HSCG85-15-Q-P45B45_225_WLB_Propulsion_Groom__Assessment_Specification_(Rev-3 _19_Jun_2015).pdf

U.S. COAST GUARD IDIQ 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)

Rev-3 (19 Jun 2015) Page 2 of 11

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

PROPULSION SYSTEM GROOMS AND ASSESSMENTS

1.0 GENERAL

1.1 Background. The U.S. Coast Guard Surface Forces Logistics Center (USCG-SFLC) –

Icebreaker, Buoy, and Construction Tender Product Line (IBCTPL) is currently supporting efforts intended to improve the system reliability of the Machinery Plant Control and Monitoring System

(MPCMS) installed onboard the 225-ft JUNIPER Class WLB Seagoing Buoy Tender (225 WLB) class.

These efforts include system improvements, component replacements, upgrades, and additional maintenance support for the MPCMS system, components, and related subsystems. In support of these efforts, the USCG-SFLC-IBCTPL requires technical support for conduct of propulsion system grooms and assessments in accordance with Original Equipment Manufacturer (OEM) guidance and directions contained within this specification. Groom and Assessment’s are considered to be a full Propulsion system inspection to include at a minimum, testing, calibrations, and repairs of the Propulsion system and associated components identified in paragraph 1.3 and detailed in Encl 1. The intent of these grooms and assessments is to ensure satisfactory operation of the propulsion plant system and associated equipment prior to MPCMS improvement efforts.

1.2 Scope. The SFLC-IBCTPL requires technical services in support of conducting grooms and assessments of the propulsion system and associated components onboard the 225 WLB class vessels.

The Contractor shall provide all personnel, labor, materials, parts, tools, test equipment, test fittings, supplies, consumables, and equipment to accomplish the following: inspections, assessments, calibrations, grooms, repairs, testing (pre-operational and operational), and associated reports. At a minimum, the USCG requires sixteen (16) grooms onboard 225 WLB vessels, with additional grooms required as the project warrants. Additional services may be required in the support of repairs, on-site technical troubleshooting, offsite / remote troubleshooting (telephone, email), and additional grooms due to planned maintenance and/or unplanned casualty response. These services will be determined by the

Contracting Officer’s Representative and approved by the Contracting Officer on an “as-needed” basis.

The Government may elect to activate any combination of optional items (within the scope of the groom) as necessary to meet required support.

1.3 System Description. The 225 WLB propulsion plant utilizes a single propeller shaft driving a controllable pitch propeller, two marine diesel engine prime movers, and a twin input / single output non-reversible reduction gear. Services for the following equipment and associated conjoining components may be required:

Caterpillar® Model 3608 Marine Diesel Engine - Direct Injected, Turbocharged, Aftercooled

(DITA)

USCG IDIQ 225 WLB Propulsion System Grooms and Assessments

Rev-3 (19 Jun 2015) Page 3 of 11

2.0 APPENDICES AND ENCLOSURES

2.1 Appendices

Appendix A – “List of United States Coast Guard 225’ WLB Buoy Tenders”

2.2 Enclosures

Enclosure (1) - “Perform Propulsion System Groom and Assessment”

3.0 REFERENCES / APPLICABLE DOCUMENTS

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

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

4.0 REQUIREMENTS

4.1 Contractor Personnel

4.1.1 Key Personnel. The Contractor shall provide all labor and materials to meet the requirements of this specification. The Contractor shall submit résumés for proposed “key personnel” (as defined below) for approval by the Government before they are authorized to work

Rev-3 (19 Jun 2015) Page 4 of 11 on this task. Résumés will not be required for management personnel supporting contract activity unless they are directly responsible for providing the required services.

4.1.1.1 Project Manager. The Contractor shall identify a “Project Manager” to serve as the single point of contact (POC) for the Contracting Officer (KO). The Project Manager shall be responsible for all Contractor work accomplished in accordance with this specification. Duties are to include, but not limited to, scheduling, coordination, and general oversight of the project. The Project Manager, or alternate, shall be available to the KO via telephone during the core hours of 0800 and 2000 EST, Monday through Friday, and shall respond to a request for discussion or resolution of technical problems within 1 business day.

The Project Manager shall meet the following requirements:

Minimum of 8 years of program management related experience, including written and oral communication skills

Knowledge and experience with propulsion plant and associated systems

4.1.1.2 Technical Supervisor. The Contractor shall identify a “Technical Supervisor” to serve as the single POC for the Contracting Officer (COR) and the ship’s Engineering

Officer (EO) while conducting grooms and assessments onboard the vessel. The Technical

Supervisor shall be present and responsible for all on-site work accomplished in accordance with this specification. The Technical Supervisor shall ensure that Contractor personnel possess the necessary qualifications to perform the work described and are proficient in the use of the hardware, software, equipment, and tooling required in support of tasking. The

Technical Supervisor shall also ensure that Contractor employees on-site are aware of, understand, and abide by all Coast Guard established rules, regulations, safe work practices, and shall have full authority to act on matters pertaining to the performance of services under this contract. Duties are to include, but not limited to, coordination with the COR serving as the Contractor’s on-site representation, and general “on-site” technical oversight. The

Technical Supervisor, designated in writing, should be available during normal USCG working hours 0800-1600 . The Technical Supervisor shall meet the following requirements:

Minimum of 5 years in support of maintenance and operations of propulsion plant systems and equipment, with special consideration given to USCG applications

Technical expertise pertaining to propulsion plant equipment, including diesel engines, governors, and control systems

4.1.1.3 Certified Technical Representative. The Contractor shall provide the services of a certified Technical Representative (Tech Rep) of the engine OEM (Caterpillar Inc.), who is authorized for the Caterpillar Model 3608 marine diesel engine, to accomplish all tasking pertaining to the MDEs and associated components. The Coast Guard requires the Certified

OEM Tech Rep to be onsite during the entire duration of the scheduled groom and assessment to ensure proper OEM procedures are followed. The Tech Rep will be responsible for the following:

Accessing OEM proprietary information, software, and tools pertinent to tasking in accordance with the specification.

Assisting with proper repair methods, and ensuring compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

Rev-3 (19 Jun 2015) Page 5 of 11

Generating a Computer Aided Marine Performance Analysis Report (CAMPAR) with the diagnostic test data and recommendations for the diesel engines.

Conducting Marine Engine Performance diagnostic testing (CAMPAR or load bank testing), ensuring compliance with OEM, U.S. Coast Guard, OSHA, and other pertinent procedures and standards.

Providing genuine, OEM-approved parts

The Contractor shall provide documentation that the Tech Rep is certified and authorized by

Caterpillar to perform work on the CAT Model 3608 marine diesel engine.

4.1.1.4 Key Personnel Replacement. Before replacing any individual identified as

“key personnel”, the Contractor shall notify the KO no less than 15 business days in advance, submitting written justification for replacement and providing the name and qualifications of any proposed replacement(s). Any proposed replacement shall possess qualifications equal to or superior to those of the personnel being replaced. The Contractor shall not replace “key personnel” without written consent from the Contracting Officer. The Government may designate additional Contractor personnel as Key prior to the specification date of award.

4.1.2 Citizenship. All Contractor employees in performance of this contract shall be citizens of the United States, or if aliens, shall be legal residents of the United States. Proof of residency shall be provided to the KO upon request.

4.1.3 Employee Conduct. Contractor employees shall comply with all applicable Government regulations, policies and procedures (e.g., fire, safety, sanitation, environmental protection, security, etc) when visiting or working at Government facilities. The Contractor shall ensure employees present a professional appearance at all times and that their conduct shall not reflect discredit on the United States, the Department of Homeland Security, or the USCG.

4.1.4 Employee Identification. Contractor employees working on-site at Government facilities shall wear a company issued identification badge. All Contractor employees shall identify themselves as Contractors when their status is not readily apparent and display their badge in plain view above the waist at all times.

4.1.5 Removing Employees for Misconduct or Security Reasons. The Government may, at its sole discretion, direct the Contractor to remove any Contractor employee from Government facilities for misconduct or security reasons. Removal does not relieve the Contractor of the responsibility to continue providing the services required in this specification. The Government will provide the Contractor with an immediate written explanation of the request to remove the employee through the KO.

4.1.6 Conflict of Interest. The Contractor shall not employ any person who is an employee of the United States Government if that employment would cause or appear to cause a conflict of interest.

4.1.7 Security Clearance / USCG Installation Access. Security clearances are not required to perform any work under this specification; however, the Contractor shall ensure personnel comply with all installation security requirements. The Contractor shall supply a list of all employees who may be required to perform work under this specification and periodically update that list. Prior to each ship visit (no later than 10 business days before scheduled arrival); the

Contractor shall submit information on visiting employees to the COR. For cutters berthed at a

Department of Defense or foreign government military facility, the KO will provide instructions

Rev-3 (19 Jun 2015) Page 6 of 11 on the method by which the cutter crew will assist the Contractor’s representatives in meeting facility access requirements at the time the Contractor is tasked.

4.1.8 Work Hours

4.1.8.1 Contractor will define work hours to include straight (regular), overtime, and premium time.

4.1.8.2 Federal Holidays. Holidays applicable to this contract are as follows:

Holiday Date / Day

New Year’s Day 1 January

Martin Luther King Day Third Monday in January

President’s Day Third Monday in February

Memorial Day Last Monday in May

Independence Day 4 July

Labor Day First Monday in September

Columbus Day Second Monday in October

Veteran’s Day 11 November

Thanksgiving Day Fourth Thursday in November

Christmas Day 25 December

4.2 Performance. The Contractor shall conduct the groom and assessments in accordance with the

Project Plan (refer to Section 5.1 “Project Plan”), tailored “as necessary” to meet the conditions of the tasking.

4.2.1 The Government will attempt to issue a task order at least 45 days prior to scheduled visit. The KO will order the groom/assessment visit, in writing, at least fourteen (14) days in advance of scheduled arrival (21 days for vessels located outside the continental U.S.). The

Government reserves the right to request an expedited groom visit due to emergency repair response. The Contractor shall acknowledge, in writing, the groom order within five (5) days of receipt of the order. Below is a notional timeline of performance milestones for a scheduled groom visit.

DAYS BEFORE GROOM ACTION

14 Days (21 days for

OCONUS)

USCG provides written notification of pending groom to the

Contractor

9 Days Contractor will acknowledge order within 5 days of receipt of written notification and provide vessel Project Plan to KO

4.2.2 Coast Guard personnel will operate all shipboard equipment, under the guidance of the

Contractor, in support of tasking. The Contractor shall be responsible for all adjustments, calibrations, and actions required in accordance with the specification.

4.2.3 The Contractor shall actively engage with the COR to ensure adequate communications are maintained throughout the conduct of the groom. This is also to ensure “crew familiarization” with the equipment and groom procedures used in support.

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4.2.4 The Contractor shall actively engage with the COR to coordinate work timelines with grooms of other systems. .

4.3 Place of Performance. The majority of services will be performed on-board the cutter, at the respective cutter’s homeport (INCONUS and OCONUS). Refer to Appendix A, “United States Coast

Guard 225’ Buoy Tenders” and http://www.uscg.mil/datasheet/225wlb.asp for additional information.

Work will be conducted “pier-side” and “underway”, with operational testing to be conducted underway within the cutter’s local area of responsibility (AOR). Underway tasking will not require overnight stay onboard the cutter. In some instances, services may be required while the cutter is moored at an alternate location or dry-docked, either at a commercial or Government facility.

4.4 Period of Performance. The period of performance for this effort will consist of a base year performance period with four one-year option periods. The decision to exercise any option shall be at the sole discretion of the KO and shall be exercised in writing. The tentative quantity for grooms and assessments is as follows (Note: This is subject to change due to vessel availability and/or funding availability):

Base Year: 4 vessels

Option Year 1: 6 vessels

Option Year 2: 5 vessels

Option Year 3: 1 vessel

Option Year 4: To Be Determined

4.5 Travel. Contractor travel is required in support of tasking.

4.5.1 All required travel in support of grooms and assessments will be paid in accordance with the fixed pricing. In the event that travel is required to additional locations other than 225 WLB homeports, or for travel in support of other tasking (i.e. meetings, casualty repairs), the COR will request a comprehensive quotation for travel in advance of the trip.

4.5.2 Price quotes for airfare, per diem, ground transportation, and other travel expenses will be made in accordance with Joint Travel Regulations (JTR), as amended.

4.5.3 Contractor personnel will be required to hold a valid U.S. Passport and area clearance to visit vessel(s) located OCONUS.

4.6 Equipment. No Government-furnished property or equipment is anticipated to be provided in support of tasking. The Contractor shall provide all materials, parts, tools, test equipment, test fittings, supplies, consumables, and equipment required. In the event Government-furnished equipment is provided, the equipment shall be used for official Government business-only, to the extent necessary to complete the requirements of this specification.

4.7 Meetings. The Contractor shall attend meetings and conferences as required by the KO and/or

COR, providing a written summation of all meetings and conferences.

4.7.1 Kick-Off Meeting. The Contractor shall attend a Kick-Off meeting with the KO, COR, and Cutter POC to discuss specification objectives (no later than 5 business days after the date of award).

http://www.uscg.mil/datasheet/225wlb.asp

Rev-3 (19 Jun 2015) Page 8 of 11

4.7.2 Progress Meetings. The Contractor shall participate in Coast Guard progress meetings

During these meetings, routine project management issues will be addressed. If discussions are required to address contract performance issues, they will be initiated by the Contractor, KO, or the COR.

4.8 Briefings. The Contractor shall provide oral briefings to the COR and Cutter POC to ensure successful coordination of all tasking.

4.8.1 Arrival Brief. At the task order level, the Contractor shall provide an arrival brief within

3 days or upon arrival. This brief will consist of overview of the Project Plan (refer to Section 5.1

“Project Plan”) and be used as a communication vehicle between the vessel and Contractor for planning purposes. Any issues, concerns, or additional tasking resulting from the brief shall be provided to the COR at the conclusion of the arrival brief. No additional work outside the original scope of the Project Plan is authorized unless approval is received by the KOvia contact modification.

4.8.2 Departure (“Out”) Brief. Upon completion of each groom and assessment visit, the

Contractor shall provide a departure (out) brief on the last day of the groom. The Contractor shall provide a draft Trip Report (refer to Section 5.2 “Trip Report”) to assist in discussion. The COR will sign the bottom of the draft report to acknowledge its receipt and be provided a copy by the

Contractor. Signature on the draft report will attest that all work was performed in accordance with the Project Plan and all recorded data was within acceptable parameters.

5.0 DELIVERABLES

5.1 Project Plan. The Contractor shall provide a Project Plan that includes detailed methodology, procedures, and steps to meet all the objectives of the specification. The draft Project Plan shall be provided to the KO at the Kick-Off Meeting for review and comment. Government comments will be provided to the Contractor from the KO (5) business days after the receipt of the Project Plan. The

Contractor shall provide a final Project Plan to the KO no later than five (5) business days after receipt of

Government comments. This Project Plan will serve as the basis for all grooms and assessment trips, provided to the vessel in advance of Contractor arrival, for planning purposes. Additionally, the Project

Plan will be used in support of vessel briefings during Contractor groom and assessment visits.

The Project Plan shall address all aspects of the propulsion groom and assessments and include the following:

5.1.1 Pre-Groom Survey. A detailed checklist and questionnaire to be completed by USCG vessel personnel (14) business days in advance of the scheduled groom visit. The intent of the

Pre-Groom Survey is to provide early identification of potential issues and allow for proper planning of additional work to ensure a successful groom visit. The Contractor shall review the completed surveys and provide recommendations, including any additional parts or tasks that fall outside the planned Groom and Assessment Procedure, at the time of order.

5.1.2 Groom, Assessment, and Testing Procedure. The written procedure to be used in support of inspection, assessments, calibrations, grooms, and testing (pre-operational and operational) of the propulsion system, as defined in Enclosure (1). The procedure shall include all steps required in support of tasking, including identification of required parts, pass/fail criteria, operational requirements, and expected durations. Specific step-by-step instructions may be omitted provided a higher-level reference source exists detailing the procedure to be used (i.e.

“Perform engine tune-up in accordance with …” in lieu of providing detailed tune-up procedure).

Rev-3 (19 Jun 2015) Page 9 of 11

However, any clarifications or additional instructions required shall be included in the procedure.

Additionally, the Contractor shall include any additional tasks (not explicitly stated in the specification) that are deemed necessary by the Contractor to ensure satisfactory grooming of the propulsion system and related components.

5.1.3 Schedule. A sequencing document (Gantt chart), based on the “Groom, Assessment, and

Testing Procedure”, that provides the schedule and sequencing for all planned inspections, assessments, calibrations, grooms, and testing (pre-operational and operational) to be performed.

The schedule shall be based on a daily-task breakdown schedule (Day 1, Day 2, …) and include expected durations of each task (hours), interdependencies, prerequisites, resources, required equipment conditions, required coordination with system grooms outside the scope of this specification, and any additional support required from the vessel. The Contractor may expend the elements of the schedule to include any additional information to ensure satisfactory completion of tasking.

5.1.4 Trip Report Template. A standardized report format to be utilized upon completion of each vessel groom and assessment (Refer to Section 5.2).

5.2 Trip Report. Upon the completion of each groom and assessment, the Contractor shall submit a trip report summarizing all work accomplished for the applicable ship visit. The intent of the trip report is to provide a comprehensive field report that includes results of inspections, assessments, data, repairs, testing, and recommendations pertaining to tasking.

5.2.1 The report shall include all work accomplished, results of inspections and assessments, actions taken, parts utilized, data collected, testing results, and recommendations based on the tasking.

5.2.2 All data collected shall be included in report. This includes all operational testing data

(trial logs), as well as measurements resulting from inspections, assessments, and adjustments. Where data values are recorded, the report shall include the acceptance values used in making acceptability determination, in addition to the values recorded. For values where there exists no acceptable range, these values must be annotated with “Info Only”.

5.2.3 For visual inspections and condition assessments (i.e. pass/fail), the use of digital pictures attesting to condition of components inspected is required. These, in conjunction with a narrative, will be used to document acceptability. Visual inspections shall be accomplished using the following guidelines:

5.2.3.1 OEM’s relevant guidance and reference documents for inspection and assessment shall be utilized and referenced accordingly (including Publication Number, Publication Date, and Title). For Caterpillar applications, this would include the appropriate documents listed in the latest published version of Caterpillar Media SEBF8029 “Index of Publications on

Reusability or Salvage of Used Parts”.

5.2.3.2 List of all instruments (make and model), including proof of calibration certification, of equipment used in support.

5.2.3.3 List of all parts and components inspected, including part numbers and serial numbers (as applicable) for machinery history and configuration tracking purposes.

5.2.3.4 All readings and measurements (clearances, tolerances, etc) recorded and used in support of OEM-reusability determinations.

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5.2.3.5 Recommendations for re-use, replacement, repair, or renewal of inspected components.

5.2.4 A parts list shall be provided (including part number information and nomenclature) of any parts replaced resulting from work accomplished.

5.2.5 The finalized trip report shall be provided electronically to the COR within ten (10) business days after completion of the groom at the task order level. A scanned copy of the signed draft trip report shall be provided with the final submission.

5.3 Format. The Contractor shall provide all deliverables in electronic format with read/write capability, using applications that are compatible with Coast Guard Standard Workstation III (Windows

Vista, Microsoft Office, and Adobe Acrobat applications).

6.0 QUALITY ASSURANCE

6.1 The Contractor shall establish and maintain a Quality Assurance (QA) Plan to ensure that all tasks are completed in accordance with the contract, specification, and applicable references. The QA

Plan shall provide the Government a complete understanding of the actions the Contractor shall put into place and be made available immediately after award.

6.2 The Contractor shall use only new, OEM-approved parts for accomplishments of tasks. If new

OEM-approved parts are not available the Contractor shall contact the KO and/or COR for approval of remanufactured parts.

7.0 DEFINITIONS AND ACRONYMS

COTR Contracting Officer’s Technical Representative

DPS Dynamic Positioning System

ECCC Engineering Control Center Console

EO Engineering Officer

IBCT Icebreaker, Buoy, and Construction Tender Product Line

INCONUS Inside the Continental United States

KO Contracting Officer

MDE Main Diesel Engine

MPCMS Main Propulsion Control and Monitoring System

OCONUS Outside the Continental United States

OEM Original Equipment Manufacturer

POC Point of Contact

SFLC Surface Forces Logistics Center

USCG United States Coast Guard

WLB Seagoing Buoy Tender (JUNIPER Class)

Rev-3 (19 Jun 2015) Page 11 of 11

Appendix A: LIST OF UNITED STATES COAST GUARD 225’ WLB BUOY TENDERS

225 WLB “A-Class”

Cutter Hull Number Homeport MDE Serial Numbers

USCGC JUNIPER WLB 201 Newport, RI 8LL00001, 8LL00002

USCGC WILLOW WLB 202 Newport, RI 8LL00003, 8LL00004

USCGC KUKUI WLB 203 Honolulu, HI 8LL00005, 8LL00006

USCGC ELM WLB 204 Atlantic Beach, NC 8LL00007, 8LL00008

USCGC WALNUT WLB 205 Honolulu, HI 8LL00009, 8LL00010

225 WLB “B-Class”

Cutter Hull Number Homeport MDE Serial Numbers

USCGC SPAR WLB 206 Kodiak, AK 8LL00011, 8LL00012

USCGC MAPLE WLB 207 Sitka, AK 8LL00013, 8LL00014

USCGC ASPEN WLB 208 San Francisco, CA 8LL00015, 8LL00016

USCGC SYCAMORE WLB 209 Cordova, AK 8LL00018, 8LL00019

USCGC CYPRESS WLB 210 Pensacola, FL 8LL00020, 8LL00021

USCGC OAK WLB 211 Charleston, SC 8LL00022, 8LL00023

USCGC HICKORY WLB 212 Homer, AK 8LL00024, 8LL00025

USCGC FIR WLB 213 Astoria, OR 8LL00026, 8LL00027

USCGC HOLLYHOCK WLB 214 Port Huron, MI 8LL00028, 8LL00029

USCGC SEQUOIA WLB 215 Apra Harbor, Guam 8LL00030, 8LL00031

USCGC ALDER WLB 216 Duluth, MN 8LL00032, 8LL00033

* NOTE: The 225 WLB “B-Class” is equipped with “IMO-compliant” MDEs, provided as an upgrade to the “A-Class” configuration. Both configurations are Mechanical Unit Injection (MUI) (i.e. fuel injectors); however, various components are of different configuration to accommodate the difference.

Enclosure (1) to “USCG IDIQ 225 WLB Propulsion System Grooms and Assessments”

Rev-3 (19 June 2015) Page 1 of 6

20200_MWC_1014_225 WLB

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

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

Rev-3 (19 June 2015) Page 2 of 6

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

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

Rev-3 (19 June 2015) Page 3 of 6

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

1. 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.

2. 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).

Rev-3 (19 June 2015) Page 4 of 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.

Rev-3 (19 June 2015) Page 5 of 6

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

1. 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.

2. 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

1. Ship’s Force will assist in data collection efforts as requested by the Contractor; however, the use of automated data recorders is encouraged.

2. 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 .

Rev-3 (19 June 2015) Page 6 of 6

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.