Attachment 2_Work Specification.pdf

USCGC OSAGE (WLR 65505)

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2021

Developed By: LCDR Frank Reed

(Rev-0, 9 October 2020)

USCGC OSAGE (WLR-65B) DOCKSIDE AVAILABILITY FY2021

ii (Rev-0)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property .................................................................................. v Consolidated List of Critical Inspection Items ............................................................................................. vi Principal Characteristics - Tender .............................................................................................................. vii General Requirements WORK ITEM 1: Engine, Overhaul, SSDG # 1 {Center Section Overhaul} WORK ITEM 2: Engine, Overhaul, SSDG # 2 {Center Section Overhaul} iii (Rev-0)

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.

DATE REV# WORK

ITEM#

CHANGES MADE

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.

iv (Rev-0)

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 2006, Coatings and Colors

Manual

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2018, General

Requirements

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2018, General

Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2018, Welding and

Allied Processes

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2018, Welding and

Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2018, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2018, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Caterpillar® Marine Model D3304B, 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).

v (Rev-0)

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 vi (Rev-0)

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)):

Work

Item Title

1 Engine, Overhaul, SSDG # 1 {Center Section Overhaul}

2 Engine, Overhaul, SSDG # 2 {Center Section Overhaul} vii (Rev-0)

PRINCIPAL CHARACTERISTICS - TENDER

65’ WLR (B-CLASS), SMALL BUOY RIVER TENDER

PHYSICAL

Length overall 65' 10"

Depth 7' 8"

Maximum beam 21' 0"

Frame spacing 1' 6"

Full load draft 5' 0 7/8" LCF Draft

Full load displacement 127.71 Long Tons Fresh Water

HULL

Hull material Steel

MACHINERY

Number of propellers 2

Number of blades 5

Diameter of propeller 48"

Pitch 46" fixed

RPM 410

TANK CAPACITIES

Fuel tanks

Fresh water tanks

Lube oil

1 (Rev-0)

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), 2018, General

Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2018, Welding and

Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2018, 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.

2 (Rev-0)

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:

3 (Rev-0)

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.

4 (Rev-0)

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.

5 (Rev-0)

QA-1 - QUALITY ASSURANCE INSPECTION FORM

(PRESERVATION CHECKLIST)

VESSEL NAME HULL # WORK ITEM

WORK ITEM TITLE

LOCATION OF WORK (INCL. FRAME #’S) AREA (SQFT)

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.

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE / TIME

6 (Rev-0)

QA-2 - QUALITY ASSURANCE INSPECTION FORM

(ENVIRONMENTAL READINGS)

VESSEL NAME HULL #

WORK ITEM

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

DATE

TIME

ACTIVITY (SURFACE

PREPARATION, PRIMER COAT,

BARRIER COAT, TOP COAT,

ETC…)

LOCATION (FRAME &

DECK, RELATION TO

EQUIPMENT, ETC.)

TEMPERATURE % REL.

HUMID-

ITY

DEW

PT.

SURFACE AMBIENT ΔT

| DP -

SURFACE |

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE / TIME

7 (Rev-0)

QA-3A - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL # WORK ITEM

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area)

Brush-blasting (non-metallic substrate)

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 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

Replica Tape Here

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:

NAME OF QP-1/NACE INSPECTOR SIGNATURE CERT. # DATE /

TIME

8 (Rev-0)

QA-3B - QUALITY ASSURANCE INSPECTION FORM

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

VESSEL NAME HULL # WORK ITEM

SURFACE PREPARATION METHOD PROFILE ACHIEVED (MILS)

MIN MAX MEAN

SSPC-SP-10/NACE No. 2

SSPC-SP WJ-1/NACE WJ-1

SSPC-SP WJ-2/NACE WJ-2

SSPC-SP WJ-3/NACE WJ-3

SSPC-SP WJ-4/NACE WJ-4

SSPC-SP-3

SSPC-SP-11

SSPC-SP-11 (inaccessible area)

Brush-blasting (non-metallic substrate)

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).

9 (Rev-0)

QA-4 - QUALITY ASSURANCE INSPECTION FORM

(SURFACE SOLUBLE SALT CONDUCTIVITY LOG)

VESSEL NAME HULL # WORK ITEM

SOLUBLE SALT CONDUCTIVITY MEASUREMENTS IAW SSPC-GUIDE 15.

DATE TEST LOCATIONS CONDUCTIVITY (MICROSIEMENS/CM)

10 (Rev-0)

QA-5 - QUALITY ASSURANCE DATA FORM

(COATING THICKNESS)

(Use one sheet for each sequence)

VESSEL NAME HULL #

WORK ITEM

COATING MFG PRODUCT NAME

BATC

H #

INDUCTI

ON TIME

COATING SYSTEM

SEQUENCE

(PRIMER/TOUCHUP/3RD

COAT, ETC.)

DRY FILM THICKNESS (DFT) MEASUREMENTS IAW SSPC-PA 2.

SPOT 1 2 3 4 5

AVERAGE

VALUE

*BASE METAL READING

(BMR) Required, If Magnetic

Pull-Off (Type I/Banana) Gauge Is

Used.

LOCATION (FRAME REFERENCE):

SPOT 1 2 3 4 5 OVERALL AVG. DFT ADJUSTMENTS

1 AVG. BMR DEVIATION

3 BEFORE ADJUSTMENTS AFTER ADJUSTMENTS

AVG.

1 AVG. BMR DEVIATION

1 AVG. BMR DEVIATION

APPLICATION METHOD (AIRLESS,

CONVENTIONAL SPRAY, ROLLED)

AVERAGE DFT

11 (Rev-0)

23300_SSDG1Ovrhl_0819_IBCT

WORK ITEM 1: Engine, Overhaul, SSDG # 1 {Center Section Overhaul}

1. SCOPE

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

Engine Engine

Model

Engine

Serial #

Engine

Arrangement #

Generator

Model

Generator

Serial #

Generator

Arrangement #

Caterpillar 3304B 83Z08169 N/A N/A N/A N/A

1.2 Government-furnished property.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2018, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2018, Welding and Allied

Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2018, Requirements for

Preservation of Ship Structures

OTHER REFERENCES

Caterpillar® Marine Model D3304B, 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).

12 (Rev-0)

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.

NOTE

The Contracting Officer (KO) will identify the engine serial and arrangement numbers of engine units and accessories to be completed under this contract.

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

3.5 Engine component cleaning and inspections.

3.1.2 Tech Rep. The Contractor shall provide the services of an OEM authorized/ licensed Tech Rep for the engine identified in Table 1 to accomplish the following on site:

Provide manufacturer's proprietary system/ equipment information, software, and tools.

Assist with and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé.

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

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5

(Interferences).

3.2 Rigging. The Contractor shall be responsible for installing and removing rigging to move engine parts into and from vessel.

NOTE

CG assistance will be provided at discretion of each vessel’s command.

3.3 Test equipment. The Contractor shall provide calibrated test equipment to perform all inspection requirements.

NOTE

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.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.4 Operational test, initial. Prior to commencement of work, the Contractor shall witness Coast Guard personnel perform an initial operational test of the Caterpillar engine to demonstrate existing operational condition.

3.4.1 Gather web deflection and thrust measurements of engine in pre-overhaul condition.

13 (Rev-0)

3.4.2 Submit a CFR with gathered web deflection and thrust measurements.

3.5 Engine component cleaning and inspection. The Contractor shall disassemble, clean, inspect and test the engine components in Table 2 below in accordance with OEM manuals and latest technical bulletins and specifications.

3.5.1 Submit a CIR for all Table 2 components marked with an asterisk.

3.5.2 Submit a CFR for all other Table 2 components with inspection findings including cylinder block and related components clearance and tolerance readings, and recommendations, to the Coast Guard Inspector (CGI) and COR no later than 24 hours after inspection.

NOTE

KO will determine component reusability.

TABLE 2 - ENGINE COMPONENTS

TOP END CENTER SECTION (INCLUDES TOP END)

Aftercooler Camshaft

Exhaust Manifold Camshaft Lifters

Rocker Shaft Assembly and Push Rods Crankshaft

Turbocharger Housing and any other components not renewed in

Table 2.

Crankshaft Vibration Damper (all models except 3608)

Water Manifold Cylinder Block

Jacket Water Pump Driven Equipment (alignment)

Salt Water Pump Engine Mounts

Heat Exchanger – All. Flywheel

Cylinder Head Spacer Plate (3508 only) Front Gear Train (Gears)

Governor Fuel Linkage Oil Cooler Core

Oil Supply Lines Oil Suction Screen

Rear Gear Train (Gears)

Spacer Plates

3.4. Renewal. The Contractor shall renew components in Table 3 with genuine, remanufactured or new, OEM components.

TABLE 3 – RENEWAL ENGINE COMPONENTS

TOP END CENTER SECTION (INCLUDES TOP END)

Complete Cylinder Head Assemblies Camshaft Bearings

Cylinder Head Gaskets and Seals Connecting Rod Bearings and Hardware (bolt and caps)

Inlet Air Line Seals Crankshaft Seals

Turbocharger Bearings, Bushings and Seals Crankshaft Thrust Plates

Valve Lubricator (If Equipped) Exhaust Manifold (Seals and Bellows)

Water Pump Bearings and Seals Fuel Injection Pumps

Water Temperature Regulators /thermostats and Seals Fuel Transfer Pump

Fuel Injectors Gear Train Bushings

Turbocharger Cartridge Inlet Manifold (Gaskets and Seals)

Head Studs Jacket Water Pump

Fuel System (Primary and secondary filters) Lubricating Oil Pump

Air Filters Main Bearings

Valve and injector Lifters (3608 ONLY) Piston rings

Sea Water Pump

14 (Rev-0)

Software (Install new software when a new ECM is installed)

Front Gear Trains (Gears)

Rear Gear Trains (Gears)

Crankshaft Vibration Dampner (3608 model engine ) including hardware

Lifter Roller Assemblies

Connecting Rods

Cylinder Liners

Piston Assembly

Crankshaft Counterweights hardware (bolts)

Spacer Plates

3.5 Renewal, KO authorization required. The Contractor shall request and, upon written KO authorization, renew components in Table 4 with genuine, remanufactured or new, OEM components.

3.6 Mandatory Turn-in Item (MTI) renewal, optional. The Contractor shall be aware that the Government reserves the right to furnish new items for installation in-place of removed MTI(s). When the Government exercises this right, the

Contractor shall remove and turn over MTI(s) in Table 4 to KO/ KS.

NOTE

If the Coast Guard or the servicing element determines 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 4 – RENEWAL MTI ENGINE COMPONENTS REQUIRING KO AUTHORIZATION

TOP END CENTER SECTION (INCLUDES TOP END)

Aftercooler Crankshaft

Exhaust Manifold Camshaft

Rocker Shaft Assembly and Push Rods Cylinder Block

Turbocharger Driven Equipment (alignment)

Water Manifold Engine Mounts (Caterpillar)

Flywheel

Oil Cooler Core

Oil Suction Screen

Governor (Overhaul by authorized governor dealer)

3.7 Optional services. The Contractor shall provide the following optional services only with written KO approval.

Machining, engine block

Cleaning, cooler

Line bore

Long block, renew.

3.8 Renewal, consumables. The Contractor shall furnish and renew all engine

Gaskets

Seals

Filters.

15 (Rev-0)

3.9 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.

3.10 Reassembly. 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 Caterpillar® Marine Model D3304B, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance.

3.10.1 Alignment Check. Contractor shall perform alignment check post engine to include but not limited to SSDG generator decoupling, engine mount repair, rear gear work, or disconnecting engine from shaft and/ or red gear

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.11 Operational test, post repairs. After completion of work, the Contractor shall thoroughly test, in the presence of the

Coast Guard Inspector and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

NOTE

The USCG considers the testing below to be separate testing evolutions. The Contractor and

Ship’s Force should coordinate test scheduling.

3.11.1 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. The contractor shall provide and utilize an external load bank to accomplish the proper engine break-in

3.11.1.1 For MDEs, the Contractor shall support both pier-side and underway testing to ensure proper engine break-in.

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

3.12 Test, Computer Aided Marine Performance Analysis Report (CAMPAR). 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 identified in Section 2 and shall include all data points required by the CAMPAR program and includes the installation of external meters and gauges in support.

3.12.1 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

CAMPAR testing is establishes 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).

3.12.2. The Contractor shall annotate the submitted test data as necessary with specification acceptable data ranges and units of measure.

16 (Rev-0)

NOTE

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).

NOTE

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.

3.13 Adjustments. Based on the results of the operational testing, the Contractor shall perform any additional adjustments to ensure proper operation of the engine.

3.14 Test record submission. Upon completion of testing, the Contractor shall submit all test results data via CFR including:

Operational logs during engine break-in

Complete CAMPAR report, including fuel demand curves and findings.

4. NOTES

4.1 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:

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

Witness all test as required by the specification.

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

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

Document all work performed in the Machinery History Log.

4.2 Ship’s force responsibilities. Ship’s force will provide post-overhaul verifications per Coast Guard instructions.

4.3 Overwhelming documentation. 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.

4.4 Definitions.

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

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

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

17 (Rev-0)

23300_SSDG2Ovrhl_0819_IBCT

WORK ITEM 2: Engine, Overhaul, SSDG # 2 {Center Section Overhaul}

1. SCOPE

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

Engine Engine

Model

Engine

Serial #

Engine

Arrangement #

Generator

Model

Generator

Serial #

Generator

Arrangement #

Caterpillar 3304B 83Z08175 N/A N/A N/A N/A

1.2 Government-furnished property.

2. REFERENCES

COAST GUARD DRAWINGS

None.

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2018, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2018, Welding and Allied

Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2018, Requirements for

Preservation of Ship Structures

OTHER REFERENCES

Caterpillar® Marine Model D3304B, 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).

18 (Rev-0)

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.

NOTE

The Contracting Officer (KO) will identify the engine serial and arrangement numbers of engine units and accessories to be completed under this contract.

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

3.5 Engine component cleaning and inspections.

3.1.2 Tech Rep. The Contractor shall provide the services of an OEM authorized/ licensed Tech Rep for the engine identified in Table 1 to accomplish the following on site:

Provide manufacturer's proprietary system/ equipment information, software, and tools.

Assist with and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé.

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

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5

(Interferences).

3.2 Rigging. The Contractor shall be responsible for installing and removing rigging to move engine parts into and from vessel.

NOTE

CG assistance will be provided at discretion of each vessel’s command.

3.3 Test equipment. The Contractor shall provide calibrated test equipment to perform all inspection requirements.

NOTE

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.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.4 Operational test, initial. Prior to commencement of work, the Contractor shall witness Coast Guard personnel perform an initial operational test of the Caterpillar engine to demonstrate existing operational condition.

3.4.1 Gather web deflection and thrust measurements of engine in pre-overhaul condition.

19 (Rev-0)

3.4.2 Submit a CFR with gathered web deflection and thrust measurements.

3.5 Engine component cleaning and inspection. The Contractor shall disassemble, clean, inspect and test the engine components in Table 2 below in accordance with OEM manuals and latest technical bulletins and specifications.

3.5.1 Submit a CIR for all Table 2 components marked with an asterisk.

3.5.2 Submit a CFR for all other Table 2 components with inspection findings including cylinder block and related components clearance and tolerance readings, and recommendations, to the Coast Guard Inspector (CGI) and COR no later than 24 hours after inspection.

NOTE

KO will determine component reusability.

TABLE 2 - ENGINE COMPONENTS

TOP END CENTER SECTION (INCLUDES TOP END)

Aftercooler Camshaft

Exhaust Manifold Camshaft Lifters

Rocker Shaft Assembly and Push Rods Crankshaft

Turbocharger Housing and any other components not renewed in

Table 2.

Crankshaft Vibration Damper (all models except 3608)

Water Manifold Cylinder Block

Jacket Water Pump Driven Equipment (alignment)

Salt Water Pump Engine Mounts

Heat Exchanger – All. Flywheel

Cylinder Head Spacer Plate (3508 only) Front Gear Train (Gears)

Governor Fuel Linkage Oil Cooler Core

Oil Supply Lines Oil Suction Screen

Rear Gear Train (Gears)

Spacer Plates

3.4. Renewal. The Contractor shall renew components in Table 3 with genuine, remanufactured or new, OEM components.

TABLE 3 – RENEWAL ENGINE COMPONENTS

TOP END CENTER SECTION (INCLUDES TOP END)

Complete Cylinder Head Assemblies Camshaft Bearings

Cylinder Head Gaskets and Seals Connecting Rod Bearings and Hardware (bolt and caps)

Inlet Air Line Seals Crankshaft Seals

Turbocharger Bearings, Bushings and Seals Crankshaft Thrust Plates

Valve Lubricator (If Equipped) Exhaust Manifold (Seals and Bellows)

Water Pump Bearings and Seals Fuel Injection Pumps

Water Temperature Regulators /thermostats and Seals Fuel Transfer Pump

Fuel Injectors Gear Train Bushings

Turbocharger Cartridge Inlet Manifold (Gaskets and Seals)

Head Studs Jacket Water Pump

Fuel System (Primary and secondary filters) Lubricating Oil Pump

Air Filters Main Bearings

Valve and injector Lifters (3608 ONLY) Piston rings

Sea Water Pump

20 (Rev-0)

Software (Install new software when a new ECM is installed)

Front Gear Trains (Gears)

Rear Gear Trains (Gears)

Crankshaft Vibration Dampner (3608 model engine ) including hardware

Lifter Roller Assemblies

Connecting Rods

Cylinder Liners

Piston Assembly

Crankshaft Counterweights hardware (bolts)

Spacer Plates

3.5 Renewal, KO authorization required. The Contractor shall request and, upon written KO authorization, renew components in Table 4 with genuine, remanufactured or new, OEM components.

3.6 Mandatory Turn-in Item (MTI) renewal, optional. The Contractor shall be aware that the Government reserves the right to furnish new items for installation in-place of removed MTI(s). When the Government exercises this right, the

Contractor shall remove and turn over MTI(s) in Table 4 to KO/ KS.

NOTE

If the Coast Guard or the servicing element determines 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 4 – RENEWAL MTI ENGINE COMPONENTS REQUIRING KO AUTHORIZATION

TOP END CENTER SECTION (INCLUDES TOP END)

Aftercooler Crankshaft

Exhaust Manifold Camshaft

Rocker Shaft Assembly and Push Rods Cylinder Block

Turbocharger Driven Equipment (alignment)

Water Manifold Engine Mounts (Caterpillar)

Flywheel

Oil Cooler Core

Oil Suction Screen

Governor (Overhaul by authorized governor dealer)

3.7 Optional services. The Contractor shall provide the following optional services only with written KO approval.

Machining, engine block

Cleaning, cooler

Line bore

Long block, renew.

3.8 Renewal, consumables. The Contractor shall furnish and renew all engine

Gaskets

Seals

Filters.

21 (Rev-0)

3.9 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.

3.10 Reassembly. 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 Caterpillar® Marine Model D3304B, Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance.

3.10.1 Alignment Check. Contractor shall perform alignment check post engine to include but not limited to SSDG generator decoupling, engine mount repair, rear gear work, or disconnecting engine from shaft and/ or red gear

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.11 Operational test, post repairs. After completion of work, the Contractor shall thoroughly test, in the presence of the

Coast Guard Inspector and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

NOTE

The USCG considers the testing below to be separate testing evolutions. The Contractor and

Ship’s Force should coordinate test scheduling.

3.11.1 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. The contractor shall provide and utilize an external load bank to accomplish the proper engine break-in

3.11.1.1 For MDEs, the Contractor shall support both pier-side and underway testing to ensure proper engine break-in.

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

3.12 Test, Computer Aided Marine Performance Analysis Report (CAMPAR). 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 identified in Section 2 and shall include all data points required by the CAMPAR program and includes the installation of external meters and gauges in support.

3.12.1 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

CAMPAR testing is establishes 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).

3.12.2. The Contractor shall annotate the submitted test data as necessary with specification acceptable data ranges and units of measure.

22 (Rev-0)

NOTE

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).

NOTE

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.

3.13 Adjustments. Based on the results of the operational testing, the Contractor shall perform any additional adjustments to ensure proper operation of the engine.

3.14 Test record submission. Upon completion of testing, the Contractor shall submit all test results data via CFR including:

Operational logs during engine break-in

Complete CAMPAR report, including fuel demand curves and findings.

4. NOTES

4.1 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:

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

Witness all test as required by the specification.

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

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

Document all work performed in the Machinery History Log.

4.2 Ship’s force responsibilities. Ship’s force will provide post-overhaul verifications per Coast Guard instructions.

4.3 Overwhelming documentation. 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.

4.4 Definitions.

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

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

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