Attachment 1_SOW_ 175 WLM Propulsion Sys Groom IDIQ (Rev 0_ 6_12_18).pdf

USCG IDIQ 175 WLM Propulsion System Grooms and Assessments

Rev-0 (6/12/2018)

U.S. COAST GUARD 175-FT “KEEPER” CLASS WLM BUOY TENDER (175 WLM)

PROPULSION SYSTEM GROOMS AND ASSESSMENTS INDEFINITE DELIVERY,

INDEFINITE QUANTITY (IDIQ)

STATEMENT OF WORK (SOW)

1.0 GENERAL

1.1 Background. The U.S. Coast Guard Surface Forces Logistics Center – Icebreaker, Buoy, and

Construction Tender Product Line (SFLC-IBCTPL) is currently supporting efforts intended to improve the system reliability of the Machinery Plant Control and Monitoring System (MPCMS) installed onboard the 175-foot KEEPER Class WLM Buoy Tender (175 WLM). These efforts include system improvements, component replacements, upgrades, and additional maintenance support for the MPCMS system, components, and related subsystems. In support of these efforts, the SFLC-IBCTPL requires services and parts for the conduct of propulsion system grooms and assessments in accordance with Original Equipment Manufacturer (OEM) guidance and directions contained within this SOW. Groom and assessments are considered to be a full propulsion system inspection to include testing, calibrations, and repairs of the propulsion system and associated components as described in Enclosure (1). The intent of these grooms and assessments is to ensure satisfactory operation of the propulsion plant system and associated equipment prior to MPCMS improvement efforts.

1.2 Scope. The SFLC-IBCTPL requires services and parts in support of conducting grooms and assessments of the propulsion system and associated components onboard the 175 WLM class vessels. The Contractor shall provide all management, supervision, personnel, labor, travel, freight, materials, parts, tools, test equipment, test fittings, supplies, consumables, and equipment to accomplish all tasking. Tasks shall include inspections, assessments, calibrations, grooms, repairs, and testing (pre-operational and operational) of the propulsion system. At a minimum, the USCG requires fourteen (14) grooms and assessments onboard 175 WLM vessels, with additional grooms and assessments required as the project warrants. Additional services may be required in the support of repairs, on-site technical troubleshooting, offsite / remote troubleshooting (telephone, email), and additional grooms due to planned maintenance and/or unplanned casualty response. These services will be determined by the Contracting Officer’s

Representative (COR) and approved by the Contracting Officer (KO) on an “as-needed” basis.

The Government may elect to activate any combination of optional items (within the scope of the groom) as necessary to meet required support.

1.3 System Description. The 175 WLM propulsion plant utilizes twin shafts with two independent azimuth propulsion units (Z-drives®), direct coupled to two marine diesel engine prime movers

(Caterpillar® Model 3508 - Direct Injected, Turbocharged, Aftercooled).

2.0 APPENDICES AND ENCLOSURES

2.1 Appendices

Appendix A – “List of United States Coast Guard 175’ WLM Buoy Tenders”

2.2 Enclosures

Enclosure (1) - “Perform Propulsion System Groom and Assessment”

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3.0 REFERENCES / APPLICABLE DOCUMENTS

Refer to Enclosure (1).

4.0 REQUIREMENTS

4.1 Tasking. The Contractor shall provide all management, supervision, personnel, labor, travel, freight, materials, parts, tools, test equipment, test fittings, supplies, consumables, and equipment to accomplish all tasking as defined in Enclosure (1). Groom and assessments shall be accomplished in accordance with the Project Plan (refer to Section 5.1 “Project Plan”), tailored

“as necessary” to meet the conditions of the tasking.

4.1.1 The Government will attempt to issue a task order at least 45 days prior to scheduled visit. The KO will order the groom and assessment visit, in writing, at least fourteen (14) calendar days in advance of scheduled arrival. The Government reserves the right to request an expedited groom visit due to emergency repair response. The Contractor shall acknowledge, in writing, the order within five (5) calendar days of receipt of the order. Below is a notional timeline of performance milestones for a scheduled groom and assessment visit.

CALENDAR DAYS

BEFORE GROOM

ACTION

14 Days USCG provides written notification of pending groom and assessment to the Contractor

9 Days Contractor acknowledge order and provide vessel Project Plan to KO and COR

4.1.2 Coast Guard personnel will operate all shipboard equipment, as requested by the

Contractor, in support of tasking. The Contractor shall be responsible for all adjustments, calibrations, and actions required in accordance with the specification.

4.1.3 The Contractor shall actively engage with the COR to ensure adequate communications are maintained throughout the conduct of the groom. This is also to ensure “crew familiarization” with the equipment and groom procedures used in support.

4.1.4 The Contractor shall actively engage with the COR to coordinate work timelines with grooms of other systems.

4.2 Personnel.

4.2.1 Technical Representative. The Contractor shall provide the services of certified

Technical Representatives (Tech Reps) of the OEM (Caterpillar Inc.) engine to accomplish all tasking. The Tech Rep shall be authorized by the OEM to perform work on the Caterpillar Model

3508 marine diesel engine and is required to be onsite during the entire duration of the scheduled groom and assessment to ensure proper OEM procedures are followed. The Tech Rep will be responsible for the following:

Accessing OEM proprietary information, software, and tools pertinent to tasking in accordance with the specification.

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

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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 testing), ensuring compliance with OEM, U.S. Coast Guard, OSHA, and other pertinent procedures and standards.

Providing genuine, OEM-approved parts

The Contractor shall provide documentation that the Tech Rep is certified and authorized by

Caterpillar to perform work on the Caterpillar Model 3508 marine diesel engine.

4.2.2 Employee Conduct. Contractor employees shall comply with all applicable Government regulations, policies, and procedures (e.g., fire, safety, sanitation, environmental protection, security, etc) when visiting or working at Government facilities. The Contractor shall ensure employees present a professional appearance in accordance with Contractor’s professional standards at all times, and that their conduct shall not reflect discredit on the United States, the

Department of Homeland Security, or the USCG.

4.2.3 Employee Identification. Contractor employees working on-site at Government facilities shall wear a company issued identification badge. All Contractor employees shall identify themselves as Contractors when their status is not readily apparent and display their badge in plain view above the waist at all times.

4.2.4 Removing Employees for Misconduct or Security Reasons. The Government may, at its sole discretion, direct the Contractor to remove any Contractor employee from Government facilities for misconduct or security reasons. Removal does not relieve the Contractor of the responsibility to continue providing the services required in this specification. The Government will provide the Contractor with an immediate written explanation of the request to remove the employee through the KO.

4.2.5 Conflict of Interest. The Contractor shall not employ any person who is an employee of the United States Government if that employment would cause or appear to cause a conflict of interest.

4.2.6 Security Clearance / USCG Installation Access. Security clearances are not required to perform any work under this specification; however, the Contractor shall ensure personnel comply with all installation security requirements. The Contractor shall supply a list of all employees who may be required to perform work under this specification and periodically update that list. Prior to each ship visit (no later than 10 business days before scheduled arrival); the

Contractor shall submit information on visiting employees to the COR. For cutters 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.

4.3 Place of Performance. The majority of services will be performed on-board the cutter, at the respective cutter’s homeport. Refer to Appendix A, “List of United States Coast Guard 175’

Buoy Tenders” for additional information. Work will be conducted “pier-side” and “underway”, with operational testing to be conducted underway within the cutter’s local area of responsibility

(AOR). Underway tasking will not require overnight stay onboard the cutter. In some instances, services may be required while the cutter is moored at an alternate location or dry-docked, either at a commercial or Government facility.

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4.4 Period of Performance. The period of performance for this effort will consist of a base year with four, one-year option periods, if exercised. The decision to exercise any option shall be at the sole discretion of the Contracting Officer and shall be exercised in writing. The tentative quantity for grooms and assessments is as follows (Note: This is subject to change due to vessel availability and/or funding availability):

Base Year: 5 vessels

Option Year 1: 5 vessels

Option Year 2: 4 vessels

Option Year 3: To Be Determined

Option Year 4: To Be Determined

4.5 Travel. Contractor travel is required in support of tasking.

4.5.1 Each task order must list separately the elements of travel costs in support for that order.

In the event that travel is required to additional locations other than homeports, or for travel in support of other tasking (i.e. meetings, casualty repairs), the Contractor shall provide a comprehensive estimate for travel in advance of the trip.

4.5.2 The negotiated travel and per diem for each task order shall represent total compensation for employees’ transportation, lodging, meals, and incidentals in accordance with FAR part

31.205-46.

4.6 Government-Furnished Property / Contractor-Furnished Property.

4.6.1 The Government will provide new fluids (engine lube oil and coolant only) in support of tasking. No additional Government-furnished property or equipment is anticipated to be provided.

4.6.2 The Contractor shall provide all materials, parts, tools, test equipment, test fittings, supplies, consumables, and equipment required. The Contractor shall provide all gaskets, seals, and filters. In the event Government-furnished equipment is provided, the equipment shall be used for official Government business-only, to the extent necessary to complete the requirements of this specification.

4.6.3 Only new or remanufactured (REMAN) OEM-approved parts shall be used for accomplishment of tasks. “Refurbished” parts will only be considered on an “as-needed” basis and shall not be installed without prior authorization by the KO.

4.7 Government Support.

4.7.1 Coast Guard personnel will operate all shipboard equipment, as requested by the

Contractor.

4.7.2 Coast Guard personnel will perform electrical tag-outs in support of maintenance and be available to advise on rigging safety procedures as necessary. All other support tasks (e.g.

rigging evolution, parts delivery, freight, etc) shall be provided by the Contractor.

4.8 Kick-Off Meeting. The Contractor shall attend a Kick-Off meeting with the KO, COR, and additional USCG representatives to discuss the objectives at the time of IDIQ award (no later than 5 business days after the date of award). The Kick-Off meeting can be accomplished in-person or via teleconference.

4.9 Briefings. The Contractor shall provide oral briefings to the COR and Cutter POC to ensure successful coordination of all tasking.

4.9.1 Arrival Brief. At the task order level, the Contractor shall provide a brief upon arrival to the vessel. This brief will consist of overview of the Project Plan (refer to Section 5.1 “Project

Plan”) and be used as a communication vehicle between the vessel and Contractor for planning purposes. Any issues, concerns, or additional tasking resulting from the brief shall be provided to the COR at the conclusion of the arrival brief. No additional work outside the original scope of the Project Plan is authorized unless approval is received by the KO.

4.9.2 Departure (“Out”) Brief. Upon completion of each groom and assessment visit, the

Contractor shall provide a departure (out) brief at the end of the performance period. The

Contractor shall provide a draft Trip Report (refer to Section 5.2 “Trip Report”) to assist in discussion. The cutter POC will sign the draft report to acknowledge its receipt and be provided a copy by the Contractor. Signature on the draft report will attest that all work was performed in accordance with the SOW and task order, and all recorded data was within acceptable parameters.

5.0 DELIVERABLES

5.1 Project Plan. The Contractor shall provide a Project Plan that includes detailed methodology, procedures, and steps to meet all the objectives of the SOW. The draft Project Plan shall be provided to the KO at the Kick-Off Meeting for review and comment. Government comments will be provided to the Contractor from the KO no later than five (5) business days after the receipt of the Project Plan. The Contractor shall provide a final Project Plan to the KO no later than five (5) business days after receipt of Government comments. This Project Plan will serve as the basis for all grooms and assessment trips; and provided to the vessel in advance of

Contractor arrival for planning purposes. Additionally, the Project Plan will be used in support of vessel briefings during Contractor groom and assessment visits.

The Project Plan shall address all aspects of the propulsion groom and assessments and include the following:

5.1.1 Pre-Groom Survey. A detailed checklist and questionnaire to be completed by USCG vessel personnel fourteen (14) business days in advance of the scheduled groom visit. The intent of the Pre-Groom Survey is to provide early identification of potential issues and allow for proper planning of additional work to ensure a successful groom visit. The Contractor shall review the completed surveys and provide recommendations, including any additional parts or tasks that fall outside the planned Groom and Assessment Procedure, at the time of order.

5.1.2 Groom, Assessment, and Testing Procedure. The written procedure to be used in support of inspection, assessments, calibrations, grooms, and testing (pre-operational and operational) of the propulsion system, as defined in Enclosure (1). The procedure shall include all steps required in support of tasking, including identification of required parts, pass/fail criteria, operational requirements, and expected durations. Specific step-by-step instructions may be omitted provided a higher-level reference source exists detailing the procedure to be used (i.e.

“Perform engine tune-up in accordance with …” in lieu of providing detailed tune-up procedure).

However, any clarifications or additional instructions required shall be included in the procedure.

Additionally, the Contractor shall include any additional tasks (not explicitly stated in the specification) that are deemed necessary by the Contractor to ensure satisfactory grooming of the propulsion system and related components.

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5.1.3 Schedule. A sequencing document (Gantt chart), based on the “Groom, Assessment, and

Testing Procedure”, that provides the schedule and sequencing for all planned inspections, assessments, calibrations, grooms, and testing (pre-operational and operational) to be performed.

The schedule shall be based on a daily-task breakdown schedule (Day 1, Day 2, …) and include expected durations of each task (hours), interdependencies, prerequisites, resources, required equipment conditions, required coordination with system grooms outside the scope of this specification, and any additional support required from the vessel. The Contractor may expend the elements of the schedule to include any additional information to ensure satisfactory completion of tasking.

5.1.4 Trip Report Template. A standardized report format to be utilized upon completion of each vessel groom and assessment (Refer to Section 5.2).

5.2 Trip Report. Upon the completion of each groom and assessment, the Contractor shall submit a trip report summarizing all work accomplished for the applicable ship visit. The intent of the trip report is to provide a comprehensive field report that includes results of inspections, assessments, data, repairs, testing, and recommendations pertaining to tasking. The trip report can be augmented with inclusion of CFRs provided the information below is adequately captured in the

CFR.

5.2.1 The report shall include all work accomplished, results of inspections and assessments, actions taken, parts utilized, data collected, testing results, and recommendations based on the tasking.

5.2.2 All data collected shall be included in report. This includes all operational testing data

(trial logs), as well as measurements resulting from inspections, assessments, and adjustments.

Where data values are recorded, the report shall include the acceptance values used in making acceptability determination, in addition to the values recorded. For values where there exists no acceptable range, these values must be annotated with “Information Only”.

5.2.3 Digital pictures attesting to condition of components inspected shall be provided for visual inspections and condition assessments (i.e. pass/fail). These, in conjunction with a narrative, will be used to document acceptability. Visual inspections shall be accomplished using the following guidelines:

5.2.3.1 OEM’s relevant guidance and reference documents for inspection and assessment shall be utilized and referenced accordingly (including Publication Number, Publication Date, and Title). For Caterpillar applications, this would include the appropriate documents listed in the latest published version of Caterpillar Media SEBF8029 “Index of Publications on

Reusability or Salvage of Used Parts”.

5.2.3.2 List of all instruments (make and model), including proof of calibration certification, of equipment used in support.

5.2.3.3 List of all parts and components inspected, including part numbers and serial numbers (as applicable) for machinery history and configuration tracking purposes.

5.2.3.4 All readings and measurements (clearances, tolerances, etc) recorded and used in support of OEM-reusability determinations.

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5.2.3.5 Recommendations for re-use, replacement, repair, or renewal of inspected components.

5.2.4 A parts list shall be provided (including part number information and nomenclature) of any parts replaced resulting from work accomplished.

5.2.5 The finalized trip report shall be provided electronically to the COR within ten (10) business days after completion of the work at the task order level. A scanned copy of the signed draft trip report shall be provided with the final submission.

5.3 Condition-Found Report (CFR). The Contractor shall utilize a Condition-Found Report (CFR) to document all conditions found during the execution of tasking. This shall include, but not be limited to, results of inspections, requests for additional parts, results of operational testing, issues discovered, etc. Refer to SFLC Std Spec 0000 (Paragraph 3.2.6) for additional information.

5.3.1 CFRs shall be submitted to the COR in electronic-format.

5.3.2 CFRs shall include information as defined in SFLC Std Spec 0000, Paragraph 3.2.6.1.4.2.

5.4 Format. The Contractor shall provide all deliverables in electronic format with read/write capability, using applications that are compatible with Coast Guard Standard Workstation III (Windows

10, Microsoft Office, and Adobe Acrobat applications).

6.0 QUALITY ASSURANCE

6.1 The Contractor shall establish and maintain a QA Plan to ensure that all tasks are completed in accordance with the contract, specification, and applicable references. The QA Plan shall provide the

Government a complete understanding of the actions the Contractor shall put into place and be made available immediately after award. The Contractor shall provide a copy of the QA Plan at the Kick-off

Meeting.

7.0 DEFINITIONS AND ACRONYMS

CFR Condition-Found Report

COR Contracting Officer’s Representative

IBCT Icebreaker, Buoy, and Construction Tender Product Line

KO Contracting Officer

MDE Main Diesel Engine

MPCMS Main Propulsion Control and Monitoring System

OEM Original Equipment Manufacturer

POC Point of Contact

QA Quality Assurance

SFLC Surface Forces Logistics Center

USCG United States Coast Guard

WLM “Keeper” Class Buoy Tender

Appendix A: LIST OF UNITED STATES COAST GUARD 175’ WLM BUOY TENDERS

Cutter Hull

Number Homeport

Starboard

MDE Serial

Number

Port MDE

Serial Number

CGC IDA LEWIS WLM 551 Newport, RI 3HM00001 9WN00001

CGC KATHERINE WALKER WLM 552 Bayonne, NJ 3HM00002 9WN00002

CGC ABBIE BURGESS WLM 553 Rockland, ME 3HM00003 9WN00003

CGC MARCUS HANNA WLM 554 South Portland, ME 3HM00004 9WN00004

CGC JAMES RANKIN WLM 555 Baltimore, MD 3HM00005 9WN00005

CGC JOSHUA APPLEBY WLM 556 St Petersburg, FL 3HM00006 9WN00006

CGC FRANK DREW WLM 557 Portsmouth, VA 3HM00007 9WN00007

CGC ANTHONY PETIT WLM 558 Ketchikan, AK 3HM00008 9WN00008

CGC BARBARA MABRITY WLM 559 Mobile, AL 3HM00009 9WN00009

CGC WILLIAM TATE WLM 560 Philadelphia, PA 3HM00010 9WN00010

CGC HARRY CLAIBORNE WLM 561 Galveston, TX 3HM00011 9WN00011

CGC MARIA BRAY WLM 562 Mayport, FL 3HM00012 9WN00012

CGC HENRY BLAKE WLM 563 Everett, WA 3HM00013 9WN00013

CGC GEORGE COBB WLM 564 San Pedro, CA 3HM00014 9WN00014

Enclosure (1) to USCG IDIQ 175 WLM Propulsion System Grooms and Assessments

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20200_MWC_0318_175 WLM

Enclosure (1) - Perform 175 WLM Propulsion System Groom and Assessment

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to conduct a groom and assessment on a designated 175 WLM propulsion system and associated components, to accomplish the following:

Validate the system is operating within the manufacturer’s specifications.

Ensure the proper communication and interoperability of the system components.

Perform planned maintenance tasks for system components. Planned maintenance tasks are those recommended by the system component manufacturers and approved by the

Coast Guard.

Participate in dockside performance test, evaluation, and validation.

Participate in underway performance test, evaluation, and validation.

Repair, renew, adjust, calibrate, and test of improperly functioning system components as required.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 175 WLM 201-001, Rev C, Machinery Spaces Arrangement

Coast Guard Drawing 175 WLM 202-001, Rev J, MPCMS Cabling Diagram

Coast Guard Drawing 175 WLM 202-002, Rev G, MPCMS Cabling Diagram COED

Coast Guard Drawing 175 WLM 202-003, Rev H, Diesel Engine Local Wiring Diagram

Coast Guard Drawing 175 WLM 202-004, Rev B, MPCMS Console Layout

Coast Guard Drawing 175 WLM 202-005, Rev B, List of MPCMS Sensors

Coast Guard Drawing 175 WLM 233-001, Rev A, Propulsion Train Installation

Coast Guard Drawing 175 WLM 233-002, Rev E, Propulsion Train Installation Drawing

Coast Guard Drawing 175 WLM 601-001, Rev T, General Arrangements – Inboard and Outboard

Profile

Coast Guard Drawing 175 WLM 601-002, Rev H, Booklet of General Drawings (IDA LEWIS)

Coast Guard Drawing 175 WLM 601-003, Rev N, Booklet of General Drawings

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3601A, SWBS 86, Amendment 11, Ship’s Information

Book (SIB)

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Coast Guard Technical Publication (TP) 3605A, SWBS 86, Amendment 7, Machinery Plant

Control & Monitoring System Operating Manual

Coast Guard Technical Publication (TP) 3605B, SWBS 86, Amendment 5, Machinery Plant

Control & Monitoring System Operating Manual – Volume 2

Coast Guard Technical Publication (TP) 3605C, SWBS 86, 22 Jul 2008, Machinery Plant Control

& Monitoring System Operating Manual – Volume 3

Coast Guard Technical Publication (TP) 3611, SWBS 202-B, 19 Oct 1999 Change 7, MDE –

Local Control/Alarm Panel

Coast Guard Technical Publication (TP) 3612A, SWBS 233, Amendment 5, Main Diesel Engine

(MDE) – Model 3508 (Part A)

Coast Guard Technical Publication (TP) 3612B, SWBS 233, Amendment 5, Main Diesel Engine

(MDE) – Model 3508 (Part B)

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of work.

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and also to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.1.1 CIR.

None.

3.1.2 Tech Rep. Refer to SOW “U.S. Coast Guard 175-FT “Keeper” Class WLM Buoy Tender (175

WLM) Propulsion System Grooms and Assessments”, Paragraph 4.2.1

3.1.3 Protective measures - general. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, the

Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec

0000, paragraph 3.3.5 (Interferences).

3.1.5 References. The Contractor shall accomplish all tasking in accordance with OEM-guidance and the references listed in Section 2 “References”.

3.2 Inspections, assessments, and groom. The Contractor shall perform inspections, assessments, and grooms of the propulsion system and associated components as follows. Submit a CFR for any additional work resulting from planned tasking.

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3.2.1 Main diesel engine and mechanical governor (3508 CAT marine diesel engine and Woodward 3161

Governor).

Inspect and adjust governor actuator linkages.

Inspect cylinder head and components (valves, fuel injectors, valve rotators).

Inspect camshaft and roller followers.

Inspect and clean magnetic pickups.

Inspect and adjust camshaft and crankshaft timing.

Inspect and adjust valve bridge.

Inspect and adjust valve lash.

Inspect and adjust fuel injector timing.

Synchronize fuel injectors.

Calibrate engine protection devices.

Inspect and adjust engine low and high idle speeds.

Inspect and adjust mechanical ballhead set point and alarm.

3.2.2 Fuel Rack Position Sensor.

Validate system is operating within manufacturer’s specifications.

Inspect condition of wiring for damage and connections for tightness.

Verify and calibrate fuel rack position linkages and voltages.

3.2.3 Miscellaneous Support Components.

Calibrate the electrical/pneumatic (E/P) transducers (Refer to CG Tech Pub 3611, 202-B, Appendix A). Verify system is free or air leaks and control pressure of 70 psi is available.

Inspect and calibrate all instrumentation (transducers, transmitters, gauges, etc) utilized in support of tasks.

Inspect and calibrate engine speed indications for all locations (MPCMS, remote panel, local panel), verifying readings with a calibrated handheld tachometer.

3.3 Operational testing. Upon completion of all work, the Contractor shall coordinate with the vessel to perform operational testing to validate all work.

3.3.1 Dockside testing (in-port). Perform dockside testing of the propulsion plant to ensure all components have been successfully inspected and groomed. Engines shall be tested in all control modes and configurations to ensure operability in support of underway testing.

NOTE

The dockside testing period may also be used in support of conducting operational grooms of Para

3.2 in effort to minimize costs and schedule. The Contractor shall ensure that any groom tasks scheduled for dockside testing are those that require relatively minor adjustments and do not pose high risk to delaying schedule.

3.3.2 Underway testing. Upon completion of successful dockside testing, perform underway testing

(notionally 1-2 days). The underway test plan shall consist of the following:

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3.3.2.1 Computer Aided Marine Performance Analysis Report (CAMPAR). Perform a CAMPAR diagnostic test for each MDE in accordance with Caterpillar’s instructions.

NOTES

1. Historically, the CAMPAR test results provided to the USCG have omitted specifications (i.e.

acceptable data ranges for recorded parameters), units of measure, and recorded data. Contractor shall augment the testing data as necessary to provide this information.

2. The USCG will consider alternate methods of accomplishing engine diagnostic testing provided all data normally collected during the performance of CAMPAR testing is obtained.

3.3.2.2 Additional trial data. Record all additional propulsion plant data not explicitly included in the

MDE diagnostic (CAMPAR) program. This will include operational data from various MPCMS displays, local analog gauges and meters, and ship course information.

NOTES

1. Ship’s Force will assist in data collection efforts as requested by the Contractor; however, the use of automated data recorders is encouraged.

2. The Contractor shall provide to the COR a list of any unobtainable parameters, including reasons for exclusion, prior to the start of testing. Every effort shall be made to minimize this list.

3.3.3 Adjustments. Based on the results of the operational testing, perform any additional adjustments, readjustments, or grooms required to ensure operation of the propulsion plant.

NOTE

These adjustments are considered to be part of the original tasking and extensions of the scope of

Para 3.2. For newly identified tasks or additional adjustments not included in the original tasking, refer to Para 3.4 .

3.4 Authorized additional work. The Contractor shall provide a separate price proposal for any additional tasking resulting from inspections, assessments, grooms, and testing, when requested by the

KO or COR. Within the proposal, the Contractor shall describe tasking, required labor, and associated costs. No additional work shall be conducted until authorized by the KO. Authorized additional work may include the following:

3.4.1 Top End Overhaul. Accomplish a Top End Overhaul (TEO).

3.4.1.1 Disassemble, clean, inspect, and test the engine components listed in Table 1. Provide a CFR of these components to the KO for potential reuse determination.

TABLE 1: COMPONENTS TO BE DISASSEMBLED, CLEANED, INSPECTED AND TESTED

DURING THE TEO

COMPONENT

Aftercooler

Exhaust Manifold

Rocker Shaft Assembly and Push Rods

Turbocharger

Water Manifold

3.4.1.2 Renew the engine components listed in Table 2.

TABLE 2: COMPONENTS TO BE AUTOMATICALLY RENEWED DURING THE TEO

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COMPONENT

Complete Cylinder Head Assemblies

Cylinder Head Gaskets and Seals

Inlet Air Line Seals

Turbocharger Bearings, Bushings and Seals

Water Pump Bearings and Seals

Water Temperature Regulators and Seals

3.4.1.3 If a modification has been authorized and released by the KO, renew the specified engine components listed in Table 3.

TABLE 3: COMPONENTS TO BE RENEWED UPON INSPECTION (WITH KO

AUTHORIZATION)

COMPONENT

Aftercooler

Exhaust Manifold

Rocker Shaft Assembly and Push Rods

Turbocharger

Water Manifold

3.4.2 Major / Center Section Overhaul (including TEO). Accomplish a Major / Center Section Overhaul

(CSO).

3.4.2.1 Disassemble, clean, inspect, and test the engine components listed in Table 4. Provide a CFR of these components to the KO for potential reuse determination.

TABLE 4: COMPONENTS TO BE DISASSEMBLED, CLEANED, INSPECTED AND TESTED

DURING THE CSO

COMPONENT

Camshaft

Camshaft Lifters

Connecting Rods

Crankshaft

Crankshaft Vibration Damper

Cylinder Block

Cylinder Liners

Driven Equipment (alignment)

Engine Mounts

Flywheel

Front Gear Train (Gears)

Fuel Injection Pump

Fuel Transfer Pump

Governor

Oil Cooler Core

Oil Suction Screen

Pistons (Crowns/Skirts)

Rear Gear Train (Gears)

3.4.2.2 Renew the engine components listed in Table 5.

TABLE 5: COMPONENTS TO BE AUTOMATICALLY RENEWED DURING THE CSO

COMPONENT

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Camshaft Bearings

Con Rod Bearings

Crankshaft Seals

Crankshaft Thrust Plates

Exhaust Manifold (Seals and Bellows)

Fuel Group

Fuel Injectors

Fuel Transfer Pump

Gear Train Bushings

Inlet Manifold (Gaskets and Seals)

Jacket Water Pump

Lube Oil Cooler

Lubricating Oil Pump

Main Bearings

Piston rings

Sea Water Pump

Valve Rotators

3.4.2.3 If a modification has been authorized and released by the KO, renew the specified engine components listed in Table 6.

TABLE 6: COMPONENTS TO BE RENEWED UPON INSPECTION (WITH KO

AUTHORIZATION)

COMPONENT

Crankshaft

Camshaft

Connecting Rods

Crankshaft Vibration Damper

Cylinder Block

Cylinder Liners

Driven Equipment (alignment)

Engine Mounts

Flywheel

Front Gear Train (Gears)

Fuel Injection Pump

Fuel Transfer Pump

Governor

Oil Cooler Core

Oil Suction Screen

Pistons (Crowns/Skirts)

Rear Gear Train (Gears)

3.4.3 Post groom on-site repair. Provide onsite troubleshooting service of the specified propulsion system component. Such may include participation in dockside or underway performance testing, evaluation, and validation. Document all efforts and changes effected.

4. NOTES

4.1 Woodward 3161 governor information. The 175 WLM MDEs have special USCG unique calibrations and are not configured with the standard calibration used for a 3508 Caterpillar engine. This governor shall be calibrated and tested to meet Woodward TSP 10257MH (available through an

Rev-0 (6/12/2018) authorized Woodward service center), to function properly on a Caterpillar 3508 Propulsion Diesel

Engine with serial number prefixes 9WN and 3HM.