Attachment 1_ SOW ALEX HALEY SSDG REPOWER.pdf

Procurement Specification ALEX HALEY SSDG Repower

1. SCOPE. The Contractor must assemble and deliver three (3) marine diesel generator sets, according to the technical requirements of this specification and its referenced standards, including all auxiliary components needed for integration into the ship’s existing systems.

2. APPLICABLE DOCUMENTS. The Contractor must complete all design and manufacturing for the generator system in accordance with the standards referenced in this section. The Contractor is responsible for understanding and applying the requirements of these standards to the design of the proposed system.

2.1. American Bureau of Shipping (ABS) Marine Vessel Rules (MVR), 2025

2.2. Institute of Electrical and Electronics Engineers (IEEE) Standards

2.2.1. Standard 45.1, IEEE Recommended Practice for Electrical Installations on Shipboard – Design, 2023

2.2.2. Standard 45.2, IEEE Recommended Practice for Electrical Installations on Shipboard – Controls and Automation, 2023

2.2.3. Standard 45.8, IEEE Recommended Practice for Electrical Installations on Shipboard – Cabling, 2016

2.3. Code of Federal Regulations Title 40, Part 1042, Control of Emissions from New and In-use Marine Compression-Ignition Engines and Vessels (40 CFR 1042)

2.4. Coast Guard Standards.

2.4.1. SFLC Standard Specification 0850, General Requirements for Drawing

Preparation (SFLC Std Spec 0850)

2.4.2. SFLC Standard Specification 0860, General Requirements for Technical

Publication Preparation (SFLC Std Spec 0860)

2.4.3. SFLC Specification D-000-0100 Rev. G Bar Coding for U.S. Coast Guard Surface

Forces Logistics Center Procured Material

2.5. Coast Guard Drawings.

2.5.1. Coast Guard Drawing 282-WMEC-201-002

2.5.2. Coast Guard Drawing 282-WMEC-209-003

2.5.3. Coast Guard Drawing 282-WMEC-210-010

2.5.4. Coast Guard Drawing 282-WMEC-300-005

2.5.5. Coast Guard Drawing 282-WMEC-300-006

2.5.6. Coast Guard Drawing 282-WMEC-300-008

2.5.7. Coast Guard Drawing 282-WMEC-300-015

2.5.8. Coast Guard Drawing 282-WMEC-300-021

2.5.9. Coast Guard Drawing 282-WMEC-300-023

2.5.10. Coast Guard Drawing 282-WMEC-301-002

2.5.11. Coast Guard Drawing 282-WMEC-345-001

2.5.12. Coast Guard Drawing 282-WMEC-345-009

ATTACHMENT 1: SOW

2.5.13. Coast Guard Drawing 282-WMEC-501-073

2.5.14. Coast Guard Drawing 282-WMEC-509-013

2.6. Coast Guard Technical Publications.

2.6.1. Coast Guard Technical Manual 0961-LP-037-9010, Ship Service Diesel Generator

(SSDG) – Diesel Engine – Model D353

2.6.2. Coast Guard Technical Manual 0961-LP-059-3010, Ship’s Service Generator

2.7. Military Standard Specifications.

2.7.1. MIL-STD-1399-300-1 Department of Defense Interface Standard, Section 300, Part 1, Low Voltage Electric Power, Alternating Current, September 2018

2.7.2. MIL-STD-461G, Department of Defense Interface Standard, Requirements for the

Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

2.7.3. MIL-DTL-23457C, Department of Defense Detail Specification, Engines, Diesel Marine, Propulsion and Auxiliary

2.7.4. MIL-STD-2073-1E: Standard Practice for Military Packaging

2.7.5. MIL-STD-129: Military Marking for Shipment and Storage

2.7.6. MIL-PRF-131: Barrier Materials, Water-Vapor-Proof, Greaseproof, Flexible, Heat-Sealable

2.7.7. MIL-D-3464: Desiccants, Activated, Bagged, Packaging Use and Static

Dehumidification

2.7.8. MIL-PRF-16173: Corrosion Preventive Compound, Solvent Cutback

2.7.9. MIL-PRF-21260: Lubricating Oil, Internal Combustion Engine, Preservative

(Corrosion Inhibiting)

2.7.10. MIL-STD-147: Palletized Unit Loads

2.8. A-A-52624A, Department of Defense Commercial Item Description (CID), Antifreeze, Multi-Engine Type

3. TECHNICAL REQUIREMENTS.

3.1. General guidance.

3.1.1. The manufacturer must have capacity to deliver the generator set, including production, testing, and packaging for shipping, within six months of contract award. Proposal must state firm completion date.

3.1.2. Specific dimensions within this document are accurate according to information and documentation available at the time of release of this specification.

Adaptations within the constraints of standard fittings and hardware may be allowed to accommodate the requirements of proposed generator set systems, but such alterations as would be necessary must be made clear in the proposal.

3.1.3. The generator diesel engine must be designed for compliance with Environmental Protection Agency (EPA) Marine Tier 3 emissions standards for constant speed auxiliary engines, in accordance with current version of 40 CFR 1042 as of February 2025.

3.1.4. The diesel generator set must be designed for a minimum service life of 20 years of operation in a prime power capacity in a marine environment.

3.2. Type approval and military standard qualifications.

3.2.1. The generator set must be type approved by a maritime classification society for use on US-flagged vessels. Requirements of this specification are based on American Bureau of Shipping (ABS) classification rules and military standards.

Demonstration of compliance with these standards will be considered for evidence of qualification under this specification, but compliance with equivalent European classification society rules may be considered.

3.2.2. The generator set manufacturer must submit documentation for the prime mover (diesel engine) demonstrating compliance with ABS MVR Part 4, Chapter 2, Section 1 – Internal Combustion Engines.

3.3. Electrical design characteristics. The generator set must be compatible with the requirements of the ship’s electrical system as described in this section.

3.3.1. Each generator set must be capable of producing a minimum of 375 kW, 460 VAC, 60 Hz, and 0.8 lagging power factor. Objective performance for the delivered generator set is 400 kW.

3.3.2. Two generator sets operating in parallel must be capable of maintaining the requirements of MIL-STD-1399-300-1 Type I power, table II under transient conditions based on starting of the largest motor, which for planning purposes may be assumed to be 315 HP.

3.3.3. A single generator must be capable of starting a motor of 185 HP across the line maintaining the requirements of MIL-STD-1399-300-1 Type I power for transient loading conditions.

3.3.4. The complete diesel generator set must meet the Electromagnetic Interference (EMI) control requirements specified in MIL-STD-461G, as applicable for surface ships, equipment located below deck.

3.3.4.1. Additional testing for the purpose of meeting the MIL-STD-461G EMI requirements of this section will not be required. Test reports demonstrating compliance with commercial EMC standards as required by ABS MVR is acceptable for establishing equivalency for the purpose of this project.

3.4. Piping and physical envelope constraints.

3.4.1. The generator set including skid and all attached auxiliary components must fit within the size envelope (length x width x height):

154” x 60” x 88”

3.4.1.1. Generator set arrangement established to meet this overall size envelope must support maintenance and overhaul work in accordance with the maintenance requirements described elsewhere in this statement of work

(SOW).

3.4.2. Fuel system interface connections compatible with 3/4” trade size supply piping are preferred.

3.4.3. Exhaust system suitable for 10” diameter flanged flexible connections are preferred.

3.4.4. Air intake must filter dust particulate and oil vapors. Must be designed for ambient air temperature of up to 50 degrees Celsius.

3.4.5. Generator air start piping compatible with 1” trade size piping is preferred. Start air supply is provided at nominal 120 psi, but may be as low as 90 psi.

3.4.6. Oil sump fill and drain connections compatible with 1” trade size piping is preferred.

3.4.7. Generator sea water for cooling of jacket water compatible with 3” trade size for supply piping connections and 2-1/2” trade size piping are preferred.

3.4.7.1. In-line strainers are installed for seawater suction.

3.4.7.2. Maximum expected seawater temperature is 95 degrees Fahrenheit.

3.4.8. Exhaust system components must be water-jacketed or heat-shielded (insulated) with non-combustible material. Exhaust piping must comply with the requirements of ABS MVR 4-6-5/11.

3.5. Engine systems and component design.

3.5.1. Cold start requirement is 35°F. Operating envelope is 40-122°F.

3.5.2. Turbocharger must be sized to maintain power quality requirements as described in MIL-STD-1399-300-1 for transient starting of largest motor load, which is a 185 HP fire pump motor.

3.5.2.1. Two generators operating in parallel must be capable of starting a 315 HP bow thruster motor.

3.5.3. Fuel consumption. Required fuel consumption must not exceed 26 gallons per hour at electrical load of 350 kW. Objective performance is 24 gallons per hour or less at 350 kW load. Fuel efficiency may be established by factory testing prior to delivery of the generator sets.

3.5.4. Sub-base (skid) mounted. Sub-base mounted generator sets must consist of a diesel engine and generator and the attached accessories assembled and aligned as a unit on a welded steel sub base (skid) which forms a rigid self-supporting structural unit for installation on its foundation in the ship without further stiffening or bracing.

3.5.4.1. Sub-base (skid) must contain no pockets which can retain liquids.

3.5.4.2. Sub-base (skid) must be arranged to provide sufficient clearance for servicing and disassembling parts such as generators, circulating pumps, air coolers, pistons, and valves without dismantling other machinery, structure, or piping.

3.5.4.3. All sub-base (skids) must be designed and constructed so that positive and accurate alignment of equipment and components is maintained.

3.5.4.4. The rigidity of sub-base (skid) and supporting structure must be sufficient to prevent misalignment which would interfere with operation of the machinery and equipment and to preclude excessive vibratory motion or rocking on the sub-base (skid).

3.5.4.5. Generator coupling requirements. The engine and alternator must be coupled with an angular alignment tolerance equal to or less than 0.005” and parallel alignment equal to or less than 0.002”.

3.5.4.6. Shock-resilient mounts must be mounted to the common skid as interface with mounting on the ship or shock-resilient mounts must be used between the engine/alternator and the common skid.

3.5.5. Installed engine auxiliaries must include seawater and jacket water circulating pumps.

3.5.6. Seawater system flow rate must not exceed velocity limits of the existing piping system, considering size, wall thickness, and piping material, as listed in CG Drawing 282-WMEC-345-001 (including revisions). Calculation must include the common seawater header piping for continuous operation of 3 generator sets in parallel. The generator set manufacturer must provide an accurate raw water pump curve with their proposal, which covers the expected operating conditions as described in this specification.

3.5.7. The jacket water cooler must be capable of maintaining jacket water within the manufacturer’s recommended range for standard conditions at all loads up to 110% rated load, when operating with sea water inlet temperatures of 28 to 95 degrees F.

3.5.8. The engine jacket water system must be provided with electric heaters and thermostatic controls to maintain the jacket water at a temperature sufficient to allow starting and rapid acceptance of load from a shutdown condition. A flow switch in the heater control circuit must be provided, which will de-energize the heater elements in the event of a loss of flow. For heating purposes, the jacket water heater must be capable of maintaining stated condition down to ambient temperature of 40 degrees F.

3.5.9. An external jacket water expansion tank must be installed above the engine in the compartment. The tank may be mounted on the generator set skid. The tank must be equipped with a gage glass. Provision must be made for the addition of chemical treatment and makeup water to the expansion tank.

3.5.10. Not Used.

3.5.11. Engine must be supplied with compressed air driven starter, and capable of being started by the existing air start piping as described in the specification section for piping requirements. Engine must be cable of starting with a minimum air pressure of 90 psi.

3.5.12. Engine fuel system must be compatible with NATO fuel standards F-76 and F- 44, fuel standards according to MIL-DTL-16884R and MIL-DTL-5624X.

3.5.13. Engine must have installed attached seawater pump for jacket water cooling system. Aftercooler must be supplied by jacket water.

3.5.14. Crankcase ventilation connection must be provided. Existing connection may be assumed to be 1” trade size.

3.5.14.1. Crankcase ventilation piping connection must be constructed in accordance with ABS MVR 4-6-5/13, Crankcase Ventilation and Drainage, and meet the requirements of ABS MVR 4-2-1 for Internal Combustion Engine Prime Movers.

3.5.14.2. Engine with closed crankcase ventilation may be offered by the vendor, which would obviate the need for this connection.

3.5.15. Piping system for the scope of the generator design must comply with the requirement of ABS MVR Part 4, Chapter 6, Section 5 – Piping Systems for Internal Combustion Engines.

3.5.15.1. Flow demand calculations for all systems making use of existing piping must be provided to ensure flow velocity is within the limits of piping systems currently installed.

3.5.15.2. Flanged connections to the engine and ancillary equipment piping must be in accordance with ANSI B16.5 (150 psi). All adapters necessary to produce Imperial-type connections (i.e. ANSI flange, SAE J514 flare, or NPT) must be provided by the Vendor.

3.5.16. The diesel engine's OEM must make the declaration of International Organization for Standardization (ISO) standard power. The diesel engine's declaration of power must be ISO standard power as defined in ISO 3046-1 (Reciprocating internal combustion engines – Performance).

3.5.16.1. The rated power must be attained under the following conditions:

3.5.16.2. Atmospheric pressure – 14.5 psia or 100 kPa

3.5.16.3. Air inlet temperature – 122 °F

3.5.16.4. Sea water inlet temperature – 28°F to 95 °F

3.5.16.5. Jacket water and lube oil at standard operating temperature

3.5.17. The engine must use OEM approved lubricants for engine service classification and viscosity grade.

3.5.18. The lube oil must be maintained at a temperature sufficient to permit start and load within 5 minutes.

3.5.19. The engine must be equipped with an automatic lube oil duplex filter assembly approved by the engine OEM. The filter assembly must be monitored for pressure differential. A relief valve must be provided external to the filter casing or other means must be provided to ensure positive flow. A tee pipe fitting must be installed in the lube oil supply line to the filter for the purpose of sampling. A ¼” sampling valve rated above the lube oil system design pressure & temperature must be fitted to this tee. The valve must be capped and the cap chained to the valve.

3.5.20. Provisions must be made on the engine oil sump for measuring and adding lubricating oil to the engine while the engine is operating. A “normal” and “add” or “low oil”, mark must be shown to indicate normal operation and the need to add.

3.5.21. Equipment and instructions for testing lube oil quality must be provided.

3.5.22. Magnesium alloys, zinc, and aluminum parts must not be used in the fuel system.

3.5.23. Turbocharger must receive lubrication from the engine lubricating oil system.

3.5.24. Turbocharger must be capable of containing within the housing any parts of the rotating members which may become fragmented due to loosening, shattering or over speeding.

3.5.25. Suitable shielding or guards for protection of personnel must be provided for hot surfaces and for flywheel couplings and other external moving parts. Flange shielding must be installed on fuel and lube oil lines as well as strainers filters.

Hot machinery surfaces must be shielded or insulated so that no external surface may exceed 220°C (428°F).

3.5.26. Shielding or guards for protection of personnel must be provided for hot surfaces and for flywheel couplings and other external moving parts. Flange shielding must be installed on fuel and lube oil lines as well as on strainers and filters. Hot machinery surfaces must be shielded or insulated so that no external surface may exceed 220°C (428°F).

3.5.27. An identification plate must be located on the engine block near the controls. A plate with an arrow showing the direction of rotation must be secured to the engine block at the power take-off end of the engine.

3.5.28. The engine identification plate information must be engraved or stamped on corrosion resisting metal. The following items must appear on the identification plate:

• Name of manufacturer

• Engine model

• Engine serial number

• Number of cylinders

• Bore and stroke

• Continuous horsepower

• Continuous RPM

• Approximate dry weight

• Date of manufacture

• Emissions rating and compliance data

3.5.29. The flywheel rim or other rotating parts of large diameter attached to the crankshaft must be marked to permit checking of the valve and injection pump timing.

3.5.30. Complete accessory components such as pumps, coolers, governors and other such items must be provided with nameplates that show: manufacturer’s name, type, part number or model.

3.5.31. An engine turning or jacking device according to the requirements of MIL-DTL- 23457C, section 3.7.15.

3.5.32. Engine identification information must be marked on the engine in accordance with all designating and marking requirements of MIL-DTL-23457C, section 3.10.

3.6. Alternator (alternating current generator) design. The alternator must comply with all relevant provisions of ABS MVR 4-8-3/3, Rotating Electrical Machines.

3.6.1. Bearing system design. The generator housing may be designed using one- or two-bearing design, but two-bearing design will be judged favorably in this regard.

3.6.1.1. Bearings must be insulated from the generator housing for prevention of bearing failure caused by shaft circulating current.

3.6.1.2. Three or four-wire platinum resistance temperature detector (RTD) temperature monitoring must be installed for each generator bearing.

3.6.1.3. The Contractor must ensure that bearing loadings and speeds are within bearing manufacturer tolerance for a minimum L10 bearing life equal to the diesel engine's center section time between overhaul. Shaft and carrier diameter must be within the bearing manufacturer tolerance. Lubrication must be appropriate for the temperature and speed factor. Calculations must be provided to the Contracting Officer (KO).

3.6.1.4. Single-bearing generators. Sets furnished with single bearing generators must have the engine end of the generator shaft piloted in either the engine flywheel or the engine crankshaft.

3.6.1.5. Bearing Seals. Either integral seals or re-greasable bearings are acceptable. If integral seals are to be used, then the integral seals are to be rated for at least the number of hours between engine overhauls in accordance with routine overhaul schedule.

3.6.2. Stator windings must be provided with 3- or 4-wire RTD for temperature monitoring.

3.6.3. Stator (armature) must be of random-wound, three-phase, ungrounded wye design.

3.6.4. Permanent magnet generator (PMG) must be part of the stator assembly for the generator’s excitation power source.

3.6.5. PMG output must be three-phase.

3.6.6. Required exciter field voltage must be compatible with 63 VDC AVR output, with a minimum field resistance of 9 ohms.

3.6.7. All engine and generator cabling must be constructed to IEEE 1580 standard and installed in accordance with IEEE 45.8. Cable must be sized for assumed ambient temperature of 45 degrees C.

3.6.8. All generator equipment enclosures must have minimum IP rating of IP22 in accordance with ABS MVR 4-8-3/15 TABLE 2, for machinery spaces above the deck plates.

3.6.9. The alternator must be rated for overload capability of 1.5 times the rated current for a time period of not less than 30 seconds, as specified by ABS MVR 4-8-3/3.

3.6.10. The alternator must be capable of withstanding mechanical and thermal stress induced by short-circuit current of at least three times the full load current for at least 2 seconds in accordance with ABS MVR 4-8-3/3.9.

3.6.11. Alternator components must be constructed in accordance with ABS MVR 4-8- 3/3.11.

3.6.12. Air cooled generator construction must use filter(s) at the inlet for the generator cooling air, suitable for filtering fine dust and entrained oil droplets.

3.6.13. Voltage sensing lines must be protected by fuses sized for interrupting generator short-circuit current and landed at a terminal board inside the generator enclosure.

3.6.14. Alternator insulation must be rated minimum of NEMA Class H with a designed temperature rise of NEMA Class B in accordance with IEEE 45.1, section 8.4.3.

3.6.15. Generator windings must utilize the vacuum-pressure impregnated solventless epoxy insulation system, in accordance with the recommendations of IEEE Std 45.1, section 8.4.3.

3.6.16. The generator terminal box must be free of internal sharp edges and stator leads must be protected from chafing. The generator terminal box must be outfitted with suitable watertight penetrations and internal [silver-plated?] copper bus stubs for connecting (3) LSTSGU-200 power feeders with two-hole silver-plated rectangular copper barrel compression lugs. Smaller stuffing tubes for appropriately sized control and monitoring system cables must also be provided.

3.6.17. The alternator must be equipped with an anti-condensation heater provided with an adjustable thermostat circuit, supplied by 120 VAC single-phase power. The heater must be secured automatically when the generator is online, and display status remotely via dry contact, which may be incorporated into the contactor.

3.7. Generator and engine system controls.

3.7.1. Engine electronic controls must be supplied and compatible with a Woodward 2301E electronic speed and load sharing controller.

3.7.2. Calculated load must be based on fuel flow – fuel rack position or equivalent.

3.7.3. Manual speed controls must be installed locally to the engine. A dry-contact output relay signal must be provided to indicate status of manual or automatic control without requirement for data-networked controls.

3.7.4. Exhaust temperature thermocouples must be installed for each cylinder and each common exhaust header.

3.7.5. Intake air temperature must be monitored by electronic engine controls and used to calculate actual engine power output.

3.7.6. Basic service software and 3 licenses, including machine configurations, must be included, delivered via USB thumb drives. DVD ROM is a suitable backup format.

3.7.6.1. Data logging capability for the engine controller, either internally or accessible via maintenance PC must be a feature that can be enabled for the control system.

3.7.6.2. Service and configuration software licenses and resulting data rights will be procured according to the FAR for purposes of engineering and maintenance personnel reconfiguration, tuning, and troubleshooting, for the installed generator sets.

3.7.6.3. Procurement for service software tools according to data rights for commercial software must not limit the government’s ability to conduct any required maintenance or configuration changes. Data rights limitations under commercial software licenses must not obligate the government to employ the manufacturer for any required maintenance or configuration changes.

3.7.7. Customer connection terminals must be available for connection of receiving station discrete inputs for all alarm and shutdown events as required by ABS MVR ACC notation, 4-9-5/17 TABLE 1 for Electric Power Generating Plant (column A).

3.7.8. At least 2 customer connections for remote emergency stop must be provided.

3.7.9. The engine system must be capable of sustained firing within 5 seconds following initiation of a start with engine in standby mode.

3.7.9.1. Engine control system must alarm if engine fails to start within this timeframe and should prevent continued start command until after a reset signal is received.

3.7.10. The system must include a device to automatically shut-off the starting air when the engine starts.

3.7.11. Any prime mover protection shutdown must be configured to require local reset action to be taken before restarting.

3.7.12. The engine must be provided with an emergency shutdown device independent of the governor. The device must be operable by a pull handle or pushbutton. It must function by interrupting fuel flow to the engine and must stop the engine without damage within 60 seconds. The device must require manual resetting before the engine can be restarted. The device may be combined with the over speed trip device. Means must also be provided to actuate the trip locally at the engine.

3.7.13. Governor system must maintain speed control of the generator set engine within 10% of the rated frequency when running at generator full load, under the various conditions as specified by ABS MVR 4-8-3/3.13.1(b). For the purpose of this project, maximum electrical step load will be considered to be 185 HP motor.

3.7.14. Voltage regulators will be provided by USCG and integrated with the generator sets at the installation in the ship.

3.7.15. The generator set must be equipped with an overspeed trip, in accordance with the requirements of ABS MVR 4-2-1/7.5.3, set to cause emergency shutdown of the engine and generator, including an output signal for securing of excitation when the engine reaches 115% of rated speed. The overspeed trip must be deterministic and free of failure (independent) of the engine control system and speed controller.

3.7.16. Sensors and means of monitoring stator temperature and bearing temperatures must be provided. The temperature monitoring system must alarm, but not shut down the generator, if a detector lead becomes open circuited.

3.7.17. A consolidated remote control and monitoring display must be provided for each generator, to be integrated into the existing operator station. The alarm and display functions required for ACC notation by ABS MVR 4-9-5/17 TABLE 1 and 4-9-6/23 TABLE 6 must be displayed and annunciated (for alarms, as applicable).

3.7.17.1 For control and actuation purposes, the remote generator sets control panel requires only start and stop commands, the paralleling, voltage, and speed control functions will be integrated into the switchboard. Alarm and display requirements from TABLE 1 and TABLE 6 must be complied with.

3.7.17.2 Remote and local control panels must display the following parameters and alarms:

• Jacket water temperature.

• Jacket water high temperature alarm.

• Lube oil pressure.

• Lube oil pressure low alarm and shutdown.

• Fuel oil pressure.

• Engine speed.

• Engine run hours.

• Exhaust temperature.

3.7.17.3 Automatic safety shutdown A3 from TABLE 6 is not applicable to this installation.

3.7.17.4 Each remote-control panel must be provided with an output for actuation of audible alarm in the control station.

3.7.17.5 Data link connection for monitoring and configuration of the engine controller must be provided at the remote-control panel. Communication protocol must utilize a published industry standard (not proprietary communication protocol). Ethernet is preferred, but serial protocols are acceptable.

3.7.18. Load sharing with both 2 and 3 generators operating in parallel must be capable of load sharing real and reactive power according to the requirements of ABS

MVR 4-8-3/3.13.3.

3.7.19. Only the automatic shutdowns for the diesel engine required by ABS MVR 4-9- 2/9.3 must be installed in the engine control system: overspeed, lube oil system failure.

3.7.20. The generator set control system must be capable of display and alarm according to the parameters of the engine listed under the A and D columns of ABS MVR

4-9-6/23 TABLE 1B.

3.7.20.1. Crankcase pressure must be monitored and alarm on high pressure.

ATTACHMENT 1: SOW

Thomas, Corry D CWO-2 USCG SFLC (USA) Fix indent to 3.7.17.1 etc

3.7.21. The generator set control system must utilize 24 VDC control power and be supplied with a battery and battery charger to be integrated with the switchboard control systems on installation of the generator. The battery must be suitably sized to power the generator set control system, speed controller (Woodward 2301E), voltage regulator, and remote monitoring panel for a period of 2 hours.

3.7.22. Battery charger must be powered by 120 VAC, single-phase, 60 Hz.

3.8. Maintenance and overhaul requirements.

3.8.1. Disassembly. Generator set must be designed such that the diesel engine and the generator can be separated and removed independently of each other. Both the diesel engine and the generator must each have specific lifting points to allow them to be removed individually.

3.8.2. Lifting Means. Eyebolts, lugs, holes or equivalent means must be provided to permit lifting the generator set and attached accessories as a complete unit. The diesel engine and the generator must have provisions for lifting individually after decoupling. Eyebolts or other means of lifting the generator or diesel engine alone must not be used for lifting the assembled generator set.

3.8.3. Fasteners must not be torque-to-yield type.

3.8.4. Threaded parts must be in accordance with the screw thread standards of FED

STD H28A or commercial equivalent. Nuts and other threaded fastenings on the engine and auxiliaries must be secured by wire, lock washers or other means to prevent the part from working loose under operating conditions. Threaded holes in aluminum intended for bolts or studs must have steel inserts.

3.8.5. Generator housing, bearings, and internal components must be configured so any required generator maintenance required on a yearly or more frequent basis is practical without disassembly. Removal of access covers is not considered disassembly for purpose of this requirement.

3.8.6. The generator set manufacturer must conduct analysis and provide expected replacement rates for major engine components and supplied accessories. The engine must have minimum 10,000 hour mean time between overhaul (MTBO) and have reliability data in accordance with the requirements of MIL-DTL- 23457C, section 3.5. Details on accessibility for maintainers in accordance with MIL-DTL-23457C, section 3.5.2.1 must be provided.

3.8.7. The contractor shall demonstrate the ability to deliver parts and materials required for repairs and overhaul to Kodiak, Alaska in a timely and cost-effective manner. The contractor must provide evidence of a robust, established supply chain for the generator sets being supplied, including partnerships and distribution networks that ensure the long-term availability of repair parts and materials. Additionally, the contractor shall include estimated pricing which reflects competitive market rates for parts and materials including delivery to Kodiak, AK, accounting for logistical challenges associated with the region. List of estimated repair parts requirements must be based on most statistically likely failures or required repairs and manufacturer’s recommended overhaul schedule for 20-year service life of the offered generator sets.

3.8.8. Qualified technicians trained and certified according to OEM standards must be available to provide on-site support in Kodiak, AK as required. Demonstrate ability to deploy technicians promptly to Kodiak for troubleshooting, inspections, crew training, and major overhauls, as required. Provide estimated technician labor rates, considering the unique geographical and logistical challenges of the region.

3.9. Technical documentation. All technical documentation must be prepared in accordance with SFLC Std Spec 0850 and 0860.

3.9.1. Failure Mode and Effects Analysis (FMEA) – must be completed for generator sets systems, including analysis for failure of all major replaceable subassembly components (as applicable to the specific design: governor, fuel injectors, engine controller, turbocharger, starting system, cylinder liners, piston, connecting rod, crankshaft, camshaft, valve assemblies, piping systems).

3.9.1.1. FMEA must include known failure rates (mean time between failure, MTBF) of generator set components to inform spare parts requirements, total lifecycle cost of the system, and expected service life.

3.9.1.2. Use of the same FMEA as submitted for classification society type approval is encouraged.

3.9.2. Operations and maintenance manuals must include operating procedures under normal operations and actions to be taken in all emergency conditions.

3.9.2.1. The operations manual must include functional descriptions, instructions for alignment, starting, and monitoring in operation, and actions to be taken in emergency conditions, for all generator set subsystems.

3.9.2.2. The maintenance manual must include in detail procedures for all maintenance and overhaul requirements for an intended service life of at least 20 years.

3.9.2.3. The manual must include a detailed parts list with illustrations for all generator sets’ components and assemblies, including relevant suppliers’ drawings.

3.9.3. Control systems troubleshooting and programming manual must be provided, which details all common troubleshooting actions to be taken at the repair technician level for all intermittent and persistent control systems errors and faults for which the vendor has encountered in the field.

3.9.4. Installation manual must include all required inspection and commissioning procedures for start-up to be conducted prior to start of testing required by this specification.

3.9.5. A detailed datasheet must be provided for the alternator, including at a minimum the following data: short-circuit ratio (SCR), sub-transient, transient, and synchronous reactance.

3.9.6. The contractor must provide details of available technical training opportunities relevant to the offered generator sets. Details must at a minimum include training curriculum, cost, locations, options for on-site training, and prospective schedules.

3.10. Factory acceptance testing (FAT) requirements. Factory Acceptance Testing (FAT) shall be conducted at the manufacturer’s facility to verify the functionality, performance, and compliance of each generator set. FAT must include all routine tests specified in ABS MVR 4-8-3/15 TABLE 3, conducted in accordance with the requirements of ABS MVR 4-8-3/3.15.

3.10.1. Type Testing:

3.10.1.1. If the alternator configuration being offered is type-approved, routine tests per TABLE 3 must be conducted.

3.10.1.2. If type testing is not applicable for the alternator configuration, full type testing must be conducted as part of the FAT.

3.10.2. Required FAT Tests. The following tests must be performed during FAT:

3.10.2.1. Visual inspection.

3.10.2.2. Insulation resistance measurement.

3.10.2.3. Winding resistance measurement.

3.10.2.4. Verification of voltage regulation system. Vendor standard voltage regulator may be used for this test, the voltage regulator model number and settings used by the OEM during factory testing (FAT) must be provided to the USCG.

3.10.2.5. Overload and over-current test.

3.10.2.6. Over-speed test.

3.10.2.7. Dielectric strength test.

3.10.2.8. Running balance test.

3.10.2.9. Generator bearing check after test.

3.10.2.10. Air gap measurement.

3.10.3. Test Reporting and Observation.

3.10.3.1. Detailed test reports, including specific results for each test, must be provided prior to shipment for each generator set.

3.10.3.2. Test reports shall be submitted to the Contracting Officer Representative (COR) prior to shipment for review and approval.

3.10.3.3. The contractor must provide an option for COR (or designated representative) to observe the FAT at the manufacturer’s facility.

3.10.4. Government acceptance. Satisfactory quality assurance (QA) inspection is required before each generator set is shipped. Inspection may be conducted by on-site test observation and review, virtual test observation, or review of test reports only, the method to be specified by the COR. Notification of planned start of FAT must be provided to the COR minimum of 2 weeks prior to start of the test. All testing will be accomplished using contractor supplied calibrated test equipment and instrumentation. All testing shall be accomplished in accordance OEM specifications and procedures and standards referenced elsewhere within this section. OEM-specific procedures shall be made available for review by the QA representative. It is the Government’s intention to have Coast Guard QA representative witness FAT, preservation, and packaging of the generator sets prior to delivery to the Coast Guard.

3.11. Installation Testing. Testing at installation is separate from the requirements of FAT and will be conducted after the generator set is installed at the final site. A specific testing plan and checklist will be developed and released by USCG prior to installation. Installation testing will be conducted using a 1 MW load bank, capable of reactive power loading. All loads are 0.8 power factor (pf), except where otherwise indicated. The following tests must be performed:

3.11.1. Required Installation Tests:

3.11.1.1. Insulation resistance testing, including polarization index.

3.11.1.2. Minimum of four hours of operation at full rated load.

3.11.1.3. Step load testing: Incremental loads of 20% to 100% of generator rated value, with a stabilization interval of 10 minutes at each step.

3.11.1.4. 50% rated load transient loading and unloading.

3.11.1.5. 110% momentary overload testing for up to 15 minutes.

3.11.1.6. Operation at 100% rated current at 0.4 pf for a minimum of 15 minutes.

3.11.1.7. Repeat the following tests while operating in parallel with 2 and 3 generators, with load proportions based on the combined connected generator ratings:

3.11.1.8. Four-hour full-load run.

3.11.1.9. Step load testing.

3.11.1.10. Operation at 100% rated current at 0.4 pf.

3.11.1.11. While operating with 2 generators in parallel, loaded with a combined load of 100% of a single generator, take 1 generator offline. The generator taken offline must not overspeed, and the generator which remains online must not stall, and must recover frequency and voltage within 2 seconds.

3.11.2. Load Sharing and Voltage Regulation:

3.11.2.1. Real power load sharing will be accomplished using the Woodward

2301E governor.

3.11.2.2. The expected voltage regulator at installation will be the Basler DECS-

150, configured for cross-current compensation reactive load-sharing.

3.11.3. Test Reporting: Detailed installation test reports, including specific results for each test, must be submitted to the designated government representative upon completion of testing for review and approval.

4. PRESERVATION, PACKAGING, PACKING AND MARKING

4.1. The contractor must individually preserve, package, mark, and ship each diesel generator set to prevent corrosion, contamination, and physical damage during storage and transportation. The following must apply:

4.2. The generator set must be treated for a lay-up of up to one year before being packaged.

Instructions must be provided for restoring the engine to operational condition post-lay-up (at preparation for installation).

4.3. Apply MIL-PRF-16173, Grade 3 corrosion-preventive compound to all exposed external unpainted metal surfaces.

4.4. Apply MIL-PRF-21260 preservative lubricating oil to internal engine components, including cylinders, crankcases, and other moving parts.

4.5. All wood material used for packaging must meet phytosanitary requirements.

4.6. Wrap each generator set in a water-vapor-proof barrier material conforming to MIL-

PRF-131, Class 1. Heat-seal the barrier material to create an airtight enclosure.

4.7. Place desiccants conforming to MIL-D-3464 inside the barrier enclosure to control moisture. Calculate the required desiccant quantity based on the volume of the package and the storage duration. Include a humidity indicator card inside the package to monitor moisture levels.

4.8. If the generator set is bolted to a solid steel frame, which serves as the structural base for transportation, handling, and storage, but does not include features for safe handling (e.g., fork pockets or lifting points), a skid or pallet conforming to MIL-STD-147 must be used to facilitate transportation and handling.

4.9. Use appropriate cushioning materials to protect the generator set from shock and vibration.

4.10. The contractor must mark all packages in accordance with MIL-STD-129. Markings must include:

4.10.1. National Stock Number (NSN), if applicable

4.10.2. Item Name

4.10.3. Part Number

4.10.4. Contract Number

4.10.5. Delivery Order Number

4.10.6. Shipping Weight (as determined by contractor)

4.10.7. Condition Code: Condition “A”

4.10.8. Coast Guard SFLC Material

4.11. The Contractor must supply bar code labels on all packages except for those that require date submissions only. All bar-code labels must:

4.11.1. Be in accordance with SFLC specification D-000-0100 Rev G.

4.11.2. Labels must be Type “V”, Grade “a”, Style “2”, Composition “b” with plastic laminate.

4.11.3. Each label must contain encoded data for the Stock Number, Contract Number, and the Delivery Order Number as applicable.

5. TEMPORARY STORAGE AND SHIPPING

5.1. The packaged generator sets must be prepared for transportation in accordance with

MIL-STD-2073-1E and MIL-STD-129 to ensure safe handling and delivery.

5.2. If a shipping address is not provided at the time of packaging completion, the contractor must store the packaged generator sets in a secure, climate-controlled facility for up to six (6) months.

5.3. The storage facility must meet the following requirements:

5.3.1. Environmental Control: Maintain a clean, dry, and climate-controlled environment to prevent exposure to moisture, temperature fluctuations, and contaminants.

5.3.2. Security: Ensure the facility is secure and protected against unauthorized access, theft, or damage.

5.3.3. Accessibility: Ensure the packaged generator set is readily accessible for inspection or shipment when the shipping address is provided.

5.4. The contractor must inspect the package every 90 days during the storage period to ensure the integrity of the barrier material and monitor the humidity indicator card.

5.5. Replace desiccants if the humidity indicator card indicates excessive moisture.

5.6. Document all inspections and provide reports to the designated government representative upon request.

5.7. If no delivery address is provided within the six-month storage period, the contractor must ship the generator set to the default address provided below:

US Coast Guard Surface Forces Logistics Center

2401 Hawkins Point RD, BLDG# 88 Baltimore, MD 21226-5000

5.8. The contractor must notify the government representative at least 10 business days prior to the expiration of the six-month storage period to confirm the default shipping destination and provide final shipping details.

5.9. Upon receipt of the shipping address or confirmation of the default destination, the contractor must coordinate the shipment of the generator set to the specified location within 30 business days.

5.10. The contractor must provide tracking information and delivery confirmation to the government representative.