Attachment_I_-_PWS_final.doc

Performance Work Statement (PWS)

Special Boat Team Twenty-Two (SBT-22)

11M RIB Engine IDIQ – Gulf Coast

1.0 GENERAL

1.1 Special Boat Team 22 – Stennis Space Center, MS

Work under this contract is provided to Special Boat Team TWENTY TWO (SBT-22) in support of the 11M RIB main propulsion repairs. Specifically, this PWS identifies the requirements for the accomplishment of maintenance or complete overhaul of the Caterpillar 3126 Marine Diesel Engine (DITA), as well as minor maintenance and preservation to the ZF Marine IRM 301 PL Marine Gear. The contractor shall provide all personnel, materials, parts, equipment, machining, and facilities necessary to conduct the ordered repairs, maintenance, overhauls, and/or upgrades.

1.2 This section identifies the repair and maintenance items associated with each work package that may be ordered under the contract.

Maintenance support shall be provided on craft as required within Stennis Space Center, MS area. For Work Packages 1, 2, 3, 4, and 5, the engine will be delivered to the contractor. For Work Package 6, engine delivery and place of performance will be specified in the task order.

1.3 Note: The term Engine Deptartment Representative (EDR) will be used in place of “SBT-22 maintenance personnel" or "Group FOUR Diesel Engine Inspector” throughout the remainder of this section for simplification. Also, the acronym SBT will be used in place of SBT-22 throughout the remainder of this section for simplification.

2.0

APPLICABLE DOCUMENTS/DIRECTIVES

The Original Equipment Manufacturer’s (OEM) Technical Manual (TM), Service Bulletins, and other documentation for the following model diesel engines shall govern maintenance and overhaul, unless modified herein or by task order. If repairs on in scope, alternate/updated engines are required, the Government will provide appropriate TMs, Service Bulletins, and other documentation to cover the requested repairs.

Marine Caterpillar Engine Model 3126 (DITA)

ZF Marine Gear IRM 301 PL

3.0

REQUIREMENTS

3.1 Support

The contractor shall provide Caterpillar Certified Maintenance Technicians and OEM / qualified parts to perform overhauls / repairs / maintenance on diesel engines. This support may also be required when troubleshooting during warranty / in-service conditions at the SBT. The results of this action may be restoration of the engine to OEM performance levels, or the determination that the engine requires further maintenance, repair, or overhaul. Location of overhaul / repair / maintenance (Work Packages 1, 2, 3, 4, 5) will be at contractor facility. Location of other repairs (Work Package 6) will be at SBT or contractor site, as specified on each individual task order. Contractor facility must be within 60 miles of the SBT.

3.2 General Maintenance / Repair / Overhaul

Upon receipt each task order, the contractor shall accomplish all repair actions identified. OEM TM procedures shall be followed in the performance of all repair actions. Parts used in the repair process shall meet the OEM requirements for use in the marine diesel engine (new, exchanged for rebuilt or re-qualified with approval for use with genuine OEM marine diesel parts). Replaced parts shall be retained for three (3) months as a standard, and be available for examination by the EDR. Following disturbance, a hydrostatic test of the jacket water system is required. If delivered with the engine, the marine gear will be correctly reattached to the engine prior to acceptance inspection. For maintained / repaired / overhauled engines (Work Package 2, 4, and 5) dynamometer testing in accordance with sub-section 5.3 shall be performed as a part of the that work package. All other dynamometer testing will be specified in the task order as Work Package 3. Upon satisfactory completion of the dynamometer test (with exception of a work package 3 pre-repair / overhaul dynamometer test), the engine shall be preserved for long term storage and air transportation in accordance with the OEM specifications (e.g. SEHS9031) and as specified in sub-section 3.5 and 3.6 below.

3.3 Acceptance Inspection

Upon completion of the maintenance / repair / overhaul action(s), the EDR shall be notified by phone or email that the diesel engine is ready for Acceptance Inspection. In the presence of the EDR, the contractor shall perform an inspection of the maintained / repaired / overhauled diesel engine. The EDR will, at time of inspection and acceptance, determine disposition of used parts with turn-in value. Parts with turn-in value shall be picked up by the EDR.

3.4 Warranty

Engines overhauled under Work Package 2 will be picked up by the and placed in stock until a requirement is received for issuance of an engine. The warranty will be applicable to parts/components replaced and related labor charges, and shall be considered to start upon issuance of the engine from the EDR and subsequent installation in a RIB. The warranty on these overhauled engines shall remain in effect for 100 engine operating hours or 12 calendar months (whichever is less), but in all cases shall not exceed 18 calendar months from acceptance and pick-up from the contractor.

For engine repair/maintenance action(s) under Work Packages 4, 5, or 6, the warranty shall be applicable to parts/components replaced and related labor charges for 100 engine operating hours from the date the engine is returned to service, not to exceed 12 calendar months from acceptance and pick-up from the contractor. Any additional OEM warranty on components used shall still apply after this period.

The contractor shall package, with each overhauled or repaired/maintained engine, a Warranty Activation Card. This card shall include the complete information on the associated engine, the contractor’s proper mailing address and phone number for warranty action(s), and a place for SBT personnel to complete the date and sign that the engine is issued from stock to be placed in service. The Warranty ActivationCard shall be filled out and signed within three days of placing the engine in service and returned to the contractor within one month. A copy of the Warranty Activation Card will be maintained by the SBT. When troubleshooting or on-scene repair actions are required to support warranty repairs, it will be the contractor’s responsibility and cost to travel to the SBT. When transportation of engines to or from the contractor is required to support warranty repairs, it will be the Government’s responsibility to arrange and execute the transportation.

3.5 Preparation for Air Transportation

Unless otherwise specified in the task order, the preserved engine shall have the following preparation action(s) taken to comply with air transportation requirements:

a. Cap all open fuel and oil openings with threaded metal pressure proof caps or plugs.

b. Cover any other openings with heavy plastic and tape to prevent the intrusion of foreign material.

c. Ensure that the fuel filter is less than half full.

3.6 Standard Preservation

Unless otherwise specified in the task order, the following requirements shall be met during engine preservation:

a. Remove Engine and marine gear rust from components and neatly preserved to a like new condition to include Caterpillar Yellow paint. Hoses (e. g., raw water, coolant) shall not be painted (hoses shall not have more than 10% paint coverage).

b. Replace Data plate with a new, clearly stamped and legible plate containing the exact same data.

c. Replace All Caterpillar stickers, labels, and insignia with new.

d. Remove Zincs and attach to engine in clean, durable, clear plastic bag. Install plastic FME caps in holes from which zincs were removed.

e. Remove air filter and place in a durable, clear plastic bag along with its associated, new, constant torque clamp; and secure to engine in a location that minimizes opportunity for damage.

f. Secure two new alternator v-belts, two new hydraulic pump v-belts, and a durably bagged, new marine gear filter (in addition to the filter installed on the marine gear) to the engine in a location that minimizes opportunity for damage.

g. Wrap engine in clear plastic with a visible 8 x 10 inch sheet that includes the date of preservation.

4.0 Delivery: Contractor shall complete up to four individual or combined Work Packages concurrently in a five week period, (e.g. four (4) combined Open and Inspect and subsequent Overhauls, or four (4) 24M-1 Maintenances, or three (3) 24 M Maintenance and one (1) Open and Inspect and subsequent Overhauls). Engine maintenance/repair/overhaul tasks shall be completed in time frames as follows:

Open and Inspect (Work Package 1) - 1 week from receipt of order Overhaul (Work Package 2) - 4 weeks from receipt of order Dynamometer (Work Package 3) - 1 week from receipt of order 24 M Maintenance (Work Package 4) - 2 weeks from receipt of order 24 M-1Maintenance (Work Package 5) - 2 weeks from receipt of order Material Services (Work Package 6) - as specified on individual task order.

4.1 Deliverable Data

The contractor shall deliver inspection and test records, reports of work accomplished, and parts replaced, associated with all work completed on each engine. Measured/observed results versus OEM expected results, micrometer readings and clearances, as well as sizes of all bearings, shims, piston rings, and like items installed during the overhaul/repair/maintenance process must be included. Parts replaced/installed must include nomenclature and manufacturer’s part number. Dynamometer testing results must include recorded values versus OEM expected results. Hard copies of these inspection, assembly, and dynamometer reports shall be attached to the engine and enclosed in a protective plastic sleeve, such as used for packing lists. Electronic copies of these reports shall be emailed to the COR and EDR within one week of completion. The COR for this contract will provide specific email addresses as required. See Technical Exhibit 2, Deliverable Schedule.

5.0 Work Packages 5.1 Open and Inspect (Work Package 1)

An Open & Inspect is normally conducted for two purposes: to determine the suitability of the engine for further repairs / overhaul and / or to determine additional work, above and beyond a standard overhaul (sub-section 5.2) to be completed under the material services work package (sub-section 5.6).

The contractor shall disassemble, clean, and inspect the engine to determine the scope of the repairs required in accordance with the OEM TM. Removal of fluids, cleaning, and other necessary actions for conduct of inspection and subsequent repair and/or overhaul shall be accomplished as specified in the OEM TM. Upon determination of the required repairs, the contractor shall provide to the EDR a detailed inspection record and price quote to restore the diesel engine to OEM specifications. The contractor shall include actions that are considered industry standard actions and therefore are not normally specified in the OEM TM. These actions may include replacement of disturbed gaskets, belts, hoses, deteriorated fasteners, and thermostat and pressure switches. Also to be included on the detailed inspection record and price quote are items over and beyond items included in a standard overhaul as specified in sub-section 5.2. The inspection record shall record the measured / observed condition and the results for each item. Once received, the EDR will review the work request determine if action will be taken in accordance with the Over and Above Work procedures outlined in DFARS PGI 217.77 – OVER AND ABOVE WORK, and DFARS 252.217-7028, Over and Above Work, procedures.

5.2 Overhaul and Dynamometer Test (Work Package 2) Overhaul work packages will be conducted in conjunction with Open and Inspect work packages (sub-section 5.1). The overhaul work package consists of a Standard Engine overall as defined herein; as well as dynamometer testing, (sub-section 5.3), preparation for air transport (sub-section 3.5), and preservation (sub-section 3.6). Any additional parts and / or machining over and above the standard overhaul will be completed under the material services work package (sub-section 5.6) if or when approved by the contracting official.

Without diminishing any other requirement of this contract, the following definition of a Standard Overhaul is provided (based on Caterpillar manual SEBU6164-06):

Parts, consumables, equipment, facilities, disposal of hazmat, and labor required to machine, clean, reassemble, and satisfactorily test, IAW OEM requirements, a Caterpillar 3126 marine engine. Parts included within the scope of this work package are those parts which must be replaced during the disassembly and reassembly of the engine regardless of the engine’s condition such as: all gaskets, seals, piston rings, thrust bearings, main bearings, connecting rod bearings, idler bearings, hoses, hose clamps, belts, thermostat, filters, consumables (including zincs), fluids, pressure caps, raw water pump impeller, and hour meters. Heat exchangers must be cleaned and pressure tested (engine oil cooler, marine gear oil cooler, aftercooler, jacket water cooler). The following components shall be inspected and or tested IAW Caterpillar reusability publications, and if they comply with the established inspection specifications, should be reused, and if not within specifications, should be repaired, or replaced: engine block, cylinder head assembly, connecting rods, pistons, turbocharger, oil pump, fuel ratio control, cam followers, fuel transfer pump, timing advance, camshaft, camshaft bearings, crankshaft, crankshaft vibration damper, gear train, fuel injection nozzles, fuel injection pump, and governor. When prudent, installation of cylinder sleeves and crank shaft grinding / oversize bearings, IAW OEM standards, is acceptable. Basic machining is included in this work package, such as: valve grind, crank & cam journal polishing, cylinder honing, etc. More complex machining such as crank or cam shaft grinding would be additional work. Any of these components found to require replacement or repair shall be listed on a quote and provided to the command in accordance with the Over and Above Work procedures.

Note that this Overhaul work package also includes many other requirements as listed in the contract such as: dyno, preservation, data, and warranty work.

5.3 Dynamometer Test (Work Package 3) Dynamometer testing shall be conducted for one of two purposes: 1) Initial testing called out in the task order as work package 3, used to determine necessity and scope of follow-on maintenance or repair, 2) Post maintenance / repair / overhaul testing certification completed as part of work packages 2, 4, and 5, demonstrating that the engine is mechanically and operationally in 'ready for issue' condition. Certification dynamometer testing done as part of work package 2, 4, and 5 must include all listed speed increments and readings and must also, at the 2950 rpm speed increment, meet the values listed in parentheses following various readings in paragraph 6 to be considered acceptable.

Note: At least 24 hours prior to the scheduled accomplishment of a dynamometer test, the contractor shall notify, by email, the EDR of intent to conduct the test. If the Government representative(s) fails to respond, or is not available, within 24 hours of notification by email by the contractor of the intent to conduct the dynamometer test, the test may be completed without the presence of the EDR. The COR or EDR for this contract will provide specific email addresses of the Government representatives who shall be notified of intent to test, as required.

Dynamometer testing shall be conducted per the following requirements. Requirements are based on Caterpillar SEBU 6164-05 Operation, Maintenance Manual and Caterpillar Test Specification 0K0538 and Caterpillar SENR 9558-02 SMCS Code 1280-081.

1. Configure engine for dynamometer test. Configuration shall include use of K&N filter (USMI # 512-7048) and Caterpillar air intake hose boot currently used on NSW 11 Meter RIBs.

2. Ensure the Dynamometer shall have a current certified calibration and also be ambient temperature and barometric pressure compensated.

3. Start and idle engine at 750 rpm until jacket water is 140 degrees Fahrenheit.

4. Verify high idle at 3285 rpm +/- 35 rpm and record high idle set point.

5. Bring engine speed to 1400 rpm, 2000 rpm, 2400 rpm, 2800 rpm, and 2950 rpm increments allowing engine parameters to settle for 10 minutes at each increment before recording below set of readings. At each rpm increment, conduct a visual walk around and inspect for leaks and abnormalities.

6. Measure and record values listed below (values in parentheses indicate requirement for final certification acceptability).

a. Engine rpm (2950 ±10 rpm)

b. Output torque

c. Output horsepower (470 to 500 horsepower)

d. Fuel burn rate-GPH (28.4 GPH maximum)

e. Jacket water temperature-Fahrenheit (190°F (+ 5 / - 10 °F))

f. Charge air cooler temperature delta (formula below)-Fahrenheit (0.73 minimum)

Turbo outlet temp - MINUS - Inlet manifold temp

-DIVIDED BY-

Turbo outlet temp - MINUS - Raw water temp

Note: Measure turbo outlet temperature (aftercooler inlet) at the rear boss on the bottom of the aftercooler. Measure inlet manifold temperature at center port on aftercooler.

g. Lube oil temperature after oil cooler-Fahrenheit (230 °F maximum)

h. Combined exhaust gas temperature-Fahrenheit (900 °F maximum)

i. Ambient air temperature-Fahrenheit

j. Fuel pressure-PSI (19 psi minimum)

k. Raw water temp at inlet to after cooler at rear inboard zinc-Fahrenheit

l. Oil pressure-PSI (60 psi (+/- 15 psi))

m. Boost pressure-PSI

n. Crankcase blow by-CFH (double the recorded horsepower maximum)

o. Charge air cooler pressure delta-PSI (2 psi max across the cooler)

p. Fuel return sight glass observation-SMCS Code:1280-081

Acceptable: A steady stream of small bubbles with a diameter of approximately 1.60 mm(0.063 inch), or bubbles 6.35 mm (0.250 inch) if two to three seconds apart.

7. At completion of all speed increment runs and corresponding data recording, continue to run engine at 2600 rpm for 10 minute cool down with 100 horsepower load.

8. At completion of 2600 rpm cool down, continue to run engine at 750 rpm for 5 minute cool down with 0 horsepower load. Secure engine and unrig.

9. If dynamometer test was being conducted to determine further repair considerations, contact EDR with specifics and dynamometer test readings. If dynamometer test was conducted to certify performance of maintained / repaired / overhauled engine, ensure dynamometer test readings and measurements are provided as specified in this contract.

5.4 24M Maintenance and Dynamometer Test (Work Package 4)

The purpose of the 24M maintenance work package is to complete all cyclical preventive maintenance, test, preserve the engine and marine gear, and restore the engine to A-condition.

a. Remove and replace with new, jacket water pump drive belt adjustment bracket and pulley, using new fasteners.

b. Inspect water pump and report any issues.

c. Adjust Fuel Timing, Valve Lash and Unit Injector Synchronization

d. Remove and replace with new, Raw Water Pump Impeller and Cover, and Cooling System Water Temperature Regulator (thermostat) and associated gaskets.

e. Clean, inspect, and adjust Engine Speed Sensor.

f. Clean and hydrostatically test Heat Exchangers, replacing associated gaskets.

g. Install new zincs in all Heat Exchangers

h. Clean and inspect Salt Water Y-Strainer

i. Change oil and filter on Engine

j. Change Extended Life Coolant (ELC).

k. Change out Secondary Fuel Filter

l. Replace with new, all hoses and associated constant torque clamps, belts, and air filter.

m. Marine Gear

i. Change oil and filter.

ii. Clean, preserve, and replace shift lever and detent (ball bearing and spring).

iii. Inspect shift lever for ease of operation.

n. Engine Control box

i. Inspect lid hinges, latch and gasket for proper operation and replace as needed.

ii. Clean and provide protective coating to all terminal strips, inspect wiring and lugs and replace as needed, and ensure there are two functional engine electrical harness keepers installed.

o. Conduct satisfactory post repair dynamometer test (sub-section 5.3).

i. Ensure #1 Injector has tamper seal installed

ii. Ensure Governor Control is lock wired where required.

p. Complete Preparation for Air Transportation (sub-section 3.5) and Standard Preservation (sub-section 3.6).

5.5 24M-1 Maintenance and Dynamometer Test (Work Package 5)

The purpose of the 24M-1 maintenance work package is the same as that for the 24M maintenance work package with the inclusion of replacing several high failure parts.

a. Remove Turbocharger and associated gaskets and seals and replace with new

b. Remove Aftercooler and associated gaskets and seals and replace with new

c. Remove Injectors and associated gaskets and seals and replace with new

d. Complete all requirements listed in Work Package 4 (24M maintenance, para 5.4)

5.6 Material Services (Work Package 6)

Repair and maintenance services not listed in, or outside of the scope of, work packages 1, 2, 3, 4, or 5. Contractor shall provide an Over and Above Work Request (OAWR) to include labor hours and materials in accordance with DFARS 252.217-7028 to the EDR for approval and forwarding to the Contracting Officer.

6.0 Quality Control: The contractor shall develop and maintain an effective quality control program to ensure services are performed in accordance with this PWS. The contractor shall develop and implement procedures, Quality Control Plan (QCP), to identify, prevent, and ensure non-recurrence of defective services. The contractor’s quality control program is the means by which he assures himself that his work complies with the requirement of the contract. The QCP shall be delivered to the COR within 10 days of contract award. Changes to the QCP shall be submitted to the Contracting Officer within five (5) work days when changes are made thereafter.

7.0 Quality Assurance: The Government will evaluate the contractor’s performance under this contract in accordance with the Quality Assurance Surveillance Plan (QASP).

8.0 Government Furnished Property/Equipment/Information/Services: N/A 9.0 Contractor Furnished Property/Equipment/Information/ Responsibilities : Provide all non-personal services to include labor, materials, equipment and supplies to complete all requirements of the performance work statement.

10.0 Security Requirements: N/A 11.0 Physical Security: The contractor shall safeguard the engines turned over to their possession for service.

12.0 Special Qualifications: The contractor shall provide a Caterpillar Maintenance Technician with current certifications when troubleshooting during warranty/in-service conditions. The results of this action may be restoration of the engine to OEM performance levels, or the determination that the engine requires further maintenance or overhaul.

13.0 Contractor Manpower Reporting: The contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for Naval Special Warfare Command via a secure data collection site. The contractor is required to completely fill in all required data fields using the following web address: http://www.ecmra.mil/ Reporting inputs will be for the labor executed during the period of performance during each Government fiscal year (FY), which runs October 1 through September 30. While inputs may be reported any time during the FY, all data shall be reported no later than October 31 of each calendar year. Contractors may direct questions to the help desk at: http://www.ecmra.mil/

14.0 Contracting Officer Representative: The (COR) will be identified by separate letter. The COR is not authorized to change any of the terms and conditions of the resulting contract or subsequent task orders.

15.0 Organizational Conflict of Interest (OCI): No OCI is anticipated under this contract. In the event OCI occurs, FAR Part 9.5 is applicable.

16.0 Place of Performance: The work to be performed under this contract will be performed at locations as follows:

16.1 Performance will be at the Contractor’s Facility for all overhaul/maintenance actions. The exception to the Contractor’s Facility is in regards to some warranty work or troubleshooting/repair work, which may also be completed at the SBT location if specified on task order.

PERFORMANCE WORK STATEMENT TECHNICAL EXHIBIT LIST

Technical Exhibit 1 - Performance Requirements Summary Technical Exhibit 2 - Deliverables Schedule

Technical Exhibit 3 – Estimated Workload Data