Attachment_1_SOW_Design_Study_replace_WMSL_gen_rev_Redacted.pdf

COAST GUARD WMSL GENERATOR REPLACEMENT DESIGN STUDY

STATEMENT OF WORK

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1. PURPOSE:

1.1. Background: The 418ft WMSL Class cutters have experienced numerous over-temperature and other service degradation events of the generator bearing system within their Ship Service Diesel Generator (SSDG) which have required early replacement of bearings, bearing housing brackets, seals, caps, and Remote Temperature Devices (RTD’s). These events have put a burden on cutter forces and support forces with increased time and cost for repairs and maintenance, SOW_Design_Study_replace_WMSL_gen_rev1 Page 2 of 12

Figure 2

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1.3. Generator failure characteristics: The generator failure events happened at less than 10,000 operational hours which is well below the 1,000,000 L10h rated life of the bearings.

(Note the Coast Guard’s RCA (Root Cause Analysis) report “National Security Cutter Generator Bearing Casualties RCA March 2015” is available from KO or COR.) These generator usage losses are characterized by various aspects, including:

1.3.1. Over-temp alarms and shut-downs

1.3.2. Bearing temperatures increasing significantly with increased generator load such as when shifting from paralleled to singled-up usage

1.3.3. Bearing operating temperature increases approximately 1:1 with seawater coolant temperature such as when sailing from cooler waters to sub-tropical or tropical waters

1.3.4. Bearing outer race spinning in housing

1.3.5. Non-Driven End (N.D.E.) and Driven End (D.E.) bearing housing wear requiring replacement of housings, bearings, and coupling hub

1.3.6. An instance on CGC-WAESCHE SSDG#2 of D.E. bearing seizing and spinning on inner race causing extreme heat resulting in grease fire, damage to rotor bearing seat, rotor replacement due to out of TIR, and replacement of coupling hub

1.3.7. Existing bearing temperature condition monitoring not giving reliable and timely warning and/or trending that the grease or bearing system is degrading and in need of service

1.3.8. N.D.E. (Non-Driven End) bearing outer race not floating axially in housing resulting in increased bearing temperature from axial loading

1.3.9. Lip seal type and material not appropriate for rpm causing heating of bearing and introduction of seal and metallic seal debris.

1.3.10. Worn or damaged lip seals cannot be replaced with an in-kind seal without removal and replacement of coupling hub

1.3.11. Re-greasing passage does not provide grease to opposite row of rollers, and does not purge rollers of wear particles

1.3.12. Seal location and orientation (lips facing inward) is not preferred for grease lubrication

1.3.13. Inaccessibility to N.D.E. bearing housing to take grease samples

1.3.14. Replacement of D.E. bearing requires cutting off and replacing coupling hub, and requires alignment check

1.3.15. Over-temping of bearings has been so sudden that the generator goes off-line before the back-up generator can come on-line causing the cutter to have a black-out

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1.4. As-delivered Bearing System Description:

1.4.1. The WMSL Class generator is rated at 1360kW,

1.4.2. The as-built bearing system components and aspects are:

2-bearing machine; driven end (D.E.) housing (in conjunction with bearing caps) retains the forward bearing axially, radially, and rotationally as the “held-bearing”, and the non-driven end (N.D.E.) retains the rear bearing radially and rotationally but allows it to float axially as the “non-held” or “floating” bearing; fit between bearing outer-race and housing and between inner-race and shaft; bearing end retainers (or caps); bearings are of the anti-friction (rolling) self-aligning two-row spherical roller bearing type vice plain (sliding) bearings; bearing internal clearance; imposed radial and axial loads;

1800 rpm operational speed; bearing-specific speed parameter; bearing heat generation; bearing heat balance; bearing cooling system; bearing condition monitoring system; generator cooling system, bearings are grease lubricated; grease type; grease operating life; re-greasing interval; lubricant condition monitoring; grease retention; seal heat generation.

1.5. Objectives: The overall objective of this study is to obtain alternate solutions of the existing generator system configuration without, changing the performance or interfaces, to the minimum extent possible. The specific objectives are:

1.5.1. To improve the overall reliability of the generator to 95% uptime, with full capability of 100% rated load.

1.5.2. To maintain the current generator technical performance requirements with minimized changes to the current interfaces and other equipment.

1.5.3. To decrease maintenance requirements of periodicity, time, skill-set, and sensitivity to no more than that which USCG experiences on other cutter classes or better.

1.5.4. To reduce TOC (Total Ownership Cost) to a minimum while retaining performance objectives (reliability, serviceability, capability, etc.as listed in requirements below)

1.5.5. To reduce overhaul periodicity, cost, and requirements, such that mean time between overhauls (MTBO) of the generator is greater than 25,000 hours, and the bearing life rating L10h is greater than 40,000 hours, the hours and skill-set required for overhaul are minimized.

1.5.6. To ensure that spare parts shall be available to USCG for the life of the vessel. Assumed to be thirty

(30) years after delivery of last hull.

1.5.7. To have solutions proffered that are well proven with tens of thousands of successful operational hours for similar machines under similar load, operating hours, and environment.

1.5.8. To have progress reports and status meetings during the period of performance to facilitate technical dialog between the contractor and USCG.

2. Requirements: To achieve the stated objectives the Contractor shall provide to the Government a study with the following:

2.1. Contractor shall present the problems that led to the above listed issues. Direct requests for additional information to KO or COR.

2.2. Contractor shall provide alternative solutions to resolve the problems, including:

2.2.1. Bearing System Replacement: (3) alternate Specifications and Evaluation (S&E) for replacement of the bearing system and related items

2.2.2. Whole-scale Generator Replacement: (3) alternate S&E for whole-scale replacement of the existing generators and any auxiliaries

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2.2.3. S&E comparison table and narrative description of all alternative solution variants, including: initial acquisition cost; cost and methodology to remove components from vessel and to install new components; cost to maintain and overhaul; total ownership cost (TOC)

2.3. Supportability:

2.3.1. For each individual alternative solution provided, the Contractor shall provide evidence of proven track records of reliability under similar load, operating hours, and environment.

2.3.1.1. In addition, the Contractor shall price out an alternate 5-year service agreement where Contractor is responsible for all repairs.

2.4. Each of the (3) alternative S&E’s shall include a sleeve-bearing system variant and an anti-friction (rolling) bearing system variant.1

2.5. The alternate specifications shall meet the requirements of the existing WMSL SSDG specification (specific to the generator) so that the replacement generator shall meet fit, form, and function of the existing generator The alternates shall be interchangeable with respect to electrical and mechanical interface and functionality, including, but not limited to:

2.5.1. Piping connections

2.5.2. Mounting to skid

2.5.3. Coupling to engine

2.5.4. Electrical connections

2.5.5. Control system communication/signals with CGMCS

2.5.6. Exhaust system

2.5.7. Ventilation

The Contractor shall document in the S&E deliverable the interfaces, functionality, and specifications of the existing generator, and that of the (3) alternate generators.

2.6. The Government’s top evaluation criteria is lowest TOC (Total Ownership Cost) which includes high reliability and low maintenance and overhaul needs, rather than lowest initial purchase price.

2.6.1. The expected life of the vessel is 30 years, and the expected life of the generator is likewise 30 years. For estimating purposes, assume 2,500 hours of annual operation per generator.

2.6.2. The Contractor shall provide bearing system dimensions, including dimensional changes from existing configuration, within the S&E along with modifications needed to accommodate such dimensional changes.2

2.7. The Alternate Generator variants specifications shall include the following improvements:

2.7.1. Bearing System:

2.7.1.1. Bearing types-

1 The Government acknowledges that the sleeve bearing system replacement solution would require a replacement or modification of the rotor.

2 The Government acknowledges that the requirement of improved bearing system life may necessitate an increase in bearing system dimensions which might increase the length of the generator.

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2.7.1.1.1. Anti-friction (rolling) bearings (Figure 5 for illustrative purposes only)

Figure 5

2.7.1.1.1.1. Spherical roller bearings shall not be incorporated, unless the Contractor can provide documentation that the speed factor and other aspects meet requirements of USCG and of bearing manufacturer.

2.7.1.1.1.2. Anti-friction bearing considerations shall include deep groove ball bearings, cylindrical roller bearings, self-aligning cylindrical roller bearings, split self-aligning cylindrical roller bearings, and toroidal bearings.

2.7.1.1.1.3. Housings shall include RTD in load zone for connection to engine ECM and to MPCMS for remote monitoring, and a second RTD for local monitoring. Readings are required to be within 2ºC of each other.

2.7.1.1.1.4. Housing shall have connection puck(s) for vibration and ultrasonic monitoring.

2.7.1.1.1.5. Bearing seat fit for both inner and outer race shall be stated and justified.

2.7.1.1.1.6. Housing seat wear mitigation shall be addressed.

2.7.1.1.1.7. Replaceable bearing sleeves, if included in an alternative solution, shall be described.

2.7.1.1.1.8. Method of ensuring unrestrained float of non-locating bearing shall be demonstrated.

2.7.1.1.1.8.1. If non-locating bearing does not float internally, then contractor shall demonstrate design to mitigate bearing binding or rotating in housing, wear of housing, fretting, etc.

2.7.1.1.1.9. Specific speed factor

2.7.1.1.1.9.1. Bearing specific speed factor shall be provided, as well as the bearing manufacturer’s recommended limits. Specific speed factor is defined as dm * 1800rpm, where dm = mean diameter of bearing.

2.7.1.1.1.9.2. Bearing chosen shall have a specific speed factor below 75% of bearing manufacturer’s maximum recommended limit.

2.7.1.1.1.10. Bearing system life

2.7.1.1.1.10.1. The L10h life shall be at least 40,000 hours.

2.7.1.1.1.11. Life adjustment factors shall be addressed for contamination level – including contamination generated within the bearing housing as well as contamination outside of the housing – bearing temperature, and lubrication.

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2.7.1.1.2. Sleeve bearings (Figure 6 for illustrative purposes only)

Figure 6

2.7.1.1.2.1. Self-aligning split sleeve bearings shall be included as a variant in each of the alternate generator solutions and as one of the bearing solutions.

2.7.1.1.2.2. Sleeve bearings shall be oil lubricated, and Contractor shall provide rationale for whether that lubrication is to be by ring or forced.

2.7.1.1.2.3. Housings shall include RTD in load zone for connection to engine ECM and to MPCMS for remote monitoring, and a second RTD for local monitoring. Readings are required to be within 2ºC of each other.

2.7.1.1.2.4. Housing shall have connection puck(s) for vibration and ultrasonic monitoring

2.7.1.2. Bearing seals

2.7.1.2.1. Anti-friction bearings:

2.7.1.2.1.1. Non-integral seals shall be non-rubbing, self-aligning, and shall be split.

2.7.1.2.1.2. Integral seals or shields shall be offered, if applicable and available.

2.7.1.2.2. Sleeve bearings:

2.7.1.2.2.1. Seals shall be non-rubbing, self-aligning, and shall be split.

2.7.1.3. Coupling Hub

2.7.1.3.1. Existing coupling hub is shrunk-fit onto the generator drive shaft.

2.7.1.3.2. For bearings and/or bearing seals at the D.E. that require the removal of the coupling hub in order to be replaced, the Contractor shall provide a hub that is designed to be removed and re-installed.

2.7.2. Envelope and maintenance/service dimensions

2.7.2.1. Maintenance envelope dimensions shall be determined by the Contractor and provided for both the existing generator and for the proposed replacement generators.

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2.7.2.2. Dimensions of proposed alternative variants shall be close to the dimensions of existing generator, with any modifications identified. The objective is to minimize modifications to the generator interfaces. For example, an alteration in the width, height, or length of the generator shall not require excessive modification of skid, or cause excessive restriction of access to the generator or to other equipment in the compartment such as to the engine, or to the gas-turbine in the case of #2 SSDG, etc.

2.7.3. Reliability

2.7.3.1. Mechanical

2.7.3.1.1. Projected percent uptime shall be provided for all alternate variants

2.7.3.1.2. Mean Time Between Overhauls(MTBO) shall be provided for all alternate variants

2.7.3.1.3. Maintenance requirements shall be provided for all alternate variants

2.7.3.1.4. Anti-Friction bearings:

2.7.3.1.4.1. Bearing System Life L10h shall be provided for all alternate variants

2.7.3.1.4.2. Bearing System Life L10h shall be at least 40,000 hours

2.7.3.2. Uptime, alarms, and shut-downs

2.7.3.2.1. The genset’s existing monitoring and protection system provides an alarm to the Machinery Propulsion Control and Monitoring System (MPCMS) system to alert the crew of an impending power transfer and shut-down, and the alternate solutions shall be tied into this system.

2.7.3.2.2. Uptime ends when the generator brings itself off-line, or the crew, in response to the alarms, needs to bring the generator off-line.

2.7.4. Maintainability

2.7.4.1. Expected maintenance and overhaul periodicity and requirements (mechanical and electrical) shall be provided for all alternate variants

2.7.4.2. Accessibility to components for maintenance, overhaul, repair, or replacement shall be described, including parts to be removed, distance needed, and hours and skill level to accomplish the task

2.7.5. TOC

2.7.5.1. The Contractor shall provide a table with TOC comparisons of the alternative variants

2.7.5.2. The Contractor shall present the TOC of each alternate variant in terms of cost and hours, periodicity, and timeframe

2.7.5.3. The TOC shall include for each alternate variant:

2.7.5.3.1. Acquisition Price

2.7.5.3.2. All requirements listed herein

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2.7.5.3.3. Warranty terms specific to parts, labor, and guaranteed uptime, and any maintenance requirements during sailing

2.7.5.3.4. Price of an optional Total Maintenance and Repair Support Agreement covering 5-years and renewable at discretion of the Government. The Total Support Agreement would cover all parts, labor, and world travel, and would guarantee an uptime during sailing as stated above. Contractor would perform preventative maintenance and overhaul services during scheduled availabilities, and repair work that cannot wait until a scheduled availability. The Contractor shall arrange for the work to be performed by technicians certified by the generator manufacturer for the generator end.

2.7.5.3.5. Estimated cost of removing the existing generators and installing the new generator, or the cost to accomplish the incorporation of a new bearing solution, as applicable.

2.7.5.3.6. Cost estimate for all logistics elements.

2.8. Periodic Preliminary Design Review meetings shall be at ½ way point and ¾ way point. Contractor shall announce meeting dates at least (2) weeks before the meeting, and the meetings shall be held at USCG Baltimore, MD offices.

3. DELIVERABLES

3.1. The contractor’s deliverable shall be a study of the alternate variants of specifications, evaluations, and TOC to address the requirements of section 2.

3.2. The study’s layout and presentation shall be:

3.2.1. (3) solutions (and variants) for only replacement of the bearing system and related items.

3.2.2. (3) solutions (and variants) for whole-scale replacement of the existing generators.

3.2.3. Comparison between the alternative solution variants, with supporting documentation, to include:

3.2.3.1. Bearing system replacement as a solution as compared to whole-scale replacement of generator.

3.2.3.2. Salient features of the variants

3.2.3.3. initial acquisition cost, and availability

3.2.3.4. Methodology, cost and timeframe to remove generator (or components from generator) from vessel, and to install new generator (or components) into vessel for all (3) SSDG locations

3.2.3.5. Man-hours, parts, skill-sets required, steps, and cost of required maintenance and overhauls

3.2.3.6. Total Ownership Cost (TOC)

3.2.4. Supportability:

3.2.4.1. Contractor shall provide proof that the replacement solution configurations have proven track records of reliability

3.2.4.2. Contractor shall provide parts sustainment for the life of the vessel, similar to the expected sustainment of the prime-movers

3.2.4.3. Contractor shall guarantee uptime as stated above, and shall include total maintenance and repair at no cost to the Government. Contractor shall provide in the S&E as a separate line item.

3.3. Preliminary Design Review (PDR) meetings:

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3.3.1. The PDR’s shall include a written report on status of the study including what requirements and deliverables are mature, what items are in progress, and a listing of any outstanding items and points that need further clarification or discussion between the contractor and USCG.

4. PERIOD OF PERFORMANCE:

4.1. Submission of S&E reports and comparison table:

4.1.1. The contractor shall submit and host the first PDR within 60 calendar days after contract award, and shall give at least 14 calendar days of notice.

4.1.2. The contractor shall submit and host the second PDR within 90 calendar days after the contract award, and shall give at least 14 calendar days of notice.

4.1.3. The contractor shall submit the final S&E deliverables no more than 120 calendar days after contract award.

4.1.4. Contractor shall submit the uptime maintenance and warranty deliverables no more than 180 calendar days after contract award.

4.2. USCG will review and will provide comments on final deliverables, warranty, and maintenance submittals to the contractor within 45 calendar days after receipt.

4.3. The contractor shall respond to USCG comments within 30 calendar days after receipt.

4.4. All deliverables shall be provided in a Microsoft©-Compatible electronic format.

5. PLACE OF PERFORMANCE:

5.1. The tasks included in this order shall be performed at the contractor site, other Coast Guard sites and cutters as necessary.

6. TRAVEL:

6.1. Travel to the Coast Guard cutters will be required to support the inspection and is considered part of the scope of this effort. This travel shall be coordinated with the COR and the announcement shall be scheduled not less than two weeks in advance of travel.

7. SECURITY CLEARANCE:

7.1. The work will not be classified. No security clearance is required, but proper identification will be required to gain access to Coast Guard Facilities/Cutters.

8. QUALITY ASSURANCE

8.1. The Contractor shall establish and maintain a quality assurance program to ensure that all tasks are completed in accordance with the contract, the Statement of Work, and the individual task order requirements. Quality requirements identified in SFLC instructions shall be satisfied where they apply.

8.2. The Government will review the content and format of the deliverables in their entirety prior to issuing approval.

9. CONTRACT MANAGEMENT

9.1. The contractor shall NOT accept any instructions issued by any person employed by the U.S. Government or otherwise, other than the Contracting Officer (KO), or the Contracting Officer’s Representative (COR) or alternate COR acting within the limits of his/her authority. The COR will be designated in writing to the Contractor, and the scope of his/her authority will be set forth therein.

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9.2. No information, other than that which may be contained in an authorized amendment to this purchase instrument duly issued by the Contracting Officer, which may be received from any person employed by the U.S. government or otherwise will be considered as grounds for deviation from any stipulations of the purchase instrument or referenced drawings and/or specification herein.

9.3. Release of information generated for the Coast Guard shall not be allowed without prior written consent of the Contracting Officer.

10. KEY USCG PERSONNEL INFORMATION

10.1. The primary COR is LT Nathaniel Selavka Nathaniel.P.Selavka@uscg.mil

10.2. The alternate COR is CWO Robert Clifton Robert.L.Clifton@uscg.mil

10.3 Government will provide notification to Contractor of any change to government contracting personnel (i.e. KO and primary/alternate COR).

mailto:Nathaniel.P.Selavka@uscg.mil mailto:Robert.L.Clifton@uscg.mil