Attachment 2 FIR (WLB 225B) DS FQ3 MJW 21R0.doc

USCGC FIR (WLB 213)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2021

Developed By: LCDR Frank Reed (Rev-0, 27 February 2021)

TABLE OF CONTENTS

iiiRevisions Record ivConsolidated List of References vConsolidated List of Government-furnished Property viConsolidated List of Critical Inspection Items viiPrincipal Characteristics

1General Requirements

11WORK ITEM 1: Renew #1 Main Diesel Engine Cylinder Liners

18WORK ITEM 2: Renew #2 Main Diesel Engine Cylinder Liners

Revisions Record This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

Consolidated List of References The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at the time of specification writing and during contract execution.

All Coast guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – from links located on the SFLC website. Commercial sites provide access to their respective documents.

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3, Jun 2020, Coatings and Colors Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Caterpillar® Marine Model D3608, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance Guidelines for “Index of Publications on Reusability or Salvage of Used Parts”, Publication, SEBF8029 (series).

Consolidated List of Government-furnished Property The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

None

Consolidated List of Critical Inspection Items The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)):

Principal Characteristics

225' WLB (B-CLASS)

Physical

Hull

Frame spacing

Machinery

Tank CAPACITIES

00000_0220_FLT

REC_00000_FLT_Commercial Project @ CG Facility (1212) General Requirements

1. SCOPE

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

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

2. REFERENCES

Coast Guard Drawings None Coast Guard Publications Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures 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 this availability.

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 to all other work subsequently authorized by changes, modifications, or extensions to the contract.

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

· Provide portable fire extinguishers for Coast Guard fire watch personnel. Coast Guard fire watch is in lieu of contractor personnel during the hours of 0800-1600, Monday through Friday, and limited to two Coast Guard fire watch personnel.

· Provide fire watch personnel and fire extinguishers for the duration of the availability period, during and beyond noted Coast Guard fire watch support.

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

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

3.3.2 Coating colors and system color schemes. Ensure that all colors and color coat/paint schemes are in accordance with COMDTINST M10360.3, Chapter 6 (Cutter and Boat Colors Exterior and Interior).

NOTE

Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes (provided in Chapter 6 of COMDTINST M10360.3) are strictly prohibited.

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

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

3.5.1 Contractor operated (non USCG) facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix A, Requirements for Environmental Protection at Contractor Operated (Non USCG) Facilities, as applicable, during the performance of this availability. Contractor shall plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor shall comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.1 USCG facilities. The Contractor shall provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, during the performance of this availability. Contractor shall plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor shall comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item shall not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.1.1 USCG Generator status. The activity Generator Status for the Coast Guard Facility is small generator.

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

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

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

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

3.5.2 Test and procedures. The Contractor shall be required to promptly conduct tests and procedures for the purpose of assessing whether operations are in compliance with applicable Environmental Laws. Analytical work shall be done by qualified laboratories; and where required by law, the laboratories shall be certified.

3.5.3 Regulatory notifications. The Contractor shall be responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The Contractor shall submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications shall be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

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

3.5.5 HW disposal. Contractor shall comply with SFLC Std Spec 0000 Appendix B, Requirements For Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.5.6 Additional Requirements. The Contractor shall be aware of the following:

3.5.6.1 No Contractor or Subcontractor shall have the authority to sign a Hazardous Waste Manifest using the Coast Guard facility’s EPA Generator ID Number or remove contract generated hazardous waste from the Coast Guard facility without COR or KO-approval.

3.5.6.2 Local environmental regulations at the Government facilities may be more stringent. As with all environmental regulations, the Contractor shall prepare for and comply with local and state regulations.

3.5.6.3 Coast Guard facilities do not maintain Facilities Response Plans (FRPs) per 33 CFR 154. Contractor shall furnish the FRP when required for over-the-water liquids transfers to and from vessels, and is required for oil/fuel transfers to/from vessels for 250 barrels (10,500 gallons) or more.

3.6 Local Policy. None.

3.7 SFLC Standard Specification approved changes. The Contractor shall be aware that the following are approved changes to published SFLC 2018 Edition Standard Specifications and supersede published content:

None.

4. NOTES

4.1 QA inspection forms. QA inspection forms (QA-1 thru QA-5), required in SFLC Std Spec 6310 to be completed and submitted during preservation of “critical-coated surfaces”, are provided at the end of this document.

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

CHECKPOINT 1 – COATING SYSTEM COMPLIANCE

Ensure all coatings are in compliance with SFLC Std Spec 6310, Appendix C.

CHECKPOINT 2 - PAINT STORAGE

Ensure all coatings are kept at a temperature of 65 to 85°F at all times, unless otherwise specified by the coating mfg.

CHECKPOINT 3 - AMBIENT CONDITIONS

Ensure surface and surrounding temperatures are each between 50 and 90°F for water-containing coatings, and 35 and 95°F for other coatings, unless otherwise specified by the coating manufacturer(s).

Ensure maximum relative humidity (RH) is as follows, from surface preparations through final curing of topcoat: 50% for tanks, voids, and vent plenum; and 85% for all other areas, unless otherwise specified by manufacturer(s).

Ensure surface temperature is at least 5°F above the dew point, unless otherwise specified by the coating mfg.

CHECKPOINT 4 - PRE-SURFACE PREPARATION

Remove surface contaminants (soluble salts, loose rust, mud, and marine growth) with low pressure fresh water wash down (maximum 5,000 psi). If oil and grease are present, perform solvent cleaning, as per SSPC SP-1.

Verify equipment setup, blast media, and surface preparation methods match designated test coupon.

CHECKPOINT 5 - SURFACE PREPARATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure cleanliness of prepared surface is as per specification (i.e.: SSPC SP-11, SP-10, SP WJ-2…).

Verify surface anchor profile using ASTM D4417-Methods B or C against SFLC Std Spec 6310. Conduct profile readings at a minimum of 5 locations for the first 1000-sqft area, and 2 locations for each succeeding 1000-sqft area.

Measure soluble salt conductivity in accordance with SSPC-Guide 15. Conduct 5 measurements per each 1000-sqft area (max. threshold: 70 microsiemens/cm for non-submerged surfaces, 30 microsiemens/cm for submerged surfaces).

CHECKPOINT 6 - PRIMER COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Verify proper mixing and stand-in (induction) times.

Ensure no paint is applied when the temperature is expected to drop to freezing before the paint has dried.

Ensure surfaces are completely dry, unless otherwise allowed by the coating manufacturer(s).

Verify wet film thickness (WFT) at random, to prevent under or over application. Verify final DFT.

Brush out all runs, sags, drips, and puddles.

Perform visual inspection for holidays and other defects.

CHECKPOINT 7 – STRIPE COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

After primer coat (mist coat after inorganic zinc), brush-apply un-thinned coat of same primer paint over edges, weld seams, cut-outs, and areas of complex geometries @ 3-4 mils wet film thickness (WFT).

CHECKPOINT 8 – TOP COAT APPLICATION

Verify environmental conditions (see CHECKPOINT 3).

Ensure overcoating window is as per manufacturer’s instructions.

Verify proper mixing and stand-in (induction) times, as applicable.

Verify wet film thickness at random, to prevent under or over application.

Brush out all runs, sags, drips, and puddles.

CHECKPOINT 9 – FINAL INSPECTION

Verify final system dry film thickness. Conduct 5 sets of 3 readings for each of the first 3 100-sqft areas, followed by 5 sets of 3 readings for each succeeding 1000-sqft area.

Ensure that system cure is in accordance with manufacturer's recommendation for intended service.

Ensure potable water tank exhaust ventilation is maintained continuously from and during coating application through final system cure, to exhaust all solvent to the atmosphere and to prevent solvent entrapment.

For immersion coatings (including tank U/W body), record date and time of the following events:

Final coat application: _____/_____; Return to service or removal from environment controls: _____/_____

CHECKPOINT 10 – RECORD KEEPING

Complete, sign, and submit all provided QA Inspection Forms.

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

Use one sheet for each activity. Record conditions every four hours from before surface preparation to application of final coating system coat.

| DP - Surface |

QA-3a - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-C)

Abrasive Manufacturer:

Abrasive Sieve Size:

Place surface profile replica tapes in the spaces provided below, to serve as permanent QA record. Maintain a separate log for each location. When an area is divided into separate sections, maintain a separate log for each section.

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Place Surface Profile

Place Surface Profile Replica Tape Here Place Surface Profile Replica Tape Here

Reading (mils):

Reading (mils):

Reading (mils):

Mean Mil Reading (IAW ASTM D4417-Method C) for above 15 readings:

QA-3b - QUALITY ASSURANCE INSPECTION FORM

(SURFACE PROFILE LOG FOR PROFILE MEASUREMENTS IAW ASTM D4417-METHOD-B)

Abrasive Manufacturer:

Abrasive Sieve Size:

Record measurements taken in the spaces provided below, to serve as permanent QA record. Maintain separate log for each location. When an area is divided into separate sections, maintain a separate log for each section.

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Reading (mils):

Mean Reading (mils)

Mean Reading (mils) IAW ASTM DD4417).

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

SOLUBLE SALT CONDUCTIVITY Measurements IAW SSPC-GUIDE 15.

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

Dry Film Thickness (DFT) Measurements IAW SSPC-PA 2.

*BASE METAL READING (BMR) Required, If Magnetic Pull-Off (Type I/Banana) Gauge Is Used.

Location (Frame Reference):

Avg.

Location (Frame Reference):

Avg.

Location (Frame Reference):

Avg.

23300_MDE1Ovrhl_0819_IBCT WORK ITEM 1: Renew #1 Main Diesel Engine Cylinder Liners

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a top end overhaul of engines described in Table 1.

1.1 Intent. This work item describes the requirements for the Contractor to perform a center section overhaul of engines described in Table 1.

Table 1. Engine(s) to Overhaul

1.2 Government-furnished property.

None

2. REFERENCES

Coast Guard Drawings None.

Coast Guard Publications Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures Other References Caterpillar® Marine Model D3608, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance Guidelines for “Index of Publications on Reusability or Salvage of Used Parts”, Publication, SEBF8029 (series).

3. REQUIREMENTS

3.1 General. The Contractor shall provide all parts, labor, tools required which includes but is not limited to (standard tools/special tools/Test Equipment/Consumables). Additionally, Contractor shall cover all core charges and ensure cores are returned to distributor.

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

· 3.3 (Engine component cleaning and inspections).

3.1.2 Protective measures.

3.1.2.1 Ensure protective measures are in place IAW General Requirements,

3.1.3 Interferences.

3.1.3.1 Contractor shall be responsible for reinstalling all interferences.

3.1.3.2 Contractor shall be responsible for rigging engine parts into and out of vessel. CG assistance provided at discretion of each vessel’s command.

3.1.4 References. The Contractor/technicians shall disassemble, clean, inspect, repair or renew and reassemble the Caterpillar engine units and accessories in accordance with the references listed in Section 2 herein.

3.1.5 Authority to proceed. The Contractor/technicians shall not proceed with any additional growth work on the engine units or accessories described in this specification, until specific instructions are given by the KO on what additional work is to be accomplished.

NOTE

The Contracting Officer (KO) will provide a written response to the Contractor, after receipt of the CIR, regarding all work to be completed for repairs. Work may not proceed until this authorization is received.

3.1.6 Responsibility for inspection. The Contractor/technicians shall be responsible for all inspections and test requirements specified herein. The Contractor shall provide the necessary calibrated test equipment to conduct all of the inspection requirements. Be aware that the Government reserves the right to verify or perform any of the inspections or tests set forth in this specification where such inspections are deemed necessary to assure that supplies or services conform to the prescribed requirements.

3.2 Operational test – initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of the Caterpillar Engine to demonstrate existing operational condition. Submit a CFR documenting operational condition of engine.

3.3 Clean and Inspect Engine Components. The Contractor shall disassemble, clean, inspect and test the engine components listed below, (Refer to Table 1) utilizing the appropriate publications as outlined in Section 2 as guidance. Provide a CIR/CFR of these components to the KO for potential reuse determination.

Table 1 - Engine Components to be disassembled, cleaned, inspected or tested during the performance of #1 MDE CYLINDER liner renewal

3.3.1 Report. The Contractor shall record the appropriate inspection findings on a CFR (clearance and tolerance readings of the cylinder block and related components). Submit a written report of all findings and recommendations to the Coast Guard Inspector (CGI) and COR within 24 hours after inspection.

3.3.2 Government’s right for furnishing various components and parts. The Contractor shall be aware that the Government reserves the right, to furnish new or rebuilt components or parts for installation, in place of the existing parts, at no additional cost to the Government. If the Government exercises this right, the Contractor shall turn over all existing components or parts to the CGI or COR as Mandatory Turn-In (MTI) items.

3.4 Automatic renewal. The Contractor shall perform the following engine component renewals with genuine, remanufactured (or new) OEM components, (Refer to Table 2).

Table 2 - Engine Components to be disassembled and automatically renewed during the performance of #1 MDE CYLINDER a liner renewal

Head gaskets (8ea.)

3.5 Discretionary renewal. If a modification has been authorized and released by the KO, the Contractor shall renew the specified engine components with genuine, remanufactured (or new) OEM components. (Refer to Table 3).

3.5.1 Exceptional Circumstances. If the Coast Guard or the servicing element determine a long block or short block is required to return the ship to operational condition, the KO may authorize the contractor to complete repairs utilizing a long block or short block vice in place overhaul of engine. KO may authorize assembly of long block offsite to accomplish repair.

Table 3 - Engine Components to be renewed upon inspection and with KO authorization

Flywheel

Oil Cooler Core

Oil Suction Screen

Governor (Overhaul by authorized governor dealer)

Table 4 - Optional Services to BE completed during an engine overhaul with KO Authorization

Optional Services

Machining of Engine Block

Cooler Clean

Line bore

Renew Long Block

3.6 Gaskets and seal. The Contractor shall furnish and renew all gaskets and seals (consumables) associated with the engine reassembly in this contract.

3.7 Fluids and Filters. The Contractor shall furnish and renew all fluids and filters associated with the engine reassembly. Contractor will be advised of Coast Guard desired engine oil preference prior to arrival conference.

3.8 Reassemble Engine Units and Accessories. After any authorized repairs and renewals, the authorized Caterpillar Contractor/technician’s shall reassemble the engine units and accessories to its original configuration utilizing the appropriate publications as outlined in Section 2.1 as guidance.

3..9 Operational testing – post overhaul.

NOTE

The USCG considers the testing below to be separate testing evolutions. The Contractor and Ship’s Force should coordinate scheduling of the three to ensure optimum use of schedule.

3.9.1 Operational "light-off" test. After completion of work, the Contractor shall witness an operational "light-off" test (by Coast Guard personnel) of the diesel engine unit and accessories to prove satisfactory operating condition.

3.9.2 Engine break-in. Upon successful completion of operational "light-off testing", the Contractor shall conduct an engine test run (break-in), under various loads, in accordance with applicable Caterpillar and Coast Guard standards. This is to ensure all internal engine components have been properly tested (seating of piston rings, proper oil flow to internal parts, temperatures) and any discrepancies are resolved.

3.9.2.1 For MDEs, this will include both pier-side and underway testing to ensure proper engine break-in.

3.9.2.2 For SSDGs and EDGs, the Contractor shall provide and utilize an external load bank to accomplish the proper engine break-in.

3.9.3 Computer Aided Marine Performance Analysis Report (CAMPAR) testing. Upon successful operational testing and engine break-in, the Contractor shall perform a CAMPAR diagnostic test for the engine in accordance with Caterpillar’s instructions. The CAMPAR testing shall include all data points required by the CAMPAR program and includes the installation of external meters and gauges in support. The Contractor shall provide all diagnostic equipment, test fittings, test measurement devices, and any additional tooling required in support of CAMPAR testing (Refer to General Requirements – Paragraph 3.3.1 “Work”).

NOTES

1. The intent of the CAMPAR testing is to establish overall condition of the engine “post-overhaul” in support of engine performance-tracking initiatives. CAMPAR testing shall be conducted in accordance with Caterpillar standards and include all data elements recorded on the complete program (i.e. fuel rates, boost pressures, etc).

2. 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 annotate the submitted test data as necessary to provide this information.

3. Ship’s Force may assist in data collection efforts as requested by the Contractor. Additionally, data collection can be accomplished using installed ship’s instrumentation (i.e. local meters, gauges, MPCMS displays, etc) provided locations are in agreement with PAR testing requirements. The Contractor shall be aware that all PAR testing locations are not monitored by the USCG and will require the Contractor to install additional gauges and/or meters (and associated test fittings) to accomplish tasking.

3.9.4 Adjustments. Based on the results of the operational testing, perform any additional adjustments (or readjustments) as required to ensure proper operation of the engine.

3.9.5 Testing data submittal. Upon completion of testing, the Contractor shall submit (as attachment to CFR) all data recorded during testing. This shall include the following:

· .Operational logs during engine break-in

· Complete CAMPAR report, including fuel demand curves and findings

4. NOTES

4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests.

4.2 Coast Guard Inspector responsibilities. Although the Contractor is responsible for applying appropriate quality assurance measures, the Coast Guard will witness the accomplishment of these measures. Therefore, a Coast Guard Inspector will:

4.2.1 Monitor the assigned work items to keep informed of progress and to ensure that the specifications are being followed.

4.2.2 Witness all test as required by the specification.

4.2.3 Be guided by the work item and seek immediate clarification when necessary.

4.2.4 Immediately bring to the attention of the Contracting Officer any work which appears to be contrary to the work item requirements.

4.2.5 Document all work performed in the Machinery History Log.

4.2.6 Ship’s force is responsible for post-overhaul verifications per Coast Guard instructions.

NOTE

When there is overwhelming documentation to record. The Engineer Officer/Engineer Petty officer may state in the Machinery History Log, “All overhaul documentation is located (indicate where) for reference.

4.3 Definitions.

4.3.1 Tools - Common tools normally contained in a standard toolbox (screwdrivers, wrenches, pliers) etc.

4.3.2 Special Tools/Test Equipment - Such as torque wrenches, calibrated electronic meters, computer devices etc not normally found in a standard toolbox.

4.3.3 Consumables - A non-reusable item such as a rag, disposable gloves, paint, oil, grease, solvent, adhesive, sealant, corrosion preventive product, cleaner, jacket water, etc.

23300_MDE2Ovrhl_0819_IBCT WORK ITEM 2: Renew #2 Main Diesel Engine Cylinder Liners

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a top end overhaul of engines described in Table 1.

1.1 Intent. This work item describes the requirements for the Contractor to perform a center section overhaul of engines described in Table 1.

Table 1. Engine(s) to Overhaul

1.2 Government-furnished property.

None

2. REFERENCES

Coast Guard Drawings None.

Coast Guard Publications Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures Other References Caterpillar® Marine Model D3608, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance Guidelines for “Index of Publications on Reusability or Salvage of Used Parts”, Publication, SEBF8029 (series).

3. REQUIREMENTS

3.1 General. The Contractor shall provide all parts, labor, tools required which includes but is not limited to (standard tools/special tools/Test Equipment/Consumables). Additionally, Contractor shall cover all core charges and ensure cores are returned to distributor.

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

· 3.3 (Engine component cleaning and inspections).

3.1.2 Protective measures.

3.1.2.1 Ensure protective measures are in place IAW General Requirements,

3.1.3 Interferences.

3.1.3.1 Contractor shall be responsible for reinstalling all interferences.

3.1.3.2 Contractor shall be responsible for rigging engine parts into and out of vessel. CG assistance provided at discretion of each vessel’s command.

3.1.4 References. The Contractor/technicians shall disassemble, clean, inspect, repair or renew and reassemble the Caterpillar engine units and accessories in accordance with the references listed in Section 2 herein.

3.1.5 Authority to proceed. The Contractor/technicians shall not proceed with any additional growth work on the engine units or accessories described in this specification, until specific instructions are given by the KO on what additional work is to be accomplished.

NOTE

The Contracting Officer (KO) will provide a written response to the Contractor, after receipt of the CIR, regarding all work to be completed for repairs. Work may not proceed until this authorization is received.

3.1.6 Responsibility for inspection. The Contractor/technicians shall be responsible for all inspections and test requirements specified herein. The Contractor shall provide the necessary calibrated test equipment to conduct all of the inspection requirements. Be aware that the Government reserves the right to verify or perform any of the inspections or tests set forth in this specification where such inspections are deemed necessary to assure that supplies or services conform to the prescribed requirements.

3.2 Operational test – initial. Prior to commencement of work, the Contractor shall witness an operational pre-test (by Coast Guard personnel) of the Caterpillar Engine to demonstrate existing operational condition. Submit a CFR documenting operational condition of engine.

3.3 Clean and Inspect Engine Components. The Contractor shall disassemble, clean, inspect and test the engine components listed below, (Refer to Table 1) utilizing the appropriate publications as outlined in Section 2 as guidance. Provide a CIR/CFR of these components to the KO for potential reuse determination.

Table 1 - Engine Components to be disassembled, cleaned, inspected or tested during the performance of #1 MDE CYLINDER liner renewal

3.3.1 Report. The Contractor shall record the appropriate inspection findings on a CFR (clearance and tolerance readings of the cylinder block and related components). Submit a written report of all findings and recommendations to the Coast Guard Inspector (CGI) and COR within 24 hours after inspection.

3.3.2 Government’s right for furnishing various components and parts. The Contractor shall be aware that the Government reserves the right, to furnish new or rebuilt components or parts for installation, in place of the existing parts, at no additional cost to the Government. If the Government exercises this right, the Contractor shall turn over all existing components or parts to the CGI or COR as Mandatory Turn-In (MTI) items.

3.4 Automatic renewal. The Contractor shall perform the following engine component renewals with genuine, remanufactured (or new) OEM components, (Refer to Table 2).

Table 2 - Engine Components to be disassembled and automatically renewed during the performance of #1 MDE CYLINDER a liner renewal

Head gaskets (8ea.)

3.5 Discretionary renewal. If a modification has been authorized and released by the KO, the Contractor shall renew the specified engine components with genuine, remanufactured (or new) OEM components. (Refer to Table 3).

3.5.1 Exceptional Circumstances. If the Coast Guard or the servicing element determine a long block or short block is required to return the ship to operational condition, the KO may authorize the contractor to complete repairs utilizing a long block or short block vice in place overhaul of engine. KO may authorize assembly of long block offsite to accomplish repair.

Table 3 - Engine Components to be renewed upon inspection and with KO authorization

Flywheel

Oil Cooler Core

Oil Suction Screen

Governor (Overhaul by authorized governor dealer)

Table 4 - Optional Services to BE completed during an engine overhaul with KO Authorization

Optional Services

Machining of Engine Block

Cooler Clean

Line bore

Renew Long Block

3.6 Gaskets and seal. The Contractor shall furnish and renew all gaskets and seals (consumables) associated with the engine reassembly in this contract.

3.7 Fluids and Filters. The Contractor shall furnish and renew all fluids and filters associated with the engine reassembly. Contractor will be advised of Coast Guard desired engine oil preference prior to arrival conference.

3.8 Reassemble Engine Units and Accessories. After any authorized repairs and renewals, the authorized Caterpillar Contractor/technician’s shall reassemble the engine units and accessories to its original configuration utilizing the appropriate publications as outlined in Section 2.1 as guidance.

3..9 Operational testing – post overhaul.

NOTE

The USCG considers the testing below to be separate testing evolutions. The Contractor and Ship’s Force should coordinate scheduling of the three to ensure optimum use of schedule.

3.9.1 Operational "light-off" test. After completion of work, the Contractor shall witness an operational "light-off" test (by Coast Guard personnel) of the diesel engine unit and accessories to prove satisfactory operating condition.

3.9.2 Engine break-in. Upon successful completion of operational "light-off testing", the Contractor shall conduct an engine test run (break-in), under various loads, in accordance with applicable Caterpillar and Coast Guard standards. This is to ensure all internal engine components have been properly tested (seating of piston rings, proper oil flow to internal parts, temperatures) and any discrepancies are resolved.

3.9.2.1 For MDEs, this will include both pier-side and underway testing to ensure proper engine break-in.

3.9.2.2 For SSDGs and EDGs, the Contractor shall provide and utilize an external load bank to accomplish the proper engine break-in.

3.9.3 Computer Aided Marine Performance Analysis Report (CAMPAR) testing. Upon successful operational testing and engine break-in, the Contractor shall perform a CAMPAR diagnostic test for the engine in accordance with Caterpillar’s instructions. The CAMPAR testing shall include all data points required by the CAMPAR program and includes the installation of external meters and gauges in support. The Contractor shall provide all diagnostic equipment, test fittings, test measurement devices, and any additional tooling required in support of CAMPAR testing (Refer to General Requirements – Paragraph 3.3.1 “Work”).

NOTES

1. The intent of the CAMPAR testing is to establish overall condition of the engine “post-overhaul” in support of engine performance-tracking initiatives. CAMPAR testing shall be conducted in accordance with Caterpillar standards and include all data elements recorded on the complete program (i.e. fuel rates, boost pressures, etc).

2. 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 annotate the submitted test data as necessary to provide this information.

3. Ship’s Force may assist in data collection efforts as requested by the Contractor. Additionally, data collection can be accomplished using installed ship’s instrumentation (i.e. local meters, gauges, MPCMS displays, etc) provided locations are in agreement with PAR testing requirements. The Contractor shall be aware that all PAR testing locations are not monitored by the USCG and will require the Contractor to install additional gauges and/or meters (and associated test fittings) to accomplish tasking.

3.9.4 Adjustments. Based on the results of the operational testing, perform any additional adjustments (or readjustments) as required to ensure proper operation of the engine.

3.9.5 Testing data submittal. Upon completion of testing, the Contractor shall submit (as attachment to CFR) all data recorded during testing. This shall include the following:

· .Operational logs during engine break-in

· Complete CAMPAR report, including fuel demand curves and findings

4. NOTES

4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests.

4.2 Coast Guard Inspector responsibilities. Although the Contractor is responsible for applying appropriate quality assurance measures, the Coast Guard will witness the accomplishment of these measures. Therefore, a Coast Guard Inspector will:

4.2.1 Monitor the assigned work items to keep informed of progress and to ensure that the specifications are being followed.

4.2.2 Witness all test as required by the specification.

4.2.3 Be guided by the work item and seek immediate clarification when necessary.

4.2.4 Immediately bring to the attention of the Contracting Officer any work which appears to be contrary to the work item requirements.

4.2.5 Document all work performed in the Machinery History Log.

4.2.6 Ship’s force is responsible for post-overhaul verifications per Coast Guard instructions.

NOTE

When there is overwhelming documentation to record. The Engineer Officer/Engineer Petty officer may state in the Machinery History Log, “All overhaul documentation is located (indicate where) for reference.

4.3 Definitions.

4.3.1 Tools - Common tools normally contained in a standard toolbox (screwdrivers, wrenches, pliers) etc.

4.3.2 Special Tools/Test Equipment - Such as torque wrenches, calibrated electronic meters, computer devices etc not normally found in a standard toolbox.

4.3.3 Consumables - A non-reusable item such as a rag, disposable gloves, paint, oil, grease, solvent, adhesive, sealant, corrosion preventive product, cleaner, jacket water, etc.