ASPEN_PROPULSION_GROOM_SPEC.docx

HSCG85-15-Q-P45B45

U.S. COAST GUARD 225-FT SEAGOING BUOY TENDER (225 WLB)

PROPULSION SYSTEM GROOMS AND ASSESSMENTS

SPECIFICATION FY15

Developed By: CWO Matthew Thornton and Michael Check (Rev-3, 19 Jun 2015)

Perform 225 WLB Propulsion System Groom and Assessment

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to conduct a groom and assessment on a designated 225 WLB propulsion system and associated components, to accomplish the following:

· Validate the system is operating within the manufacturer’s specifications.

· Ensure the proper communication and interoperability of the system components.

· Perform planned maintenance tasks for system components. Planned maintenance tasks are those recommended by the system component manufacturers and approved by the Coast Guard.

· Participate in dockside performance test, evaluation, and validation.

· Participate in underway performance test, evaluation, and validation.

· Repair, renew, adjust, calibrate, and test of improperly functioning system components as required.

1.2 Government-furnished property. None.

2. REFERENCES

COAST GUARD DRAWINGS

225 “A” Class:

Coast Guard Drawing 225 WLB 201-001, Rev F, Machinery Spaces Arrangement Coast Guard Drawing 225 WLB 202-001, Rev F, MPCMS Cabling Diagram Coast Guard Drawing 225 WLB 202-002, Rev G, MPCMS COED Coast Guard Drawing 225 WLB 202-003, Rev J, Diesel Engine Local Wiring Diagram Coast Guard Drawing 225 WLB 202-004, Rev D, List of MPCMS Sensors Coast Guard Drawing 225 WLB 233-001, Rev G, Propulsion Train Installation Drawing Coast Guard Drawing 225 WLB 233-201, Rev -, Main Propulsion Diesel Engine Coast Guard Drawing 225 WLB 252-004, Rev D, 723PLUS Governor Digital Marine Control System 721 Replacement Ripout & Installation Arrgt & Details Coast Guard Drawing 225 WLB 601-001, Rev U, General Arrangements – Inboard and Outboard Profile Coast Guard Drawing 225 WLB 601-002, Rev R, Booklet of General Drawings

225 “B” Class:

Coast Guard Drawing 225B WLB 201-001, Rev C, Machinery Spaces Arrangement Enclosure

(1) to

“USCG

IDIQ

225 WLB

Propulsion

System

Grooms and Assessments”

Rev-3 (19 Ju ne

2015) Page of

Coast Guard Drawing 225B WLB 202-001, Rev G, MPCMS Cabling Diagram Coast Guard Drawing 225B WLB 202-002, Rev D, MPCMS Connection Table Coast Guard Drawing 225B WLB 202-003, Rev C, Diesel Engine Cabling Diagram and Connection Cables Coast Guard Drawing 225B WLB 202-004, Rev A, List of MPCMS Sensors Coast Guard Drawing 225B WLB 233-001, Rev D, Propulsion Train Installation Drawing Coast Guard Drawing 225B WLB 601-001, Rev L, General Arrangements – Inboard and Outboard Profile Coast Guard Drawing 225B WLB 601-002, Rev K, Booklet of General Drawings

COAST GUARD PUBLICATIONS

225 “A” Class:

Coast Guard Technical Publication (TP) 3501, Section A, SWBS 86, Amendment 17, Ship’s Information Book (SIB) Coast Guard Technical Publication (TP) 3505A, Section A, SWBS 86, Amendment 5, Machinery Plant Control & Monitoring System Operating Manual Coast Guard Technical Publication (TP) 3505B, Section A, SWBS 86, Amendment 2, Machinery Plant Control & Monitoring System Operating Manual – Appendix D Coast Guard Technical Publication (TP) 3522A, Section A, SWBS 233, Amendment 6, Main Diesel Engine (MDE) – Model 3608 (Volume 1 of 2) Coast Guard Technical Publication (TP) 3522B, Section A, SWBS 233, Amendment 7, Main Diesel Engine (MDE) – Model 3608 (Volume 2 of 2) Coast Guard Technical Publication (TP) 3523, Section A, SWBS 241, Amendment 9, Reduction Gear – Model 96DHCMG-CP

225 “B” Class:

Coast Guard Technical Publication (TP) 3518A, Sections A and B, SWBS 233, Amendment 12, Main Diesel Engine (MDE) – Model 3608 Coast Guard Technical Publication (TP) 3518B, Sections A and B, SWBS 233, Amendment 11, Main Diesel Engine (MDE) – Model 3608 Coast Guard Technical Publication (TP) 3523, Section B, SWBS 241, Amendment 9, Reduction Gear – Model 96DHCMGH-CP Coast Guard Technical Publication (TP) 3581, Section A, SWBS 86, Amendment 6, Ship’s Information Book (SIB) Coast Guard Technical Publication (TP) 3585, Section A, SWBS 86, Amendment 6, Machinery Plant Control & Monitoring System Operating Manual Coast Guard Technical Publication (TP) 3585, Section B, SWBS 86, Amendment 5, Machinery Plant Control & Monitoring System Operating Manual – Appendix D

Non-Class Specific:

Coast Guard Technical Publication (TP) 3593, Sections A thru C, SWBS 233, Amendment 0, 723PLUS Digital Control – Model 8280-1109 Coast Guard Technical Publication (TP) 4627, Section A, SWBS 233, Amendment 0, Electronic Speed Governors – Model SG03

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

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 work.

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

3.1.1 CIR. None.

3.1.2 Tech Rep. Refer to Specification - “USCG 225 WLB Propulsion System Grooms and Assessments

3.1.3 Protective measures - general. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces in the vicinity of 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).

3.1.5 References. The Contractor shall accomplish all tasking in accordance with OEM-guidance and the references listed in Section 2 “References”.

3.2 Inspections, assessments, and groom. The Contractor shall perform inspections, assessments, and grooms of the propulsion system and associated components as follows.

NOTES

The

Contractor shall provide all required personnel, labor, materials, parts, tools, test equipment, test fittings, supplies, consumables, and equipment to accomplish tasking as defined in

Para

3.2 and

Para 3.3.

Required parts are considered those parts that are needed in support of defined tasking below

(Para 3.2 and 3.3).

This would include o-rings, gaskets, miscellaneous hardware, etc requiring replacement in conjunction with planned inspections, assessments, and grooms.

Parts identified as a result of inspections are considered additional and will be supported as “growth”.

Submit a

CFR

for any additional work and/or required parts resulting from planned tasking

(Refer to

Para 3.6).

3.2.1 Main diesel engine and mechanical governor (3608 CAT marine diesel engine and Woodward EPG13 Governor).

· Inspect and adjust governor actuator linkages.

· Inspect cylinder head and components (valves, fuel injectors, valve rotators).

· Inspect camshaft and roller followers.

· Inspect and clean magnetic pickups.

· Inspect and adjust camshaft and crankshaft timing.

· Inspect and adjust valve bridge.

· Inspect and adjust valve lash.

· Inspect and adjust fuel injector timing.

· Synchronize fuel injectors.

· Calibrate engine protection devices.

· Inspect and adjust engine low and high idle speed.

· Inspect and adjust mechanical ballhead set point and alarm.

3.2.2 Digital Marine Speed Control Unit (Woodward 723PLUS Digital).

· Document and save on ship’s laptop and on back-up CD/DVD all initial settings.

· Inspect condition of wiring for damage and connections for tightness.

· Validate system is operating within manufacturer’s specifications, using Servlink / Watch Window PC for set-up and calibrations.

· Perform I/O Verification and Calibration procedures, adjusting parameters as necessary.

· Perform “Dynamics De-Clutched” and “Dynamics Clutched” procedures, adjusting parameters as necessary.

3.2.3 Fuel Rack Position Sensor (Heinzmann SG03 Amplifier).

· Validate system is operating within manufacturer’s specifications.

· Inspect condition of wiring for damage and connections for tightness.

· Verify and calibrate fuel rack position linkages and voltages.

3.2.4 Miscellaneous Support Components.

· Inspect and calibrate all instrumentation (transducers, transmitters, gauges, etc) utilized in support of tasks.

· Verify and record the speed/pitch schedules in MPCMS for each operating mode (“ONE- ENGINE TRANSIT, “TWO-ENGINE TRANSIT”, “ONE-ENGINE MANEUVERING”, TWO-ENGINE MANEUVERING”).

· Inspect and calibrate engine speed indications for all locations (MPCMS, Woodward electronic governor, local panel), verifying readings with a calibrated handheld tachometer.

3.3 Operational testing. Upon completion of all work, the Contractor shall coordinate with the vessel to perform operational testing to validate all work.

3.3.1 Dockside testing (in-port). Perform dockside testing of the propulsion plant to ensure all components have been successfully inspected and groomed. Engines shall be tested in all control modes and configurations to ensure operability in support of underway testing.

NOTE

The dockside testing period may also be used in support of conducting operational grooms of

Para 3.2 in effort to minimize costs and schedule.

The

Contractor shall ensure that any groom tasks scheduled for dockside testing are those that require relatively minor adjustments and do not pose high risk to delaying schedule.

3.3.2 Underway testing. Upon completion of successful dockside testing, perform underway testing (notionally 1-2 days). The underway test plan shall consist of the following:

3.3.2.1 Computer Aided Marine Performance Analysis Report (CAMPAR). Perform a CAMPAR diagnostic test for each MDE in accordance with Caterpillar’s instructions.

NOTES

Historically, the

CAMPAR

test results provided to the

USCG

have omitted specifications

(i.e.

acceptable data ranges for recorded parameters), units of measure, and recorded data.

Contractor shall augment the testing data as necessary to provide this information.

The

USCG

will consider alternate methods of accomplishing engine diagnostic testing provided all data normally collected during the performance of

CAMPAR

testing is obtained.

3.3.2.2 Additional trial data. Record all additional propulsion plant data not explicitly included in the MDE diagnostic (CAMPAR) program. This will include operational data from various MPCMS displays, local analog gauges and meters, and ship course information.

NOTES

Ship’s

Force will assist in data collection efforts as requested by the

Contractor;

however, the use of automated data recorders is encouraged.

The

Contractor shall provide to the

COR

a list of any unobtainable parameters, including reasons for exclusion, prior to the start of testing.

Every effort shall be made to minimize this list.

3.3.3 Adjustments. Based on the results of the operational testing, perform any additional adjustments, readjustments, or grooms required to ensure operation of the propulsion plant.

NOTE

These adjustments are considered to be part of the original tasking and extensions of the scope of

Para 3.2.

For newly identified tasks or additional adjustments not included in the original tasking, refer to

Para 3.4

3.4 On site Troubleshooting Support (Unplanned). Provide onsite troubleshooting service of the specified propulsion system. Such may include participation in dockside or underway performance testing, evaluation, and validation. Document all efforts and changes effected.

3.4.1 The Contractor shall provide a separate price proposal for any additional tasking resulting from inspections, assessments, grooms, testing, casualty response, or required (unplanned) support. Within the proposal, the Contractor shall describe tasking, required labor, and associated costs. No additional work shall be conducted until authorized by the KO or COR. Authorized additional work may include but not be limited to.

· Post Groom on-site repair. Provide onsite troubleshooting service of the specified propulsion system component. Such may include participation in dockside or underway performance testing, evaluation, and validation. Document all efforts and changes effected.

· Engineering support services. The Government may require the conduct of engineering analyses to support system/component design changes, hardware and software modifications, or related efforts. Such analyses may include, but are not limited to feasibility studies, inspection reports, reports of onboard technical surveys, specification development, failure analyses, etc. The Contractor shall submit a proposal to provide such services, when requested by the KO. The Contractor shall perform those services, which are subsequently authorized by the KO

3.4.2 Responsiveness. If the ship is at home port, the technical representative shall arrive at the cutter within 72 hours of receiving authorization from the COR. If the ship is away from home port, initiate travel within 48 hours of receiving authorization from the COR; the technical representative shall arrive at the cutter or designated embarkation point no longer than 48 hours later.

3.5 Remote Troubleshooting Support. Provide remote troubleshooting support to individual cutter crews and support staff upon KO or COR request. Document all requests to include time, date, and a summary of troubleshooting services provided. If a problem is not resolved within 4 hours of the initial request electronically notify the COR immediately.

3.5.1 Responsiveness. . During regular working hours, acknowledge all requests within 1 hour and provide initial technical action for the crew no later than 2 hours after acknowledgement to the COR. If this time frame cannot be met, then notify the COR or KO within 4 hours after acknowledgement and provide a plan for responding.

3.6 Additional Parts. Parts that are identified as requiring replacement, but considered outside the scope of the planned grooms (Refer to Para 3.2), will be addressed via separate task order.

3.6.1 Composite Labor Rate. Composite labor rate is a single cost of labor to include straight, overtime and premium time for all tech levels to include OEM certified technicians. Composite Labor rate will be a set amount agreed upon by the contractor and the Gov. to cover the labor costs associated with Para 3.6 Additional Parts.

4. NOTES

This section is not applicable to this work item.

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