5351

Compressed-air starting system Inspect W1024

Fuel Injection pumps Renew W2095

Charge-air preheating Remove, clean and check control valve (TC valve)

Intercooler (low pressure) Clean interior of cooler, check for damage

W1133

Conrod bearings Renew W1083

Gear train Perform visual inspection W1086

Governor actuator Inspect governor linkage

Turbocharger control system Overhaul exhaust flaps, air flaps, actuating cylinders and solenoids

W1131

Pistons Inspect skirts and crowns, fit new piston rings

W2044

Engine oil pump Renew W1094

Oil thermostat Inspect W1128

Component maintenance Before starting maintenance work, carry out test run and record operating parameters.

Then drain coolant and flush cooling systems.

Starting air distributor: Inspect components, check settings.

Adjust if Necessary.

Fuel thermostat (if fitted): Fit new thermostat actuator.

Check rockers, roller tappets, pushrods and pushrod ball heads for wear.

Check engine alignment Check function of monitoring devices

W2012 W2041 W2036 W2084 W2036 W2069

Air Sides of the LP intercoolers Clean and Inspect W2068

P/N: 584-DEI-KIT

Y Cylinder Head Replacement Kit NSN: 2815-01-619-2838

PN: 584-CYL-HD-RPLM

N Cylinder Liner Kit NSN: 2815-01-619-2672

PN: 584-CYL-LNR-KIT

20 *

Y Piston Skirt NSN: 2815-12-381-5442

PN: 5840300615

Y LP Turbocharger Replacement Kit NSN: 2990-01-619-4969

PN: 584-LPTURBO-RPLM

Y HP Turbocharger Replacement Kit NSN: 2950-01-620-0381

PN: 584-HPTURBO-RPLM

Y Injector Replacement Kit NSN: 2910-01-621-1898

PN: 584-INJ-SWAP-KIT

Y Fuel Injection Pump Kit NSN: 2910-01-619-2228

PN: 584-FL-INJ-PMP-KIT

Y Jacket Water Pump Replacement Kit NSN: 4320-01-619-2545

PN: 584-JWPMP-RPLM

Y Sea Water Pump Replacement Kit NSN: 4320-01-619-2264 1

PN: 584-SWPMP-RPLM

Y Lube Oil Pump Kit NSN: 4320-01-619-2729

PN: 584-LO-PMP-KIT

N Preheater Pump Replacement Kit NSN: 2815-01-619-2234

PN: 584-PREHTRPMP-

RPLM

N Conrod Bearing NSN: 3120-12-358-7417

PN: 5840301960

N Jacket Water Thermostat (LS) NSN: 6685-01-193-3818

PN: 584-THERMLS-RPLM

N Jacket Water Thermostat (RS) NSN: 6685-01-619-2848

PN: 584-THERMRS-RPLM

N Piston NSN: 5815-12-334-9610

PN: 5840301117

20 *

N Turbo Charger Exhaust, Outlet Elbow NSN: 2950-12-360-6215

PN: 5110800468

N Turbo Charger Exhaust, Floating Exhaust Pipe Joint

NSN: 3120-12-360-5719

PN: 5841400265

N Sealing Ring NSN: 5330-12-315-3724

PN: 5841420857

N Sealing Ring NSN: 5330-12-165-6459

PN: 114C62033-1

4.3 MPDE, 24,000 Hour Onboard Overhaul. The Contractor must accomplish the 24,000-hour overhaul per Coast Guard Technical Publication 7930 and in accordance with Coast Guard Technical Publications 7028 and 7031. The 24,000-hour overhaul encompasses engine block rotation and crankshaft renewal. The Contractor is responsible for developing a rigging plan for the MPDE, interferences, and engine components. The Contractor must provide new engine oil and engine fluids. Following completion of work, the Contractor must perform bilge clean-up in accordance with SSPC-SP-1 solvent clean. During sea trials, the Contractor must ensure correct break-in operations and make any required adjustments. After completion of sea trials, the Contractor must perform the 50-hour service on the MPDE.

P/N: 584-DEI-KIT

Y Cylinder Head Replacement Kit NSN: 2815-01-619-2838

PN: 584-CYL-HD-RPLM

N Cylinder Liner Kit NSN: 2815-01-619-2672

PN: 584-CYL-LNR-KIT

20 *

Y Piston Skirt NSN: 2815-12-381-5442

PN: 5840300615

Y LP Turbocharger Replacement Kit NSN: 2990-01-619-4969

PN: 584-LPTURBO-RPLM

Y HP Turbocharger Replacement Kit NSN: 2950-01-620-0381

PN: 584-HPTURBO-RPLM

Y Injector Replacement Kit NSN: 2910-01-621-1898

PN: 584-INJ-SWAP-KIT

Y Fuel Injection Pump Kit NSN: 2910-01-619-2228

PN: 584-FL-INJ-PMP-KIT

Y Jacket Water Pump Replacement Kit NSN: 4320-01-619-2545

PN: 584-JWPMP-RPLM

Y Sea Water Pump Replacement Kit NSN: 4320-01-619-2264

PN: 584-SWPMP-RPLM

Y Lube Oil Pump Kit NSN: 4320-01-619-2729

PN: 584-LO-PMP-KIT

N Preheater Pump Replacement Kit NSN: 2815-01-619-2234

PN: 584-PREHTRPMP-RPLM

N Conrod Bearing NSN: 3120-12-358-7417

PN: 5840301960

N Jacket Water Thermostat (LS) NSN: 6685-01-193-3818

PN: 584-THERMLS-RPLM

N Jacket Water Thermostat (RS) NSN: 6685-01-619-2848

PN: 584-THERMRS-RPLM

N Piston NSN: 5815-12-334-9610

PN: 5840301117

N Turbo Charger Exhaust, Outlet Elbow NSN: 2950-12-360-6215

PN: 5110800468

N Turbo Charger Exhaust, Floating Exhaust Pipe Joint

NSN: 3120-12-360-5719

PN: 5841400265

N Sealing Ring NSN: 5330-12-315-3724

PN: 5841420857

N Sealing Ring NSN: 5330-12-165-6459

PN: 114C62033-1

N Piston & Conrod Kit NSN: 2815-01-619-2682

PN: 584-PST-CNRD-RPLM

Y Crankshaft NSN: 3950-01-F20-6038 P/N: X51403100006/32

Y Engine Rotation Tool NSN: 2815-01-619-2838

PN: 584-1163RTN-TLN

N Geislinger Coupling PN: X58425100027 1

Y Exhaust Manifold PN: 5841404818 1

4.4 MPDE, Renew. The Contractor must renew the MPDE in accordance with Coast Guard Technical Publications 7028 and 7031. The Contractor is responsible for developing a rigging plan for the MPDE, interferences, and engine components. The Contractor must provide new engine oil and engine fluids. Following completion of work, the Contractor must perform bilge clean-up in accordance with SSPC-SP-1 solvent clean. During sea trials, the Contractor must ensure correct break-in operations and make any required adjustments. Following completion of sea trials, the Contractor must perform the 50-hour service on the MPDE. The following GFE will be provided:

Y Main Propulsion Diesel Engine, 9666 HP, MTU Detroit Diesel, Inc.

PN: 20V 1163 TB 93 1

5 General Technical Requirements: The following technical requirements apply to all technical and engineering services, maintenance and emergent repair, and MPDE overhaul tasks.

5.1 Protective measures. The Contractor must furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor must remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

5.2 Receipt of GFP. The contractor will receive the GFP listed above using the Coast Guard 1149. After receipt of the GFP, the contractor must inventory and inspect the condition of the GFP upon receipt and provide a CFR documenting all GFP received and condition.

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

5.4 Scaffolding. The Contractor must, in accordance with CFR Title 29, Part 1915, Subpart E, erect suitable staging or scaffolding, as required, to facilitate work.

5.5 Safety precautions. The Contractor must rig suitable safety netting, to protect workers during possible falls, and to protect the engine room and machinery from falling tools.

5.6 Fluid disposal. The contractor must dispose all fluids in accordance with all applicable Federal, state, and local regulations and SFLC Std Spec 0000.

5.7 Rigging. The Contractor is responsible for rigging of all and necessary tools, materials, including GFP from and to the pier as well as from and to the engine room. When necessary, the Contractor must provide crane service to move materials, tools and GFP to and from pier, deck and engine room. The Contractor must provide any special tools and equipment not specifically identified as GFP tools. When rigging is required, the Contractor must provide a rigging plan for completion of work for affected equipment, interferences, and components, for removal from and reinstallation onto the vessel safely and without damage, using the references for guidance.

Suitable padeyes welded to the ship’s structure may be required. Existing padeyes, as documented on Coast Guard Drawing 750-WMSL-243-003, may be used after visual inspection for damage and pull testing. The Contractor may install additional padeyes if required or warranted by the Contractor’s rigging plan. Pull test all padeyes (existing and Contractor installed) to 150% their “expected working loading”. In no case may a padeye’s “expected working load” (a) exceed the tabulated maximum working load for the padeye’s size or (b) exceed the structure’s (that padeye is attached to) ability to carry the load. At conclusion of pull test, dye penetration inspect the padeye for damage. The Contractor can use beam clamps as required if rated for expected load. The table below lists the maximium working loads for various sized padeyes. Expected working loads may be considerably less than maximum working load, e.g. a 1” padeye used in the rigging plan will have an “expected working load” of only 6,000 lbs (not the maximum 9,800 lbs) and pull tested to 9,000 lbs. At the conclusion of work, any Contractor-installed padeyes must be removed, welds ground flush to base metal, and disturbed coatings and insulation restored.

Padeye Size Max Working Load

1/2" 2,400 lbs

3/4" 5,800 lbs

1" 9,800 lbs

1-1/8" 12,100 lbs

1-3/16" 13,300 lbs

6 Other General Requirements

6.1 Recognized Federal Holidays. The Contractor may be required to work on the following federal holidays:

New Year’s Day Labor Day Martin Luther King JR’s Birthday Columbus Day President’s Day Veteran’s Day Memorial Day Thanksgiving Day Juneteenth Christmas Day Independence Day

6.2 Hours of Operation. Cutter normal working hours while inport are from 7:00 A.M. to 3:30 P.M., Monday thru Friday, except Federal holidays or when the Government facility is closed, due to local or national emergencies, inclement weather, administrative closings or similar Government directed facility closings.

6.3 Period of Performance. The Contractor must at all times maintain an adequate workforce for the uninterrupted performance of all tasks defined within this PWS. The Contractor may be required to work outside of the normal working hours and days, to include weekends. The performance period for MPDE 8,000 and 16,000 hour overhauls on a single vessel is 56 calendar days for a single MPDE or 84 calendar days for two MPDEs overhauled concurrently. The performance period for the MPDE 24,000 hour onboard overhaul on a single vessel is 84 calendar days for a single MPDE or 112 days for two MPDEs overhauled concurrently. The performance period for MPDE renewal is 105 calendar days for a single MPDE or 119 days for two MPDEs renewed concurrently.

6.4 Place of Performance. The work to be performed under this contract will be performed at cutter homeports of Alameda, CA, Charleston, SC, Honolulu, HI, and worldwide as required for emergent repairs.

6.5 Reporting Requirements. Contractor personnel shall report to the Contacting Officer’s Representative any information or circumstances of which they are aware that may pose a threat to the security or safety of U.S. Coast Guard personnel, contractor personnel or resources, immediately.

6.6 Occupational Safety and Health and Environmental Standards. The Contractor is required to follow 29 CFR 1915 (OSHA Shipyard Industry Standard), while performing work at the U.S.

Coast Guard Yard. The Contractor must provide all required personal safety equipment for their employees, such as, but not limited to; safety helmet, safety glasses and shoes, floatation devises, and hearing protection. All safety equipment must meet OSHA standards. Failure of the Contractor employees to comply with the above requirements could result in a shutdown of operations. The Contractor must also have a current Safety Plan, which must be submitted for review as part of their quote.

6.7 Environmental Requirements. The Contractor is responsible to comply with all applicable Federal, State and local environmental laws and regulations including but not limited to the Clean Water Act, the Oil Pollution Act, the Endangered Species Act, and the Coastal Zone Management Act.

6.8 Special/Technical Qualifications. The Contractor must submit documentation that demonstrates compliance to these special/technical qualifications: The Contractor must be an OEM authorized/ licensed Tech Rep for MTU America Inc., specifically the MTU 20V1163TB93 Diesel Engine.

6.9 Contracting Officer’s Representative (COR). The COR will be identified by separate letter. The COR will monitor all technical aspects of the contract and assist in contract administration. The COR is authorized to perform only those functions designated in the letter, issued by the Contracting Officer. A letter of designation, issued to the COR (a copy of which will be sent to the Contractor), states the responsibilities and limitations of the COR, especially with regard to changes in cost or price, estimates or changes in performance dates. The COR is not authorized to change any of the terms and/or conditions of the contract. All contract changes that impact price or cost, quality of work and the performance schedule may only be approved or made by the Contracting Officer.

6.10 Personnel/Qualifications. All work shall be performed by OEM authorized/ licensed Tech Reps for MTU America Inc., specifically the MTU 20V1163TB93 Diesel Engine.

6.11 Coordination with COR. The Contractor must coordinate all work requirements, stated herein, with the Contracting Officer and the COR.

7 Quality Control: The Contractor must provide a Quality Assurance Surveillance Plan (QASP) that addresses all necessary measures taken by the Contractor to assure that the quality of the end service meets contract and commercial quality requirements.

8 Government Furnished Items and Services: The list of property which the Government will furnish is identified with each work task. Those lists supersedes any other material obligations indicated or implied by reference drawings.

9 Contractor Responsibilities and Furnished Items and Services: The Contractor must furnish all equipment and services required to perform work under this contract, other than those explicitly addressed as GFP in this PWS.

10 Applicable References and Technical Data: The following items are applicable to this contract:

10.1 Coast Guard Drawings:

Coast Guard Drawing 750-WMSL-100-001, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750-WMSL 100-019, Rev J, Unit 1330 Structure – 2nd Deck to Main Deck - Fr 22 to Fr 35 (ASC100133)

Coast Guard Drawing 750-WMSL-100-031, Rev E, Unit 2300 Structure - Inner Bottom - FR 52 to FR 64 (ASC100230)

Coast Guard Drawing 750-WMSL 100-034, Rev J, Unit 2330 Structure – 2nd Deck to Main Deck - Fr 52 to Fr 64 (ASC100233)

Coast Guard Drawing 750-WMSL 100-039, Rev L, Unit 3140 Structure Mn Dk to 01 Lvl - Fr 64 to Fr 76 (ASC100314)

Coast Guard Drawing 750-WMSL 100-043, Rev L, Unit 3240 - Main Deck to 01 Level - Fr 76 to Fr 82 (ASC100324)

Coast Guard Drawing 750-WMSL 100-049, Rev L, Unit 4220 Structure - 02 Lvl and Above - Fr 33 to Fr 44 (ASC100422)

Coast Guard Drawing 750-WMSL 100-052, Rev K, Unit 4320 Structure 02 Lvl and Above - Fr 48 to Fr 53 (ASC100432)

Coast Guard Drawing 750-WMSL 100-053, Rev K, Unit 4420 Structure - 01 Level and Abv - Fr 52 to Fr 67 (ASC100442)

Coast Guard Drawing 750-WMSL 100-055, Rev H, Unit 4130 - Structure - 03 Level - Pilot House (ASC100413)

Coast Guard Drawing 750-WMSL-101-030, Rev C, Shell Expansion Scantlings (AS3101017)

Coast Guard Drawing 750-WMSL-243-003, Rev B, Shipping & Unshipping Of Propulsion Shafting (ASC243004) (UNSIGNED)

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

Coast Guard Drawing 750-WMSL 600-046, Rev G, Fab & Instl of Hull Outfit Design, Unit 4130

(ASC600413)

Coast Guard Drawing 750-WMSL 635-001, Rev -, Thermal & Acoustic Insulation (ASC635001)

Coast Guard Drawing 750-WMSL-835-003, Rev D, Propulsion Shafting Alignment Procedure

(ASC835003)

Coast Guard Drawing 750-WMSL-801-004, Rev B, Booklet of General Plans (ASC801001C)

NAVSEA Drawing 804-5773931, Rev A, Acoustic & Thermal Insulation for Compartments Installation Details

10.2 Coast Guard Publications:

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Jun 2006, Coatings and Colors Manual

Coast Guard Technical Publication 7024A, 27-NOV-18, Main Diesel Engine - Removal Spaces and Weights

Coast Guard Technical Publication 7025A, 30-OCT-17, Main Diesel Engine - Fluids and Lubricants Specifications (A001061/35E)

Coast Guard Technical Publication 7026, 31-MAY-07, Main Diesel Engine - Repair Tool Catalog

Coast Guard Technical Publication 7028, 31-MAY-07, Main Diesel Engine - Workshop Manual

Coast Guard Technical Publication 7031, 09-MAY-18, Main Diesel Engine - Parts Catalog

(M034562/01DE)

Coast Guard Technical Publication 7796, 13-SEP-12, Main Diesel Engine- Preservation & Represervation Specs (A001070/00E)

Coast Guard Technical Publication 7930, 01-MAY-21, Main Diesel Engine – Maintenance Schedule MTU

Coast Guard Technical Publication 7947, 19-OCT-16, Main Diesel Engine - Parts Catalog

(MA30155/01DE)

Coast Guard Technical Publication 7948, 07-NOV-16, Main Diesel Engine - Plant Documentation (S000083/00E)

Coast Guard Technical Publication 9553, 16-MAY-18, Main Diesel Engine - Parts Catalog

(MA30298/00DE)

Coast Guard Technical Publication 9554, 12-SEP-17, Main Diesel Engine - Plant Documentation (S000164/01E)

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 5000 (SFLC Std Spec 0740), 2022, Auxiliary Machine Systems

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

10.3 Other References:

Code of Federal Regulations (CFR) Title 29, Part 1915, Subpart E, Sep 2015, Scaffolds, Ladders and Other Working Surfaces

American Welding Society, AWS D1.2-96, 1996, Structural Welding Code, Steel

MTU Drawing X00033903/32-F72/15/147N/R

MIL-PRF-900, Mar 1991, Rubber Gasket Material, 45 Durometer Hardness

MIL-PRF-1149, Jun 1998, Gasket Materials, Synthetic Rubber, 50 and 65 Durometer Hardness

The Society for Protective Coatings (SSPC) Paint Application Specification No. 1 (SSPC-PA Guide 1), 2004, Shop, Field, and Maintenance Painting of Steel

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2004, Solvent Cleaning

MTU Technical Documentation S000082/00E, 2011, Functional Descriptions, Operating Instructions, and Instructions for General Overhaul

Naval Sea Systems Command (NAVSEA) S0600-AA-PRO-160, 8/15/2008, Underwater Ship Husbandry Manuals - Chapter 16 (Cofferdams)