P-200-0426-1.doc

USCG-Surface Forces Logistics Center HSCG40-10-X-XXXXX Date-January 21, 2010

REVISION

No. 1-0

CHANGE___0__

MAIN PROPULSION SPECIFICATION

FOR 75 WLR & WLIC VESSELS AND 65 WLR VESSELS

P-200-0426

ORGINATED BY J.H. Prokop DATE 01/21/2010 ORIGINATOR’s COMMAND ______Surface Forces Logistics Center______

DEPARTMENT / DIVISION ______Main Propulsion Machinery Section _____

INTERNAL REVIEWER T. GAHS DATE _12/2009__

MAIN PROPULSION SPECIFICATION

FOR 75 WLR & WLIC VESSELS

1.0 SCOPE:

1.1. This specification covers the requirements for replacement main propulsion plant for the 75 WLR & WLIC Class cutters and the 65 WLR class cutters. The 75 WLR/WLIC cutters are 75-foot pusher tenders that work in conjunction with 130-foot and 90-foot barges. 65 WLR class cutters are 65-foot pusher tenders that work in conjunction with 90, 99, and 130-foot barges. The primary mission of these vessels is aids to navigation.

1.2. Specification Precedence - Any conflict between this specification and applicable documents identified in this specification shall be resolved in this order:

1.2.1. This specification

1.2.2. Applicable documents

1.3. Departure from Specification - Departure from this specification shall not be allowed unless approved by the Coast Guard Contracting Officer.

1.3.1. If the contractor finds it necessary to implement change or depart from applicable specifications, they shall request permission.

1.3.2. Request by contractors for change shall clearly describe the changes proposed, the reasons for and advantages of the changes proposed, and the contract’s price increase or decrease (if any) that would result.

2.0 APPLICABLE DOCUMENTS

2.1. 40 CFR 94.8 Emission Regulations for Marine Engines. 9/19/03

2.2. ANSI/ASQC Q9003-1994, Model for Quality Assurance in Final Inspection and Test

2.3. ANSI/NCSL Z540-3-2006, Calibration Laboratories and Measuring and Test Equipment-General Requirements

2.4. ANSI S2/27-2002

American International Standard Guidelines for the Measurement and Evaluation of Vibration of Ship Propulsion Machinery

2.5. ASTM D975 – 2009 Rev B Standard Specification for Diesel Fuel Oils

2.6. ISO 3046/1 Reciprocating internal combustion engines - Performances - Part 1:

Declarations of power, fuel and lubricating oil consumptions, and test methods 5/9/02

2.7. ASTM D7478/D7478M Standard Specification for Heavy Duty Sheathed Wood Crates 10/1/2008.

2.8. ELC specification D-000-0100 Bar Code Requirements 10/1/91

2.9. ABS Guide, Steel Vessels under 90 meters (295 feet) in length Part 4 Machinery

Equipment and systems, 1997

2.10. Society of Naval Architects and Marine Engineers; Technical and Research, Code C5,

2.11. 9/1/99.

2.12. MIL-L-2104 G Lubricating Oil, Internal Combustion Engine,

2.13. Combat/Tactical Service. 1997

2.14. MIL-F-16884 FUEL, NAVAL DISTILLATE. 11/14/02.

2.15. MIL-T-5624 TURBINE FUEL, AVIATION, GRADES JP-4, JP-5, AND JP-5/JP-8 ST.

9/18/98.

2.16. M9000.6E COMDTINST Navel Engineering Manual. 21OCT04.

2.17. MIL-P-24534A-1991 Planned Maintenance System: Development of Maintenance Requirement Cards, Maintenance Index Pages, and Associated Documentation.

2.18. COMDTINST M3501.3E Casualty Reporting Procedures (Materiel). 11DEC95

2.19. COMDTINST M8000.2D, Ordnance Manual. 24OCT08

2.20. COMDTINST 10550.25B, Electronics Manual. 03MAY07

2.21. COMDTINST M10470.10F, Rescue and Survival Systems Manual. 03JAN07

3.0 REQUIREMENTS

3.1. General

3.1.1. Main propulsion system configuration shall be identical to 75 WLR/WLIC vessels.

3.1.2. All drive train components shall have continuous power and torque ratings and shall be capable of transmitting the full power, torque, and thrust of the propulsion system in the ahead and astern directions

3.1.3. The propulsion system shall permit unlimited freewheeling of any un-powered propulsor while the vessel is operated on another propulsor. The contractor shall be responsible to make provisions for any required lubrication and cooling in the marine gear.

3.1.4. Each engine shall be a non-reversible self-contained marine diesel with individually replaceable cylinder liners. The primary propulsion engines shall be identical make and model to each other, except for placement of controls and external components.

3.1.5. Where engine ratings require adjustments for inlet conditions the formulas of Section 10 of ISO 3046/1 shall be used.

3.1.6. Service Environment

a. The vessel is designed to operate under the environmental conditions listed in this Section except as noted elsewhere in the Specification. (Note: Environmental temperatures in the WLIC AORs may exceed stated temperatures) Summer

Winter

Dry Bulb

Dry Bulb

Outside Air

950F

00F

Sea Water

850F

280F

3.2. Propulsion Plant Overall Dimension Limits

3.2.1. The propulsion plant shall be restricted to the following dimensional limits. The overall dimensions shall be: length less than or equal to 110”, measured from the front of the engine to the output flange on the reduction gear. Width shall be less than or equal to 57” and the height shall be less than or equal to 65”.

3.3. Propulsion Plant Rating

3.3.1. The propulsion engine model shall be a current production model and operated in commercial marine, naval service, or U.S. Government marine service at a rating equal to or in excess of the required engine rating for a period of at least one year. The propulsion engine shall be rated at a minimum of 650 horsepower at full continuous rating. The ratings shall be based on the Original Equipment Manufacturer’s (OEM) published catalog data.

3.3.2. The vessel shall be capable of operating at the maximum continuous speed for various periods of time limited only by the availability of fuel and/or duration of the mission. The engine will be operated approximately 2000 hours per year. Over a period of a year or more, the vessel & associated barge will operate approximately 85% of the time at the desired full power and the remaining time at 25% power.

3.3.3. The Contractor shall verify and provide evidence of verification that the engine met the following conditions on or before the proposal due date:

a. The engine offered shall have a rating no less than the commercial work boat continuous duty rating.

3.4. Emissions

3.4.1. Engines shall be 40 CFR 94.8 certified by the manufacturer. Evidence of compliance shall be submitted to the Contracting Officer with the proposal.

3.5. Engine Lubricating Oil System

3.5.1. Each engine shall be capable of using lube oil that meets MIL-L-2104F requirements.

3.5.2. Each engine shall be supplied with an integral oil sump and engine driven circulating pump providing lubrication for the engine.

3.5.3. Each engine shall be equipped with a lube oil strainer on the suction side of the pump and full flow filter(s) on the discharge side. The filter(s) shall be conveniently located to facilitate filter changes. Elements shall conform to engine manufacturer’s specifications. A relief system shall be provided external to the filter casing. The relief system shall bypass oil around the filter(s) if the filter(s) becomes clogged.

3.5.4. The engine shall be equipped with a crankcase ventilation system to dissipate through the engine’s intake system all fumes generated by the engine in the crankcase. The system shall pass crankcase vapors through a separation device and shall maintain crankcase pressure in the range of –5 mm to 5 mm HG (-2.7" to +2.7" of water) under all normal load and speed ranges. Oil shall be returned to the sump.

3.5.5.

3.5.6. Fast Lube Oil Change System (FLOCS)

a. A fast lube oil change system (FLOCS) shall be installed on the diesel engines to allow for convenient oil changes.

b. FLOCS shall consist of lube oil flexible suction hose and a ¾” male quick disconnect positive shut off coupling (FSN 4730-01-149-9946), individually connected to the diesel engines normal oil drain point.

c. FLOCS suction hose shall be of sufficient length to extend above the engine room deck grates.

3.6. Cooling System

3.6.1. Each engine shall be cooled by means of a closed, self contained, fresh water system in which the jacket water is circulated by means of an attached engine driven pump. Jacket water will be cooled through a keel cooler.

3.6.2. The contractor shall provide the Keel Cooler sizing requirements for the engine being supplied. Sizing requirements shall be submitted with proposal.

a. Keel Cooler size requirements shall include adequate cooling for a vessel to be underway at full power and also operating in neutral (no movement) for long periods of time.

b. The vessels are limited to keel cooler size. Presently there is one keel cooler for each engine. The vessels space limitations for keel coolers are 10 foot 3 inches long by 13 inches wide. The Keel Cooler pocket runs in the fore and aft direction of the vessel.

3.6.3. Water pumps – The engine water pump drive arrangement shall prevent water leakage into the engine lubrication system. The pumps shall be so mounted or provided with a continuous vent to prevent the entrapment of air. Pumps, which are not self-draining, shall be provided with petcocks or other means of being drained completely without the use of special tools. The pumps shall be installed with the outlet horizontal or upward to prevent air binding of pump casings.

3.6.4. Each engine jacket water system shall be provided with an electric heating system to maintain the jacket water at a temperature sufficient to allow starting and rapid acceptance of load from a shutdown condition. Ambient compartment temperature shall be considered to be 40oF.

a. Engine jacket water heater shall be capable of operating on 220VAC, supplied with a adjustable thermostat with temperature ranges from 100OF – 120OF and have an auto shutoff feature.

3.6.5. An external jacket water expansion tank (if required) shall be supplied with each engine. The expansion tank shall be installed above each engine in the compartment in accordance with the manufacturer’s instructions and/or recommendations. The tank shall be equipped with a level indicator that is readily visible. Provision shall be made for the addition of chemical treatment to the expansion tank.

3.6.6. A jacket water conditioner test kit shall be furnished. It shall be capable of indicating the inhibitor concentration level and the presence of chlorides in the cooling water.

3.6.7. The contractor shall disclose the engine heat rejection to cooling and air in 0F. Disclosure will also be submitted in proposal.

3.7. Fuel Oil System

3.7.1. Each engine shall have a fuel oil system configured as follows:

3.7.2. Each engine shall be capable of using both marine diesel fuel oil in accordance with MIL-F-16884 and JP-5 in accordance with MIL-T-5624

3.7.3. In addition to the fuel injection pumps and injectors, the system for each engine shall include a hand operated priming pump, an engine driven rotary positive displacement type supply pump, a relief valve connected to the discharge side of the pump, a duplex filter-water separator, a separate filter and the necessary piping, valves and fittings. A duplex pressure gage shall be furnished to indicate the pressure drop across the filter-water separator. The fuel system shall be capable of operating with a 3-meter static suction lift. If the duplex filter-water separator is on the suction side of the supply pump then the filter shall be installed on the discharge side of the pump. If the duplex filter-water separator is on the discharge side of the supply pump then the filter shall be installed on the suction line of the pump.

3.7.4. The contractor shall provide a fuel consumption curve for the engine being provided. To be submitted with proposal.

3.8. Exhaust System

3.8.1. Each engine’s exhaust system shall meet the requirements below:

3.8.2. The exhaust headers shall be water cooled, blanketed or head shielded. Provisions shall be made to drain the headers from either end to evacuate liquids or gases..

3.8.3. Pipefittings shall be provided near the turbocharger inlet and exhaust flange in an easily accessible location for the connection of the manometer gages.

3.8.4. Contractor shall provide engine exhaust data for exhaust system. Data shall be submitted with proposal.

3.9. Engine Diagnostic System

3.9.1. Each ship set of engines shall include the WLR 005 / HP 003 diagnostic code reader and associated software licenses required to perform required analysis.

3.10. The Contractor shall provide a starting system for each engine. The starting system shall comply with ABS Guide, Steel Vessels under 90 meters (295 feet) in length Part 4

Machinery Equipment and systems, 1997, section 4/4.15.3.

3.10.1. The starting system shall be air start.

3.10.2. Available air characteristics on the vessels are: Two 10.7 cubic foot (80 Gal) receivers with 250-PSI air pressure. Engines shall take into account limited compressed air supply when considering the design of air starters.

3.11. Governor

3.11.1. A variable speed governor suitable for the service intended shall be provided.

3.12. Engine Shut Off & Overspeed Trip

3.12.1. For protection against engine overspeed an independent speed-limiting device shall be provided that will automatically control the engine when it exceeds 115 percent of full rated RPM. Each engine shall be provided with an emergency shutdown device, operable by a pull cable, which will shut off combustion air to the engine. The pull cable shall be operable from a location adjacent to the primary access to the engine compartment. The device shall require manual reset before the engine can be restarted. The emergency shutdown shall be independent of the normal stop mechanism. The materials used in the device shall be selected for resistance to fire damage so as not to be consumed or rendered unserviceable by fire.

3.12.2. Each engine shall be provided with fuel system shut off device. This devise shall be used to shut down the engine under normal operation. The devise shall be able to be operated by electrical means such as an electric switch mounted on the engine gauge panel. A remote engine shut down switch shall be supplied with the engine and shall be mounted on the cutters bridge console. Engine should be able to be shut down from either position.

3.13. Shields and Guards

3.13.1. Flange shielding shall be provided on fuel and lube oil lines, filters, and strainers.

3.13.2. Shields and guards shall be provided to protect personnel from contact with hot surfaces and moving parts. Max temperature of unguarded components is 1400F.

3.13.3. Finger guards shall be provided to protect personnel from moving/rotating machinery.

3.14. Gauges and Controls

3.14.1. Instrumentation shall be supplied and installed on a panel mounted adjacent to each engine. English standard top or larger labeling with SI standard smaller labeling gages shall be provided. Gages, indicators, or switches referring to non-installed equipment shall be removed and blanked out.This instrumentation shall include but need not be limited to the following:

a. Engine Lubricating Oil Pressure

b. Engine lubricating Oil filter Differential Pressure

c. Engine Lubricating Oil Temperature

d. Engine Jacket Water Outlet Temperature

e. Fuel Pump Discharge Pressure

f. Fuel Manifold Pressure

g. Left and Right Hand Intake Combustion Air Pressure

h. Engine Jacket Water Pump Discharge Pressure

i. Engine tachometer

j. Hour-meter

k. Reduction Gear Lubricating Oil Pressure

l. Reduction Gear Lubricating Oil Temperature

3.14.2. Controls for starting, Stopping, and speed regulation shall be mounted on the instrument panel. The instrument panel shall also contain controls for manually starting and stopping the keep-warm and pre-lube oil systems. Local alarms and switches for same shall be provided for the following:

a. Engine Over-speed

b. Engine High Jacket Water Temperature

c. Engine Low Lubricating Oil Pressure

d. Reduction Gear Lubricating Oil low Pressure

3.14.3. Each engine shall be caused to shut down on conditions of low lubricating oil pressure. Shut down shall occur only after an alarm has sounded and the condition of the condition causing the alarm has degraded further. Each engine shall be equipped with a master override switch to prevent shut down due low lubricating oil pressure, but this override shall not prevent alarm actuation.

3.14.4. Remote Instrumentation panel shall be supplied by engine manufacturer. This panel will be mounted on the bridge console. The remote instrumentation shall be electric type with sending units on the engine. This instrumentation shall include but need not be limited to the following:

a. Engine RPM Tachometer

b. Shaft RPM Tachometer

c. Engine Lubricating Oil Pressure alarm

d. Engine Jacket Water Temperature alarm

e. Reduction Gear Lubricating Oil Pressure alarm

f. Reduction Gear lubricating oil temperature alarm

g. Main Engine Start

h. Main Engine Stop

3.15. Propulsion Reduction Gears

3.15.1. The rating of the reduction gears shall be continuous duty and rated to be used on workboats. The gear ratio should be such that the shaft speed range shall be between 500 and 550 RPM.

3.15.2. The reverse/reduction gear and clutch units shall be compatible with the technical and performance characteristics of the installed propulsion engines. Each reverse/reduction gear unit shall be identical and shall have power and torque ratings to match the maximum continuous power and torque of the installed engine. The hydraulically actuated reverse/reduction gear units shall be capable of transmitting full engine rated horsepower both ahead and astern. The reverse/reduction gear units shall control the rotation of the propellers. In the ahead direction the starboard shaft shall provide right hand rotation and the port shaft shall provide left hand rotation as viewed from aft looking forward.

3.15.3. If the reverse/reduction gear installed is equipped with a Trolling valve feature then the clutch oil circulating and cooling systems shall be designed to dissipate maximum heat generated by continuous trolling for a period of not less than six (6) hours.

3.15.4. Each reverse/reduction gear unit shall be furnished with a self-contained lubricating lube oil system and shall use the same grade lube oil as the engines. The system shall consist of an attached sump, pump(s), filter(s) and cooler(s). Pump(s) shall provide adequate lubrication during all operating conditions including freewheeling of a shaft with its engine secured. An oil-to-water heat exchanger and temperature regulating valve shall be furnished to maintain safe operating temperatures of the lube oil during any vessel operating condition.

3.15.5. The reverse/reduction gear units shall be a current production model and operated in commercial marine, naval service, or U.S. Government marine service at a rating equal to or in excess of the required reverse/reduction gear unit rating for a period of at least one year. The Contractor shall verify and provide evidence of verification that the reverse/reduction gear unit met the following conditions on or before the proposal due date:

a. The reverse/reduction gear unit offered shall have a rating no less than the commercial workboat continuous duty rating.

3.15.6. A companion flange shall be supplied with the reverse/reduction gear. The flange shall be sized to accommodate a 4 inch to 5 inch shaft.

3.16. Reduction Gear Gauges and Alarms

3.16.1. Instrumentation shall be supplied and installed on the engine instrument panel. This instrumentation shall include but need not be limited to the following:

a. Reduction Gear Lubricating Oil Pressure Gauge

b. Reduction Gear Lubricating Oil Temperature Gauge

3.16.2. The following alarms (for each reduction gear) shall be provided on the engine instrument panel and the bridge console:

a. Reduction Gear Low Lube Oil Pressure Alarm

b. Reduction gear high temp alarm.

3.17. Vibration Analysis

3.17.1. The Contractor shall perform and submit the results of a torsional vibration analysis, which shall include all components in the propulsion mass elastic system. The analysis shall show that throughout the operating speed range including possible overspeeds in turns, propeller cavitation conditions and cylinder misfiring, there are no vibratory stresses in excess of those in ANSI S2.27-2002 and the equipment or component manufactures. Analysis shall be submitted with proposal.

3.17.2. Vibration Analysis shall include all the deliverable detailed in Section 7 Report of the ANSI S2.27-2002

3.18. Data for Provisioning (DFP)

3.18.1. The Contractor shall only be required to provide UPDATED Data for Provisioning (DFP) that includes drawings, commercial technical manuals, catalog data and product specification sheets, which form the minimum data to provision a system or piece of equipment. UPDATED shall me anything that has changed from the immediately preceding contract for engines on the 65’ and 75’.Examples of the DFP include, but are not limited to: certification data, name plate data, component characteristics data, commercial specification sheets, end item/component prices, manufacturer’s identification (or Commercial and Government Entity Code (CAGE)), part number, shelf life, and special material / operating requirements. This data will then be used for the Coast Guard’s identification, cataloging, selection and determination of initial requirements for support items to be procured through the provisioning process. Updates will be provided as required through the term of the contract.

3.18.2. As a minimum, the Contractor’s UPDATED DFP shall be detailed enough to include:

a. A listing that identifies all the piece parts, which can be assembled, re-assembled, and/or replaced.

b. General arrangement, diagrammatic drawing and/or detailed Technical Publication that describes the end item, end item’s equipment and/or piece parts; material, mechanical electrical, dimensional characteristics, location, and their function within the assembly.

c. A list of all special tools and test equipment required to maintain the end item.

d. A listing of spare parts recommended by the Contractor to support the end item for a period of one (1) year. The listing must contain end item/component prices.

e. The contactor shall provide a complete equipment parts list for a (OEM recommended Overhaul). Overhaul parts will meet O.E.M. specifications. The overhaul replacement parts list shall give a full description of each part with O.E.M. part number and (NSN) National Stock Number if available

f. The contractor shall provide a list of special tooling, which is needed for equipment installation, Mechanical Troubleshooting and diagnostic testing. The list shall also include all Special Tooling needed to complete a major overhaul.

g. The contractor shall provide a list of software/licenses needed to accomplish diagnostic testing.

3.18.3. DFP is required for each piece of equipment being procured by the Government through this specification.

3.18.4. The Contractor shall notify the Coast Guard within five (5) working days of any changes effecting equipment/piece parts configurations during the performance of the contract.

3.18.5. Contractor to Vendor/Subcontractor DFP Obligations. The Contractor shall put provisions in his lower-tier subcontractors and supply agreements requiring compliance with this specification. The DFP that the Coast Guard requires from the Contractor’s vendors/subcontractors shall be provided by the Contractor.

3.18.6. Procurement Obligations. Support items that the Coast Guard identifies through the provisioning process shall not be considered by the Contractor, vendor, or subcontractor as a commitment or obligation on the part of the Coast Guard to procure such items.

3.19. ENGINEERING DOCUMENTATION PACKAGE (EDP)

3.19.1. This section defines the minimum requirements for the Contractor to supply documents and data (EDP) necessary for Coast Guard engineers to integrate the Contractor’s equipment into the design of Coast Guard vessels. Examples of EDP include, but are not limited to: hard copy paper drawings, electronic drawing files, commercial catalogue sheets, off-the-shelf tech pubs, photographs, etc.

The Contractor’s EDP shall be detailed enough to include:

a. General arrangement drawings detailing overall dimensions; required maintenance area dimensions; locations, size and type of all piping and electrical connections to vessel’s systems.

b. Footprint drawings detailing the foundation/mounting areas and specifying any special interface requirements as may be necessary.

c. The overall weight shall be identified.

d. Piping diagram of each fluid system detailing the pressure and flow characteristics and requirements of each fluid system.

e. Ventilation Requirements-intake air and engine space.

f. Electrical schematic of each circuit detailing the voltage and amperage requirements.

g. Manual, tech pub, and/or catalogue data detailing the installation requirements for each piece of equipment.

3.19.2. Drawings may be submitted as electronic media. Electronic media must be in AUTOCAD and at least Version 2000 or later. Where electronic media is submitted it shall be with the manufacturer’s permission to use the files in Coast Guard drawings.

EDP documents supplied as electronic will require two (2) copies.

Delivery of all EDP shall be included with the proposal.

3.20. MANDATORY REPLACEMENT PARTS.

3.20.1. Spare Parts.

a. The contractor shall provide a twelve-month supply of replacement spare parts for each engine/red gear. The spare parts shall meet the O.E.M. specifications. Parts shall include but not be limited to filters, strainers, belts and gaskets/o-rings. A spare part inventory list shall be provided with each delivery. The inventory list shall give a full description of each part with O.E.M. part number and (NSN) National Stock Number if available. One kit to be packaged with each propulsion plant.

b. A list of proposed spare parts shall be submitted with proposal.

Note: Section 6.2 Organizational Level Maintenance should be referenced for selection of replacement spare parts.

3.21. WARRANTY –The contractor shall provide a warranty for the entire marine engine/reduction gear for a minimum of one year from installation or 2000 operating hours, whichever occurs first. This warranty shall apply to the entire marine engine/reduction gear that may be in storage before installation, for a period up to 24 months. Storage commences upon receipt of engine at the designated Coast Guard facility. The contractor shall contact the unit to arrange a resolution of a warranty claim within twenty-four (24) hours after receiving notification by the Coast Guard. The contractor shall provide a manned warranty call in telephone number.

3.22. TRAINING - The contractor shall be responsible for providing training for the awarded unit. The contractor shall provide the written requirements for maintenance and operator training, as outlined in section 3.22.1, on their engine. This shall include facilities (space) and equipment mockup requirements, maintenance philosophy, as well as any proposed training plans. The CG will use this information to conduct analyses to determine our sustainment training options.

3.22.1. Types of Training

a.

b.

c. 3.5 days of operator/maintainer training provided at manufacturer’s facilities.

d. Initial Operator Training.

e.

Note: Equipment Technical Manuals, Drawings, Schematics and Videos can be used, but shall not suffice for training requirement.

3.23. Technical Representative Assistance.

3.23.1. The contractor shall be responsible to provide Technical Representative Assistance for the initial light off of each set (Port/Stbd) propulsion units also through out the vessels entire sea trial period to include initial operating training.

3.23.2. The contractor shall be responsible to provide Technical Representative Assistance to Coast Guard facilities within 48 hours in various locations through out the United States. Locations include:

Charleston, SC

Mayport, FL

Baltimore, MD

Corpus Christi, TX

St. Petersburg, FL

Galveston, TX

Morgan City, LA

Demopolis, AL

Omaha, NE

Sallisaw, OK

Dubuque, IA

Paris Landing, TN

St. Louis, MO

Vicsksburg, MS

Pine Bluff, AR

Greenville, MS

Hickman, KY

Memphis, TN

Natchez, MS

E. Chattanooga, TN

Buchanan, TN

Owensboro, KY

Keokuk, IA

Sewickley, PA

East Peoria, IL

4.0 QUALITY ASSURANCE

4.1.1. GENERAL - The Contractor shall maintain an inspection system, which shall ensure each item offered to the Government for acceptance conforms to contract requirements. The system shall be documented and in compliance with ANSI/ASQS Q90003.

4.1.2. RECORDS - The Contractor shall maintain records of all inspections and tests. The records shall indicate the nature and number of observations made, type of deficiencies found and the corrective action taken. Records shall be furnished upon arrival of the Coast Guard Representative.

4.1.3. CONTRACTORS CALIBRATION SYSTEM ‑ The Contractor as well as any Subcontractors shall be required to maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540-1.

The system includes as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to ensure adherence to calibration schedules. Calibration standards shall be traceable to the National Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for Government review.

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

4.1.5. QUALITY CHECKPOINTS – OEM is responsible for all checkpoints.

4.2. GENERAL TEST REQUIREMENTS

4.2.1. Engine dyno test parameters detailed in APPENDIX A shall be recorded and submitted to the Contracting Officer for approval. The submission shall be in the format per (APPENDIX A).

4.2.2. Engine testing shall be verified and accepted by a Coast Guard Representative.

4.2.3. Any unusual noises, external leakage, or any other noncompliance to this specification, as determined by the U.S. Coast Guard representative, shall be cause for the propulsion unit to be found unacceptable.

4.2.4. TEST REPORT - The Contractor is responsible to deliver a test report

a. One copy of the test report shall be packed and delivered with each engine delivered under this contract.

b. One copy of the test report shall be provided to the U.S. Coast Guard Representative upon final test acceptance.

4.2.5. PACKING INSPECTION - The Contracting Officer shall be notified prior to the preservation, packaging, and marking of the completed units in accordance with section 5.0.

4.2.6. NOTIFICATIONS & INSPECTIONS - The Contractor shall be responsible for notifying the Contracting Officer at least seven (7) working days prior to being ready for any inspections or testing. Prior to notification, the engine shall pass the required initial full dyno test. All test parameters shall be documented and readily available for Government review.

4.2.7. Prior to notification, the engine shall pass the required initial full dyno test. All test parameters shall be documented and readily available for Government review.

5.0 PRESERVATION PACKAGING & MARKING

5.1. PRESERVATION - The engine/reduction gear assemblies shall be preserved for long-term storage up to 24 months as per OEM’s recommendations. The contractor shall provide all items to restore units to full operational status. Items shall be supplied with the propulsion unit at time of delivery.

5.2. PACKAGING - The wooden shipping container shall be constructed and mounted to the pallet as per ASTM D7478/D7478M.

a. The Contractor shall securely fasten the engine into the approved shipping container. It shall be fastened in a matter that adequately ensures mechanical protection during multiple common carrier practices.

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

a. Machine made stencils shall be used for all marking.

b. All marking shall be in black print and at least 1" high.

c. The marking shall be in the format as follows:

STOCK NUMBER XXXX-XX-XXX-XXXX

ITEM NAME Diesel Engine

PART NUMBER

SERIAL NUMBER "As per Enclosed Engine" CONTRACT NUMBER See Contract DELIVERY ORDER NUMBER As submitted on the Order SHIPPING WEIGHT As Determined by Contractor

QUANTITY & UNIT OF ISSUE 1- EA

PRESERVED FOR LONG TERM

STORAGE ON Date preserved

CONDITION CODE CONDITION A

OTHER DATA AS COAST GUARD SFLC MATERIAL

DIRECTED REUSABLE CONTAINER,

DO NOT DAMAGE.

DO NOT STACK.

5.4. BAR CODING - Bar code labels shall be supplied on all Contract Line Item Numbers (CLIN), except for those that require data submissions only.

a. All bar coded labels shall be in accordance with ELC specification D-000-0100.

b. The actual labels shall be Type "V", Grade "A", Style"2", Composition "b" with plastic laminate.

c. Each label shall contain encoded data for the Stock Number, the Delivery Order Number and the Contract Number.

6.0 NOTES

6.1. GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1. GOVERNMENT DOCUMENTS

Specifications and Standards (DODISS Documents)

Standardization Document Order Desk

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA 19111-5094

215-697-1187

6.1.2. DOD & Navy Publications & Forms (NOT DODISS).

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

6.1.3. Surface Forces Logistics Center

2401 Hawkins Point Rd.

Baltimore, MD 21226-1792

410-762-6903 (ESD/TIMB)

6.2.

6.2.1.

6.2.2.

6.2.3.

a.

b.

6.2.4.

6.2.5.

a.

b.

1.

2.

3.

4.

5.

c.

APPENDIX A

Engine Test Report

1.0 Requirements

1.1. General Test Requirement

1.1.1. Test parameters detailed in this Appendix shall be used during the test procedure and a test report in the format as per this Appendix shall be submitted to the Contracting Officer for approval.

1.1.2. Any unusual noises, external leakage, or any other noncompliance to this specification, as determined by the U.S. Coast Guard representative, shall be cause for the propulsion unit to be found unacceptable.

1.1.3. All engine testing will be verified and accepted by the U.S. Coast Guard Representative.

1.1.4. Note: The test run has expanded to 9 phases and 8 hours to adhere to sound engineering practices delineated in American Bureau of Shipbulding Naval Vessel Rules, January 2007

1.2. Pre-Test Preparation Requirements

1.2.1. Each engine shall be fitted with a new lube oil filter.

1.2.2. Each engine shall be filled with New MIL-PRF-2104G

grade 15W40 lube oil.

The fuel oil shall be as per ASTM-D-975 grade # 2 diesel and flow through a 20 micron filter/separator before entering pump.

1.2.3. The cooling system shall be filled with clean potable water.

1.2.4. Each engine shall be tested with all hang on attachments to include all those items listed in Appendix A. (Exhaust Shields are required to be attached during test.)

1.3. Pre-Start Requirements

1. Fill engine cooling system.

2. Prime fuel system.

3. Fill lube oil system.

4. Take lube oil samples for analysis

1.4. Post Test Preparations Requirements

1.4.1. ALL ENGINE LUBE OIL FILTER ELEMENTS SHALL BE REPLACED WITH NEW FILTER ELEMENTS AFTER COMPLETION OF ENGINE TEST.

1.4.2. LUBE OIL SAMPLES SHALL BE TAKEN AFTER TEST (ENSURE LUBE OIL CONTROL SAMPLE IS TAKEN BEFORE ENGINE RUN)

1. Spectrographic analysis of each lubricating-oil sample to be analyzed shall be conducted to measure in ppm the concentration of oil additive elements and wear metal elements of oil-wetted components such as the following: aluminum, calcium, chromium, copper, iron, lead, magnesium, molybdenum, nickel, phosphorous, silicon, silver, tin, and titanium. The degree of accuracy of the spectrographic analysis shall be as given as a maximum standard deviation in pp per ppm range as shown below. Acceptable trending rates for wear metal elements of oil wetted components shall be provided prior to start of testing.

2. Physical analysis of each lubricating-oil sample to be analyzed shall be composed of the tests and in accordance with the indicated ASTM test methods listed below (ASTM shall be the most up to date version available at the time of test):

Alternatives Condemning Limit

Viscosity at 100C maximum mm2/s

SAE 30, SAE 5W-30, SAE 10W-30 : 14.0

SAE 40, SAE 10W-40, SAE 15W-40 : 18.0

Viscosity at 100C minimum mm2/s

SAE 30, SAE 5W-30, SAE 10W-30 : 9.0

SAE 40, SAE 10W-40, SAE 15W-40 : 11.5

2.0 TESTS & TEST PARAMETERS

2.1. Basic Run-In: 30 Minutes at 50% continuous load and speed rating

OEM Design

MIN/MAX Actual

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp in DEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

STOP ENGINE: CHECK ALL FLUID LEVELS AND TOP OFF AS REQUIRED

Comments: __________________________________________________________________

2.2 Operational Test

NOTE - Readings shall be taken and recorded at the end of the phase. All line items with specific parameters are to be observed and actual readings recorded.

2.2.1 Phase 1: 120 Minutes at 100% continuous load and speed rating.

1. GENERAL

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp inEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

h. Engine Speed RPM _____/_____ ______

i. Horsepower BHP _____/_____ ______

2. TEMPERATURE

a. Jacket Water From Engine DEG F _____/_____ ______

b. Jacket Water to Engine DEG F _____/_____ ______

c. Lube Oil Temp to Cooler DEG F _____/_____ ______

d. Lube Oil Temp From Cooler DEG F _____/_____ ______

e. Inlet Air DEG F _____/_____ ______

f. Air to Air Cleaner DEG F _____/_____ ______

g. Air From Air Cleaner DEG F _____/_____ ______

h. Exhaust at Turbo Outlet DEG F _____/_____ ______

3. PRESSURES OEM Design

MIN/MAX Actual

a. Ambient Atmospheric In.HG _____/_____ ______

b. Air Manifold In. HG _____/_____ ______

c. Crankcase IN-H20 _____/_____ ______

d. Jacket Water PSI _____/_____ ______

e. Lube Oil To Filter PSI _____/_____ ______

f. Lube Oil From Filter PSI _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

Comments:

2.2.2 Phase 2: 60 Minutes at 60% continuous load and 100% speed rating.

NOTE - Readings shall be taken and recorded at the end of the phase. All line items with specific parameters are to be observed and actual readings recorded.

1.GENERAL

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp inEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

h. Engine Speed RPM _____/_____ ______

2.TEMPERATURE

a. Jacket Water From Engine DEG F _____/_____ ______

b. Jacket Water to Engine DEG F _____/_____ ______

c. Lube Oil Temp to Cooler DEG F _____/_____ ______

d. Lube Oil Temp From Cooler DEG F _____/_____ ______

e. Inlet Air DEG F _____/_____ ______

f. Air to Air Cleaner DEG F _____/_____ ______

g. Air From Air Cleaner DEG F _____/_____ ______

h. Exhaust at Turbo Outlet DEG F _____/_____ ______

3.PRESSURES OEM Design

MIN/MAX Actual

a. Ambient Atmospheric In. HG _____/_____ ______

b. Air Manifold In. HG _____/_____ ______

c. Crankcase IN-H20 _____/_____ ______

d. Jacket Water PSI _____/_____ ______

e. Lube Oil To Filter PSI _____/_____ ______

f. Lube Oil From Filter PSI _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

Comments: __________________________________________________________________

2.2.3 Phase 3: 10 minutes 0% load and Idle Speed

NOTE - Readings to be taken and recorded at the end of the hour. All line items with specific parameters are to be observed and actual readings recorded.

1. GENERAL

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp inEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

h. Engine Speed RPM _____/_____ ______

2. TEMPERATURE

a. Jacket Water From Engine DEG F _____/_____ ______

b. Jacket Water to Engine DEG F _____/_____ ______

c. Lube Oil Temp to Cooler DEG F _____/_____ ______

d. Lube Oil Temp From Cooler DEG F _____/_____ ______

e. Inlet Air DEG F _____/_____ ______

f. Air to Air Cleaner DEG F _____/_____ ______

g. Air From Air Cleaner DEG F _____/_____ ______

h. Exhaust at Turbo Outlet DEG F _____/_____ ______

3. PRESSURES OEM Design

MIN/MAX Actual

a. Ambient Atmospheric In. HG _____/_____ ______

b. Air Manifold In. HG _____/_____ ______

c. Crankcase IN-H20 _____/_____ ______

d. Jacket Water PSI _____/_____ ______

e. Lube Oil To Filter PSI _____/_____ ______

f. Lube Oil From Filter PSI _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

Comments: ____________________________________________________________

2.2.4 Phase 4: 110 minutes at 100% load and speed rating.

NOTE - Readings to be taken and recorded at the end of the hour. All line items with specific parameters are to be observed and actual readings recorded.

GENERAL

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp inEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

h. Engine Speed RPM _____/_____ ______ a Jacket Water From Engine DEG F _____/_____ ______

b. Jacket Water to Engine DEG F _____/_____ ______

c. Lube Oil Temp to Cooler DEG F _____/_____ ______

d. Lube Oil Temp From Cooler DEG F _____/_____ ______

e. Inlet Air DEG F _____/_____ ______

f. Air to Air Cleaner DEG F _____/_____ ______

g. Air From Air Cleaner DEG F _____/_____ ______

h. Exhaust at Turbo Outlet DEG F _____/_____ ______

3.PRESSURES OEM Design

MIN/MAX Actual

a. Ambient Atmospheric In. HG _____/_____ ______

b. Air Manifold In. HG _____/_____ ______

c. Crankcase IN-H20 _____/_____ ______

d. Jacket Water PSI _____/_____ ______

e. Lube Oil To Filter PSI _____/_____ ______

f. Lube Oil From Filter PSI _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

Comments: __________________________________________________________________

2.2.5 Phase 5: 10 minutes at 0% load and idle speed rating.

NOTE - Readings to be taken and recorded at the end of the hour. All line items with specific parameters are to be observed and actual readings recorded.

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp inEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

h. Engine Speed RPM _____/_____ ______ a Jacket Water From Engine DEG F _____/_____ ______

b. Jacket Water to Engine DEG F _____/_____ ______

c. Lube Oil Temp to Cooler DEG F _____/_____ ______

d. Lube Oil Temp From Cooler DEG F _____/_____ ______

e. Inlet Air DEG F _____/_____ ______

f. Air to Air Cleaner DEG F _____/_____ ______

g. Air From Air Cleaner DEG F _____/_____ ______

h. Exhaust at Turbo Outlet DEG F _____/_____ ______

3.PRESSURES OEM Design

MIN/MAX Actual

a. Ambient Atmospheric In. HG _____/_____ ______

b. Air Manifold In. HG _____/_____ ______

c. Crankcase IN-H20 _____/_____ ______

d. Jacket Water PSI _____/_____ ______

e. Lube Oil To Filter PSI _____/_____ ______

f. Lube Oil From Filter PSI _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

Comments: __________________________________________________________________

2.2.6 Phase 6: 30 minutes at 50% load and 75% speed rating.

NOTE - Readings to be taken and recorded at the end of the hour. All line items with specific parameters are to be observed and actual readings recorded.

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp inEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

h. Engine Speed RPM _____/_____ ______ a Jacket Water From Engine DEG F _____/_____ ______

b. Jacket Water to Engine DEG F _____/_____ ______

c. Lube Oil Temp to Cooler DEG F _____/_____ ______

d. Lube Oil Temp From Cooler DEG F _____/_____ ______

e. Inlet Air DEG F _____/_____ ______

f. Air to Air Cleaner DEG F _____/_____ ______

g. Air From Air Cleaner DEG F _____/_____ ______

h. Exhaust at Turbo Outlet DEG F _____/_____ ______

3.PRESSURES OEM Design

MIN/MAX Actual

a. Ambient Atmospheric In. HG _____/_____ ______

b. Air Manifold In. HG _____/_____ ______

c. Crankcase IN-H20 _____/_____ ______

d. Jacket Water PSI _____/_____ ______

e. Lube Oil To Filter PSI _____/_____ ______

f. Lube Oil From Filter PSI _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

Comments: __________________________________________________________________

2.2.7 Phase 7: 10 minutes at 0% load and idle speed rating.

NOTE - Readings to be taken and recorded at the end of the hour. All line items with specific parameters are to be observed and actual readings recorded.

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp inEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

h. Engine Speed RPM _____/_____ ______ a Jacket Water From Engine DEG F _____/_____ ______

b. Jacket Water to Engine DEG F _____/_____ ______

c. Lube Oil Temp to Cooler DEG F _____/_____ ______

d. Lube Oil Temp From Cooler DEG F _____/_____ ______

e. Inlet Air DEG F _____/_____ ______

f. Air to Air Cleaner DEG F _____/_____ ______

g. Air From Air Cleaner DEG F _____/_____ ______

h. Exhaust at Turbo Outlet DEG F _____/_____ ______

3.PRESSURES OEM Design

MIN/MAX Actual

a. Ambient Atmospheric In. HG _____/_____ ______

b. Air Manifold In. HG _____/_____ ______

c. Crankcase IN-H20 _____/_____ ______

d. Jacket Water PSI _____/_____ ______

e. Lube Oil To Filter PSI _____/_____ ______

f. Lube Oil From Filter PSI _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

Comments: __________________________________________________________________

2.2.8 Phase 8: 10 minutes at 85% load and 100% speed rating.

NOTE - Readings to be taken and recorded at the end of the hour. All line items with specific parameters are to be observed and actual readings recorded.

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp inEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

h. Engine Speed RPM _____/_____ ______ a Jacket Water From Engine DEG F _____/_____ ______

b. Jacket Water to Engine DEG F _____/_____ ______

c. Lube Oil Temp to Cooler DEG F _____/_____ ______

d. Lube Oil Temp From Cooler DEG F _____/_____ ______

e. Inlet Air DEG F _____/_____ ______

f. Air to Air Cleaner DEG F _____/_____ ______

g. Air From Air Cleaner DEG F _____/_____ ______

h. Exhaust at Turbo Outlet DEG F _____/_____ ______

3.PRESSURES OEM Design

MIN/MAX Actual

a. Ambient Atmospheric In. HG _____/_____ ______

b. Air Manifold In. HG _____/_____ ______

c. Crankcase IN-H20 _____/_____ ______

d. Jacket Water PSI _____/_____ ______

e. Lube Oil To Filter PSI _____/_____ ______

f. Lube Oil From Filter PSI _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

Comments: __________________________________________________________________

2.2.9 Phase 9: 110 minutes at 110% load and 100% speed rating.

NOTE - Readings to be taken and recorded at the end of the hour. All line items with specific parameters are to be observed and actual readings recorded.

a. Idle Engine Speed RPM _____/_____ ______

b. Lube Oil Pressure PSI _____/_____ ______

c. Crankcase Pressure IN-H20 _____/_____ ______

d. Jacket Water Temp inEG F _____/_____ ______

e. Jacket Water Temp out DEG F _____/_____ ______

f. Lube Oil Temp DEG F _____/_____ ______

g. Fuel Oil Pressure PSI _____/_____ ______

h. Engine Speed RPM _____/_____ ______ a Jacket Water From Engine DEG F _____/_____ ______

b. Jacket Water to Engine DEG F _____/_____ ______

c. Lube Oil Temp to Cooler DEG F _____/_____ ______

d. Lube Oil Temp From Cooler DEG F _____/_____ ______

e. Inlet Air DEG F _____/_____ ______

f. Air to Air Cleaner DEG F _____/_____ ______

g. Air From Air…