Attachment 1_Specification.pdf

PRM_0522

WORK ITEM 1: 2815-12-348-2440, Engine, Diesel, Repair

1. SCOPE

1.1 Intent. This specification describes the requirements for the overhaul of non-ready for issue MTU 8V396 TE94 marine diesel engines. These engines are installed onboard the Coast Guard’s 87’ WPB Patrol Boats. The engines to be overhauled have reached the time interval, in accordance with (IAW) MTU Maintenance Echelon W6, in which 14,000 hour maintenance tasks are required, or may have experienced a catastrophic failure.

1.2 Commissioning. This specification describes the requirements for commissioning services of a newly installed MTU 8V396 TE94 engine.

1.3 Support. This specification describes the requirements for technical support for the MTU 8V396 TE94 engine system.

1.4 Government-furnished property.

MTI ITEM DESCRIPTION NSN

P/N

CAGE

QTY

(EA.)

ESTIMATED COST

($/UNIT)

Y ***Engine, Diesel NSN: 2815-12-348-2440

PN: 8V396 TE94

N Crate NSN: N/A 1 *Government-loaned property, which shall be returned to the Coast Guard upon completion of the contract.

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

***Government-furnished property, which is to be supplied by the Coast Guard.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

None

OTHER REFERENCES

ANSI/NCSL Z540.3-2006 (R2013), Dated 26 Mar 2013, Technical Requirements for the

Calibration of Measuring and Test ASQ/ANSI/ISO 9001, Dated 20 Nov 2015, Quality Management Systems – Requirements Geislinger Coupling E56/7,5/90 Bearing Housing Description, Assembly Instructions

N060558/00E Installation of MTU Electronic Systems E 530 606/06E

ISO/IEC 16388-2007, May 15 2007 Information technology — Automatic identification and data capture techniques — Code 39 bar code symbology specification

MIL-C-104-C Dated 24 June 93, Crates Type II, Class II, Style A MIL-STD-129R, 27 Sep 2019 Military Marking for Shipment and Storage MTU 8V396TE94 Maintenance Manual M020046/21E MTU 8V396TE94 Parts Catalog M033971/01DE MTU 8V396TE94 Tolerances & Wear Limits List M070026/00E MTU Tool List M004021/20DE MTU Fluids and Lubricants Specification A001061 MTU Preservation and Re-preservation Specifications A001070 MTU Exhaust Turbo Charger ZR140 M040052/10E MTU Bosch Fuel Injection Pump, PE ZWM 170/100RS 30 Description, Assembly Instructions, Spare Parts List M040095/00E MTU Solenoid Actuator, Description, Assembly Instructions M040082/10E MTU Service Information 396-99/0562B Electric Governor Actuator with Oil Drain MTU Fluids and Lubricants Specification A001061/39 MTU Engine management System Type ECS 396/S Version E & F with ETB 4E/ETB 4F

Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E MTU Customer Connecting System CCS for ECS 396, E 531 416/00E MTU Customer Connecting System CCS for ECS 396, E 531 415/00E MTU Electrical Start Device SUE-ES for ECS 396, E 531 482/00E MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED MTU Junction Box CCS-ECS 396E Illustrated Parts Catalog E 535 151/01ED MTU Local Operating Panel for ECS E 531 301/01E MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED MTU Monitoring & Control Unit Documentation E 535 164/00ED

2.1 Specification order of precedence. The Applicable Documents described are required to be adhered to in fulfilling the contract. In the event of a conflict between the text of this specification and the references cited herein, this work item shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

2.2 Departure from specification. Departure from this specification shall not be allowed unless approved by the Contracting Officer.

• If the Contractor finds it necessary to suggest implementing change or depart from applicable specifications they shall request permission.

• Request for change shall clearly describe the changes proposed, the reason for change, advantages of the proposed changes, price increase or decrease (if any) resulting from the change.

2.3 Document availability. The documents listed in this section are referenced in sections 3, 4 and 5 of this work item and drawings stated in this Work Item. To obtain the referenced documents see section 6.1.

3. REQUIREMENTS

3.1 General. The contractor shall overhaul the engine and components listed in MTU Maintenance Echelon W6. All 14,000 operating hour tasks shall be accomplished.

3.1.1 Distributor agreement. The contractor must possess a current MTU distributor agreement authorizing the service of their products. Any changes and/or modifications to the distributor agreement shall be forwarded immediately to the Contracting Officer. The Coast Guard reserves the right to request from the contractor proof of their distributor agreement at any time.

3.1.2 Bulletins. Contractor must have access to service bulletins applicable to the 8V396 TE94 engine.

3.1.3 Experience. The contractor shall provide, when requested by the Contracting Officer, detailed evidence of their experience overhauling, repairing, and testing of the MTU 8V396 TE94 marine diesel engine and components listed in this specification.

3.1.4 Business portal. The Contractor shall have access to MTU’s secure MTU IT Business portal and the MTU Central Data.

3.1.5 Calibration. All tools and test equipment shall be calibrated in accordance with section 4.3.

3.1.6 Technician qualifications. The contractor shall ensure all work performed under this contract is by technicians possessing the training, qualifications, and certifications (specified in the referenced manuals) to the level appropriate for the specific task they are performing. Any work performed by un-certified/qualified, or under certified/qualified technicians will be subject to contractual remedies.

3.1.7 MTU parts. The overhaul and component inspections shall be completed using current MTU parts, components, processes, and practices.

3.1.8 Testing. Testing shall be conducted in accordance with MTU factory acceptance run-in and final acceptance protocol.

3.1.9 Notification. The contractor shall notify the Contracting Officer 14 days prior to all testing. The Coast Guard reserves the right to witness all testing.

3.1.10 Dynameter testing. The overhauled engine shall be dynamometer tested to full load, 1120 KW, IAW MTU run-in/final acceptance test procedures

3.1.11 Final acceptance. The contractor shall provide the Contracting Officer an electronic copy of the final acceptance, engine test certificate (Birth Certificate) within 14 days after testing.

3.1.12 Storage. Upon receipt of components, regardless of condition, the contractor shall store material inside in a secure area away from adverse weather.

3.1.13 Overhaul quantity. The contractor shall be capable of overhauling up to 14 engines per year.

3.1.14 Subcontractors. The contractor is solely responsible to facilitate and coordinate subcontractors’ performance requirements.

3.1.15 Reports. The contractor shall submit reports within the time line set forth in the delivery schedule.

3.1.16 Contractor points of contact. The contractor shall submit resume’ for the primary Project Manager (PM) and Alternate Project Manager (APM) who shall be the single point of contact for the Contracting Officer and the Contracting Officers Representative. The name, position, title, experience of these persons shall be stated in writing to the Contracting Officer prior to contract award. The PM and APM shall be abreast of all support the contractor is currently providing the USCG under this contract, and shall be able to address inquiries from the Contracting Officer and the Contracting Officers Representative regarding that support. The PM shall be able to read, write, speak and understand English fluently.

3.1.17 Non-applicable certification. American Bureau of Shipping (ABS) certification is not applicable to this specification.

3.2 Overhaul engine. When directed by the Contracting Officer, using the applicable MTU Technical Publications and Standards, the contractor shall provide all labor, equipment, special tools, materials, and parts to receive, inspect, overhaul, test, preserve, paint, package, and provide warranty for the engine and components listed in MTU Maintenance Manual M020046/21E. All 14,000-hour maintenance tasks shall be accomplished. The contractor shall incorporate, all applicable MTU engine service bulletin modifications. The contractor shall complete these requirements in accordance with the referenced delivery order.

• (a) The contractor shall receive a not-ready for issue engine, NSN 2815-12-348-2440, document the as-received condition and submit appendix A.

• (b) The contractor shall separate the transmission and return to SFLC using a provided due in #.

The contractor shall disassemble engine, inspect and submit condition found report appendix B.

Include cost for any additional work.

• (c) The contractor shall maintain critical dimensions documentation, as specified in Maintenance Manual M020046/21E, and made available to Contracting Officer or Contracting Officer Representative (COR) upon request.

• (d) The contractor shall conduct a dynamometer test in accordance with the factory run-in and acceptance test procedure on overhauled engine per appendix C and submit report.

• (e) The contractor shall preserve the engine IAW MTU Preservation and Re-preservation Specifications A001070. Freeze protection is required IAW, chapter 5.3.2, Storage with unfilled medium circuits. Use internal preservation corrosion inhibitor Glysacorr P133 antifreeze at 50% volume or equivalent. Submit to the Contracting Officer MTU Check Sheet for Preservation upon preservation completion.

• (f) The contractor shall paint the overhauled engine with Valspar LIC 50 general purpose polyurethane enamel, RAL9010 white following all manufactures surface preparations, mixing ratios, and dry times. Paint shall be sprayed on all surfaces 3-5 mils thick.

• (g) The contractor shall package the overhauled engines in accordance with Preservation and Re-preservation Specifications A001070, chapter 8.2, Climate-compatible long term storage. Mark overhauled engine IAW section 5.4 of this specification.

• (h) The contractor shall submit a cumulative tracking report on the 15th of each month with status of all open delivery/task orders appendix

3.3 Commission engine. When directed by the Contracting Officer the contractor shall provide a technical representative for up to two days to provide start-up commissioning services on the overhauled 8V396 TE94 engine(s) aboard an 87’ WPB in accordance with MTU specifications. This shall be accomplished at a location designated by the Coast Guard. The contractor shall submit a Commissioning Report, appendix E. When commissioning services cannot be completed because of an existing shipboard discrepancy, the contractor shall submit a condition found report and a cost estimate to correct discrepancies using rates for section 3.4 (TECHNICAL SUPPORT) of this specification.

3.4 Technical support. When directed by the Contracting Officer the contractor shall provide technical support for the 8V396 TE94 propulsion system to include; the Engine Control System (ECS), and Remote Control System (RCS) at the location determined by the Coast Guard. This support includes, but is not limited to; phone support, on-site technical assistance to equipment diagnostics, troubleshooting, and repairing equipment faults. All requests for technical support will authorized by the Contracting Officer under a separate task order.

3.5 Root cause failure analysis. In the event of a catastrophic failure of an 8V396 TE94 engine the Contracting Officer, on a separate task order, may send the failed engine to the Contractor’s facility to determine the root cause of failure. A report of findings shall be submitted to the Contracting Officer within thirty (30) days of receipt of the failed engine.

3.6 Warranty. The engines are being overhauled as system stock and will be placed into inventory and not for immediate installation. The Contractor shall provide a warranty for a period of one (1) year of operation, following up to two (2) years in storage. Storage commences upon receipt of the component at the designated Coast Guard facility. The warranty commences the date the engine is installed on an 87’ WPB. The warranty shall cover all parts and workmanship defects. The contractor shall contact the 87’ WPB cutter within twenty –four (24) hours after receiving notification by the Coast Guard of a warranty claim.

3.7 Re-preservation. When directed by the Contracting Officer the contractor shall receive an overhauled engine from Coast Guard inventory that requires re-preservation. The contractor shall re-preserve the engine in accordance with MTU Specifications. The re-preservation shall include dynamometer testing.

3.8 Travel. The contractor shall be required to travel to support this statement of work section 3.4 Technical support. Costs for transportation, lodging, meals, and incidental expenses incurred shall be reimbursed using the current Federal Travel Regulations and not to exceed the maximum per diem and lodging rates for the time/location of performance. See Federal Acquisition Regulation (FAR) 31.205-46

(a) (2).

4. QUALITY ASSURANCE

4.1 General. The Contractor shall maintain an inspection system which shall ensure each item offered to the Coast Guard for acceptance conforms to contract requirements. The system shall be documented and in compliance with ASQ/ANSI/ISO 9001.

4.2 Records. The Contractor shall maintain records of all measurements, inspections, and tests. The records shall indicate the nature and number of observations made, type of deficiencies found and the corrective action taken. Records shall be furnished upon request of Contractors Officers Representative

(COR).

4.3 Contractors calibration system. The Contractor as well as any Subcontractors shall be required to maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540-3. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to ensure adherence to calibration schedules. Calibration standards shall be traceable to the National Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for Contractors Officers Representative (COR).

4.4 Responsibility for inspection. The Contractor shall be responsible for all inspections/test requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all inspection requirements. All testing and inspection shall be at the Contractors facility or other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspection/tests set forth in this specification where such inspections are deemed necessary to ensure that supplies or services conform to the prescribed requirements.

4.5 Required tests. Each component provided under this contract shall be operationally tested when required by MTU procedures.

4.6 Test report. The Contractor shall submit the final test reports in accordance with this specification.

• One copy of the test reports shall be packed with each component delivered under this contract.

• One electronic copy of the test reports shall be provided to the Contracting Officers Representative (COR).

4.7 Packing inspection. The Contracting Officer shall be notified after preservation seven (7) days prior to the packaging, and marking of the completed units. The Coast Guard reserves the right to perform an on-site inspection if deemed necessary.

5. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 Preservation. The contractor shall preserve the engine IAW MTU Preservation and Re-preservation Specifications A001070. Freeze protection is required IAW, chapter 5.3.2, Storage with unfilled medium circuits. Use internal preservation corrosion inhibitor Glysacorr P133 antifreeze at 50% volume or equivalent. Submit to the Contracting Officer MTU Check Sheet for Preservation upon preservation completion.

5.2 Packing. Each engine shall be packaged in accordance with MTU Preservation and Re-preservation Specifications A001070, section 8.2, in climate-compatible long term storage packaging in a re-usable skid mounted wooden box. Each container shall be internally braced and cushioned to prevent movement of the assembly. The container and internal bracing shall be capable of protecting the assembly while in storage and from rough handling during multiple shipments.

5.2.1 The Contractor shall place in a plastic envelope in each container, copies of all test and inspection results, caution tags, and coolant flush instructions to be completed prior to light off.

5.3 Marking. Each preserved, packed, and packaged item shall be stenciled in the upper left-hand side of the two longest sides, (two opposite sides if square) of each box. Marking is in accordance with MIL-

STD-129R.

5.3.1 Machine made stencils shall be used for all marking.

5.3.2 All marking shall be in black print on a contrasting back ground (white paint) and at least 2” high.

5.3.3 The marking shall be in the format as follows:

NATIONAL STOCK NUMBER 2815-12-348-2440

ITEM NAME ENGINE, DIESEL

PART NUMBER 8V396 TE94

SERIAL NUMBER As per enclosed item

CONTRACT NUMBER (See Contract)

DELIVERY ORDER NUMBER (As submitted on the Order)

SHIPPING WEIGHT (LBS) As Determined by Contractor

QUANTITY & UNIT OF ISSUE 1 - EA

PRESERVED FOR LONG

TERM STORAGE ON

Date preserved

CONDITION CONDITION A

OTHER DATA AS DIRECTED

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER,

DO NOT DAMAGE.

DO NOT DESTROY.

5.3.4 The following marking shall be placed on all four sides and the top of each box, in stenciled black print at least 2” high.

• Reusable Container- Do Not Damage Remove Bolts Prior To Removing Cover Use Forklift To Unload Do Not Lift By Cover

5.4 Bar coding. U.S. Coast Guard requires bar coding of the NSN, IAW ISO/IEC 16388-2007 Code 39 Symbology.

5.4.1 Bar coding label. Can be applied separately or as part of the marking required in 5.3.

5.5 Shipping. Unless otherwise directed, the Contractor shall ship and deliver the propeller(s) to the government address specified in paragraph 5.8.1. Notify the KO and COR about the shipment (07) days in advance. Provide timely shipping information to KO and COR including the name of the shipping company, date of shipment leaving Contractor’s facility, and expecting arrival date and time at the government facility. No shipment shall arrive outside of government normal business hours as determined by the KO.

5.5.1 Address. Unless otherwise specified, the Contractor shall ship, and deliver all parts to the following government addresses:

US Coast Guard Surface Forces Logistics Center 2401 Hawkins Point RD, Receiving Room - Bldg. 88 Baltimore, MD 21226

6 NOTES

6.1 Document sources.

6.1.1 Government document sources.

• Department of Defense Single Stock Point (DODSSP)

Building 4, Section D 700 Robbins Avenue Philadelphia, PA 19111-5094 215-697-2667/2179

FAX 215-697-1462

• DOD & Navy Publications & Forms (Other Than DODSSP) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2000

• USCG Surface Forces Logistics Center 707 Ordnance Road Baltimore, MD 21226 Attn: Technical Information Management Branch 410-762-6471

6.1.1 Commercial document sources.

• Rolls-Royce Solutions Americas

39525 Mackenzie Drive Novi, MI 48377 248-560-8000 https://www.mtu-solutions.com/eu/en.regionselect.html_

• American National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 Phone: 212-642-4900 https://www.mtu-solutions.com/eu/en.regionselect.html_

• (ISO) International Organization for Standardization BIBC II Chemin de Blandonnet 8, CP 401 1214 Vernier, Geneva, Switzerland Phone +41 22 749 01 11 Fax: +41 22 733 34 30 Email: central@iso.org mailto:central@iso.org