HSCG85-15-R-P45865_Draft_SOW.pdf

23303_WFS_1214_420

MDE Technical Representative and Shop Overhaul Services

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to provide the services of a certified repair facility and Technical Representative to oversee maintenance of the main diesel engines.

1.2 Government-furnished property (GFP).

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y Complete Cylinder Head

Assy. KS27100 plus all ancillary equipment and seals required for installation

Not Assigned Yet (WPNXXXXX) 12 $60000

N Main Bearing Kit KS12100 8 $1300 N Resilient Mounts 740386 76 $1400 N Cam Bearing Set KS42170 8 $400 N Cam Bearing Thrust Half KS42180 4 $500 N Stud, Short, Connecting Rod KS33230 36 $155 N Stud, Long, Connecting Rod KS33209 36 $250 N Piston Ring (Chrome-

Ceramic), Upper

KS34406 12 $1325

N Piston Ring, intermediate KS34401 24 $300 N Piston Ring , Grooved Oil

Scraper

KS34420 12 $350

N Big End Bearing Kit KS33260 18 $850 N **Bearing Bushing – Oil

Pump

KS 71018 8 $840

N **Packing for KS 71039 – Oil Pump

KS 71040 2 $35.40

N **Joint for KS 71044 – Oil Pump

KS 71045 2 $7.74

N Seal Kit, Geislinger SPG410214 1 $3287 N D-Ring, Cylinder Liner KS21426 12 $82 N Joint for KS67603 – CA

Wastegate

KS67612 4 $10

N Sealing Piece – CA Wastegate

KS67609 4 $10

N Guide Ring for KS67604 – CA Wastegate

KS67616 8 $600

N Piston Sealing Ring for KS67604 – CA Wastegate

KS67617 4 $15

N Joint for KS67601 – CA Wastegate

KS67640 4 $15

N Bushing – Governor Linkage KS58126 20 $25

1.3 Period of Performance. The main engine work will be performed from date of award to 17 April 2015.

1.4 Place of Performance: USCGC HEALY at Base Seattle 1519 Alaskan Way S., Seattle, WA 98134.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 420-WAGB 801-1, Rev -, Booklet of General Drawings

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 5016, 01-NOV-03, S9233-Dh-MMC-010 - Main Diesel

Engine (MDE) (Volume 1) Coast Guard Technical Publication (TP) 5017, 01-NOV-03, S9233-Dh-MMC-020 - Main Diesel

Engine (MDE) (Volume 2) Coast Guard Technical Publication (TP) 5018, 01-NOV-03, S9233-Dh-MMC-030 - Main Diesel

Engine (MDE) (Volume 3) Coast Guard Technical Publication (TP) 5019, 01-NOV-03, S9233-Dh-MMC-040 - Main Diesel

Engine (MDE) (Volume 4) Coast Guard Technical Publication (TP) 5020, 01-NOV-03, S9233-Dh-MMC-050 - Main Diesel

Engine (MDE) (Volume 5) Coast Guard Technical Publication (TP) 5021, 01-NOV-03, S9233-Dh-MMC-060 - Main Diesel

Engine (MDE) (Volume 6) Coast Guard Technical Publication (TP) 5022, 01-NOV-03, S6265-A4-MMC-010 - Main

Generators, Synchronous Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative. The Contractor shall provide the services of a certified Technical Representative (Tech Rep), who is familiar with - the Sulzer 12ZAV40S Diesel Engine, manufactured by Wartsila Defense Inc, to accomplish the following tasks – on site:

• Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

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

• Technical Representative shall be present for all disassembly, inspection, and reassembly of the Diesel Engine components.

3.1.2.1 The Contractor shall provide a Tech Rep that is a certified Mechanical Superintendant of Wartsila.

3.1.2.2 The Contractor shall submit the name of the Tech Rep to the Contracting Officer’s Representative ( COR) at the award of the contract.

3.1.2.3 The Contractor shall be required to have this Technical Representative present during the period of performance during normal work hours. Work hours will be Monday through Friday, 0700-1600.

3.1.3 Protective measures.

Not applicable.

3.1.4 Interferences.

None.

3.2 General Information

3.2.1 The HEALY is equipped with four (4) Sulzer 12ZAV40S main diesel engines (MDEs). Each MDE is attached to a propulsion generator.

3.2.2 The work to be accomplished on each main diesel engine is detailed in Table 3.2.2

TABLE 3.2.2

MDE No. 1 (Engine Serial Number 2025/740386) Work Item Amplifying Info Tech Pub Reference

Main Bearing Inspection/Renewal #1 & #3 1201-1/A1

Cam Bearing Inspection/Renewal A4 & B5 4201-1/A1

Big End Bearing Inspection/Renewal ALL 3302-1/A1 Cylinder Head Renewal – install new injection valves ALL 2701-1/A1 Cylinder Liner Inspection, Honing & Reseal ALL 2105-1/A1 Piston Inspection & Piston Ring Renewal ALL 3401-1/A1 Crank Counterweight Inspection 3101-3/A1 Crankweb Deflection 3101-1/A1 Over speed Trip Inspection/Overhaul 5303-1/A1

Lube Oil Pump Inspection/Overhaul – Renew Bushings 7101-1/A1

Geislinger Coupling Inspection/Overhaul Appendix D “Auxiliary Equipment” Charge Air Waste Gate Overhaul/Calibration

6735-1/A2

Renew Governor Linkage Bushings

None

MDE No. 2 (Engine Serial Number 2026/740387) Work Item Amplifying Info Tech Pub Reference

Main Bearing Inspection/Renewal #1 & #3 1201-1/A1 Cam Bearing Inspection/Renewal A3 & B5 4201-1/A1 Big End Bearing Inspection/Renewal A4 & B1 3302-1/A1 Crankweb Deflection 3101-1/A1

Crank Counterweight Inspection 3101-3/A1

MDE No. 3 (Engine Serial Number 2027/740388)

Main Bearing Inspection/Renewal #1 & #5 1201-1/A1 Cam Bearing Inspection/Renewal A4 & B0 4201-1/A1 Big End Bearing Inspection/Renewal A3 & B2 3302-1/A1 Resilient Mount Renewal All Crankweb Deflection 3101-1/A1

Crank Counterweight Inspection 3101-3/A1

MDE No. 4 (Engine Serial Number 2028/740389)

Main Bearing Inspection/Renewal #1 & #5 1201-1/A1 Cam Bearing Inspection/Renewal A4 & B0 4201-1/A1 Big End Bearing Inspection/Renewal A3, A5, B1, B2 3302-1/A1 Resilient Mount Renewal All Crankweb Deflection 3101-1/A1

Crank Counterweight Inspection 3101-3/A1

3.2.3 Labor to accomplish this work will be provided by the Coast Guard Naval Engineering Department Seattle, HEALY Port Engineers, and Ships force.

All engine work is to be conducted in accordance with Coast Guard Technical Publication (TP) 5018, 01- NOV-03, S9233-Dh-MMC-030 - Main Diesel Engine (MDE) (Volume 3) and applicable CG Maintenance Procedure Cards.

All work on Geislinger Coupling shall be conducted in accordance with NAVSEA Tech Pub S9233-DH- MMC-050 using all new soft parts (o-rings, gaskets, etc) provided as GFP.

Any parts that are being reused shall be installed in the same location from which they were removed.

Other contractors are installing significant upgrades to the Machinery Plant Control and Monitoring System (MPCMS) for the propulsion system controls. Coordination with these contractors and the COR will be paramount for a successful completion of this work and the MPCMS upgrades.

3.3 General Intent and Instructions

3.3.1 Work in this specification item will be performed under the direction of the technical representative and will follow procedures in the manufacturer's technical manual.

The contractor shall submit a comprehensive report containing the results of all inspections and work accomplished. Include all measurements taken compared with allowable clearance readings and a written assessment of the bearing and component wear. Include high resolution color photos of each bearing removed and any item presenting unusual wear. One electronic format (CD or DVD) and two color hard copies of the report shall be delivered to the COR within two weeks of completion of sea trials.

3.3.2 #1 Geislinger Coupling overhaul: Prior to removing the coupling, measure and record coupling alignment and length over flanges and submit a CFR.

3.3.2.1 Measure spring pack wear upon disassembly of coupling.

3.3.2.2 After installing overhauled coupling, measure and record coupling alignment and length over flanges and submit a CFR.

3.3.3 Resilient Mount Renewal: Prior to mount renewal, check generator-engine alignment and measure crankshaft deflections. Submit results via CFR. Once new mounts are installed, check generator-engine alignment and measure crankshaft deflections. Submit results via CFR.

3.3.3.1 After all mounts are installed and a two week ‘settling’ time has passed, use the appropriate measuring device to measure, record, and submit via CFR the following for each new mount:

• Ambient Generator Room Temperature

• Vertical Clearance for each mount on the engine and generator side

• Horizontal Clearance for each mount on the engine and generator side

3.4 Engine Parts, Gaskets, O-Rings, Etc.

3.4.1 It is the Government's belief that only the Original Equipment Manufacturer (OEM) or his authorized representative possesses the necessary technical information, engineering data, and specifications required to manufacture and/or re-qualify components (parts) to ensure form, fit, and function compatibility with existing equipment. The Government DOES NOT possess the necessary drawings, technical specifications, etc., to supply with this specification. This information is proprietary to the OEM. For these reasons, only components produced by the OEM, whether new or reconditioned, will be accepted.

3.5 General Conditions

3.5.1 Specialized tools listed in the manufacturer's technical instructions which are required to remove the bearing shells for inspection are available aboard the vessel.

3.6 Inspection Procedures For GFM Engine Parts

3.6.1 The Coast Guard shall provide the contractor the new engine parts listed as GFP in sufficient time to allow the contractor to complete the inspection procedure for the engine parts. The new engine parts will be available for inspection when the contract starts.

3.6.1.1 The technical representative shall complete an inventory of all GFP engine parts in the presence of the Coast Guard Inspector. Submit a CFR documenting the results of the inspection.

NOTE

The intent of this procedure to identify any parts discrepancies and to allow enough time to provide those parts, prior to the start of the new engine installation.

3.7 Acceptance Testing

3.7.1 Test Performance – All acceptance tests shall be performed in the presence of the Coast Guard Inspector. Provide a written report to the Coast Guard Inspector of all test results within one week of test completion.

3.7.2 Upon completion of maintenance work, the engine shall be tested in accordance with OEM technical publications. The contractor shall submit a testing schedule to the COR, for approval, no later than 30 days prior underway trials. Underway trials are tentatively scheduled for 28May 2015; expect trials to last 3 days.

3.8 Shop overhaul work. The Contractor shall provide an OEM certified repair facility to overhaul, assemble, and certify the parts and assemblies listed in table 3.2.2, using the provided GFP.

TABLE 3.8

Work Item Quantity Tech Pub Reference Cylinder Head assembly and testing 12 2701-1/A1 Cylinder Liner Inspection, Honing & Reseal 12 2105-1/A1 Piston Inspection & Piston Ring Renewal 12 3401-1/A1 Lube Oil Pump Inspection/Overhaul – Renew Bushings 1 7101-1/A1

Geislinger Coupling Inspection/Overhaul 1 Appendix D “Auxiliary Equipment”

4. NOTES

This section is not applicable to this work item.

MDE Technical Representative and Shop Overhaul Services