REV-0 MIDGETT (WMSL-418) UPDS NR2-SSDG-CAT-Ovhl FQ4 FY26 AKW.docx

USCGC MIDGETT (WMSL-418) CAT SSDG OVERHAUL DOCKSIDE AVAILABILITY FY2026

USCGC MIDGETT (WMSL 756) - CATERPILLAR® NR2 SSDG ENGINE OVERHAUL

SPECIFICATION FOR DOCKSIDE REPAIRS

FY2026

Developed By: Akhila K Wijayaratne (Rev-0, 16 AUG 2026)

TABLE OF CONTENTS

USCGC MIDGETT (WMSL-418) CAT SSDG OVERHAUL DOCKSIDE AVAILABILITY FY2026

Revisions Record This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

Consolidated List of References The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

· MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

· Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

· Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws:: www.gpoaccess.gov The Government is aware of the following internet web links where contractors may procure commercial specifications:

· American Welding Society (AWS): http://www.awspubs.com/index.php

· ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

· NFPA: http://www.nfpa.org

· SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS

Coast Guard Drawing 418A-WMSL-540-001, Rev C, Fuel Oil Diagram Coast Guard Drawing 418A-WMSL-540-002, Rev A, Diesel Eng And Gas Turb LO Fill, Trans, & Service Sys Coast Guard Drawing 418A-WMSL-551-001, Rev A, Compressed Air Diagram Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangement Coast Guard Drawing 750-WMSL-508-001, Rev C, Piping and Machinery Insulation Schedule and L/M (ASC508001) Coast Guard Drawing 750-WMSL-520-001, Rev H, Seawater Cooling System Diagram (ASC520001) Coast Guard Drawing 750-WMSL-635-002, Rev K, Insulation Arr & Details Thermal, Acoustic, & Fire (ASC635002) Coast Guard Drawing FL-1204-3, Rev A, Fleet Welded Padeyes And Links

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Coast Guard Technical Publication (TP) 7119, Rev A, SWBS 311, Dec 2023, Ship Service Diesel Generators Model 3512B Coast Guard Technical Publication (TP) 7368C, SWBS 311, Feb 2022, Ship Service Diesel Generators (SSDG) Model 3512B Parts Manual Coast Guard Technical Publication (TP) 14025, Rev A, Apr 2025, Ship Service Diesel Generator Sets Caterpillar 3512B Marine Auxiliary Technical Manual Volume 1 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 3041 (SFLC Std Spec 3041), 2022, Shipboard Electrical Cable Test Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2022, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, and Installation Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2022, Auxiliary Machine Systems Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

American National Standards Institute (ANSI/EASA) AR100, 2020, Recommended Practice for the Repair of Rotating Electrical Apparatus Caterpillar® Marine Model D3512 Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance Caterpillar® Guidelines for Reusability, “Index of Publications on Reusability or Salvage of Used Parts”, Caterpillar Publication SEBF8029 (series) Code of Federal Regulations (CFR) Title 29, Part 1915, Occupational Safety and Health Standards for Shipyard Employment NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), July 2012, Requirements for Fabrication, Welding, and Inspection of Submarine Structure The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2016, Solvent Cleaning

USCGC MIDGETT (WMSL-418) CAT SSDG OVERHAUL DOCKSIDE AVAILABILITY FY2026

Consolidated List of Government-furnished Property The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

($/UNIT)

PN: 128-6786

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center

Consolidated List of Critical Inspection Items The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)):

Principal Characteristics

418' WMSL

Physical

Machinery

Hull

HSLA-80 Steel

ABS EH 36 Steel

ABS AH 36

Frame spacing

Electrical

TANK CAPACITIES

00000_0725_FLT

REC_00000_FLT_Commercial Project @ Contractor’ Facility (0121) General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed at a commercial contractor’s facility for Coast Guard vessels.

1.2 Term interchangeability. The terms 'Contractor', 'CG Yard', 'NAVSTA EVERETT', 'shipyard', 'Base', and 'Coast Guard Industrial' are used interchangeably in this specification. Where the primary service provider is Coast Guard personnel, references to contractor and other noted descriptors within this specification or within drawings, publications, SFLC Standard Specifications or other commercial and military references are deemed the same as prime service provider.

2. REFERENCES

Coast Guard Drawings None Coast Guard Publications Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Latest Version, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Latest Version, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), Latest Version, Fire Prevention and Response Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), Latest Version, Requirements for Preservation of Ship Structures Other References Code of Federal Regulations (CFR) Title 29, Part 1915, Occupational Safety and Health Standards for Shipyard Employment NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), July 2012, Requirements for Fabrication, Welding, and Inspection of Submarine Structure

3. REQUIREMENTS

3.1 General. The Contractor must conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability. The requirements in this WI applies to all work under the scope of this contract, whether explicitly stated in all following work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.1.1 The Contractor must conform to all requirements specified in SFLC Std Spec 5550 and in the Fire Protection and Response work item, as applicable, during the performance of this availability.

3.1.1.1 Fire Safety Plan submission. The Contractor must submit a copy of the CFR 1915, Subpart P, Fire Safety Plan with the Contractor’s bid when work will be conducted in a Contractor–owned facility. Include any MOA(s) with local firefighting facilities.

3.1.1.2 Fire Plan submission. The Contractor must submit a copy of the developed availability specific fire plan, as requested in the Fire Protection and Response work item, seven (7) days before the Arrival Conference.

3.1.2 Safety Certifications. The Contractor must provide the credentials for anyone certifying that a space is safe for workers or hot work in accordance with 3.3.1 of SFLC Std Spec 0000.

note NAVSEA drawings listed will be available FOR INSPECTION ONLY from the Coast Guard Port Engineer post-award. SFLC will not redistribute NAVSEA documents. Contractors can apply to NAVSEA headquarters directly for copies.

3.2 Fire watch requirements. The Contractor must refer to 3.3.1.3 (Fire watch requirements) of SFLC Std Spec 0000, in accomplishing the following task:

Provide portable fire extinguishers for Coast Guard fire watch personnel. Coast Guard fire watch is in lieu of contractor personnel during the hours of 0800-1600, Monday through Friday, and limited to two Coast Guard fire watch personnel.

Provide fire watch personnel and fire extinguishers for the duration of the availability period, during and beyond noted Coast Guard fire watch support.

3.3 Preservation requirements. The Contractor must accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec 6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

3.3.2 Coating colors and system color schemes. The Contractor must obtain a written KO authorization to deviate from any coatings required in SFLC Std Spec 6310 Appendix C before work.

3.3.3 In-process quality control measures. The Contractor must abide by all the safety, preservation, and quality control requirements specified in SFLC Std Spec 0000, paragraph 3.2.4.2 (In-process QC measures for “critical-coated surfaces”).

3.3.3.1 Quality control requirements. The Contractor must abide by the following when performing preservation related inspections. The following measurements must be randomly spaced throughout for the purposes of providing a representation of the entire prepared or coated surface.

3.3.3.1.1 Surface profile measurements. One surface profile measurement must be taken for every 200 square feet for the first 1000 square feet; for each additional 500 square feet or less, one profile measurement must be taken. Profile measurements must be taken in accordance with SFLC Std Spec 6310, paragraph 3.1.8.3 (Surface profile measurements). A “measurement” for surface profile is defined as follows:

· ASTM D4417, Method B: One profile measurement is the average (mean) of 10 individual readings.

· ASTM D4417, Method C: One profile measurement is the average (mean) of 2 individual readings.

3.3.3.1.2 Soluble salt conductivity measurements. 5 conductivity measurements must be taken every 1000 square feet. For submerged (immersed) applications conductivity measurements must not exceed 30 microsiemens/cm. For non-submerged (non-immersed) applications conductivity measurements must not exceed 70 microsiemens/cm. If a conductivity check fails, clean the surface in accordance with SFLC Std Spec 6310, paragraph 3.1.8.5 (Soluble salt removal).

3.3.3.1.3 Coating thickness measurements. Three area measurements must be taken for the first 1000 square feet; for each additional 1000 square feet, perform an additional area measurement. A “measurement” for coating thickness is defined as follows:

· SSPC-PA 2 defines an area measurement as 5 separate spot measurements randomly spaced throughout a 100 square foot area.

· SSPC-PA 2 defines a spot measurement as 3 gage readings and each new gage reading the probe must be moved to a new location within a 1.5-inch diameter circle defining the spot.

3.4 Welding and brazing requirements. The Contractor must perform all welding and allied processes, and NDE in accordance with SFLC Std Spec 0740.

NOTE

NAVSEA approval is NOT required for welding procedures submitted but the procedures must be reviewed and shown to satisfy the requirements set forth in NAVSEA TP 1688, by a welding regulatory agency. The requirements for welding Strenx 900 are considered the same as those for welding HY-130.

3.5 Environmental protection requirements. The Contractor must adhere to the following environmental protection requirements in accordance with the SFLC Stand Spec 0000:

3.5.1 Contractor operated (non USCG) facilities. The Contractor must provide and maintain environmental protection as defined in SFLC Std Spec 0000 Appendix A, Requirements for Environmental Protection at Contractor Operated (Non USCG) Facilities, as applicable, during the performance of this availability. Contractor must plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project. Contractor must comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or regulation in this or any other item must not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.1.1 Plans and permits. The CG Facility has unit specific permits including the following:

Spill Prevention Control and Countermeasures (SPCC) Plan: Unit has a SPCC Plan which requires certain unit-specific procedures be followed for the storage, inspection, and transfer of petroleum products in containers 55 gallons or greater.

National Pollutant Discharge Elimination System (NPDES) Storm Water (SW) Permit: Unit has an NPDES SW permit which requires unit-specific procedures be followed for the storage and inspection of equipment and materials which may contribute contaminants to storm water discharges.

Air Emission Permit: Unit has an Air Emission Permit which requires unit-specific procedures be followed for the emissions of VOCs and hazardous air pollutants.

3.5.2 Test and procedures. The Contractor is required to promptly conduct tests and procedures for the purpose of assessing whether operations are in compliance with applicable Environmental Laws. Analytical work must be done by qualified laboratories; and where required by law, the laboratories must be certified.

3.5.3 Regulatory notifications. The Contractor is responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting Officer or COR, and if work is being performed at a USCG Facility, the local Facility Engineer or Engineering Officer. The Contractor must submit copies of all regulatory notifications to the Contracting Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities. Regulatory notifications must be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

3.5.4 Environmental manager. The Contractor must appoint in writing an Environmental Manager for the project, who is responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager must ensure compliance with Hazardous Waste Program requirements, including hazardous waste handling, storage, manifesting, and disposal; implement the Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas; ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the Environmental Records binder and required documentation, including environmental permits compliance and close-out.

3.5.5 HW disposal. Contractor must comply with SFLC Std Spec 0000 Appendix A, Requirements For Environmental Protection At Contractor Operated (Non USCG) Facilities for HW disposal.

3.6 Local Policy. The Contractor must refer to site (e.g., Base) Regulations and Instructions for details regarding local policies (e.g., crane services, parking, or facility usage).

3.7 SFLC Standard Specification approved changes. Approved updates to the 2022 SFLC Standard Specifications will appear here.

3.7.1 SFLC Standard Specification 5550: Replace paragraph 3.11.3 to state, “Material supporting imminent work shall be brought on the cutter and stored where the work is being performed. Material that appreciably contributes to fire load shall be removed at the end of each work shift when personnel are not present. Trash, debris, and packaging materials shall be promptly removed from the vessel at the end of each work shift and not allowed to accumulate.” Advance the paragraph numbering of the Fire Prevention and Safety Inspection form to 3.11.4.

4. NOTES

None.

31100_AKW_0826_WMSL

WORK ITEM 1: Caterpillar (CAT) Ship Service Diesel Generator, Engine Major Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform the Major Overhaul on each of the Ship Service Diesel Generator (SSDG) Caterpillar 3512B Diesel listed in Table 1.

TABLE 1 – NAME PLATE DATA

1.2 Government-furnished property.

($/UNIT)

PN: 128-6786

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 418A-WMSL-540-001, Rev C, Fuel Oil Diagram Coast Guard Drawing 418A-WMSL-540-002, Rev A, Diesel Eng And Gas Turb LO Fill, Trans, & Service Sys Coast Guard Drawing 418A-WMSL-551-001, Rev A, Compressed Air Diagram Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangement Coast Guard Drawing 750-WMSL-508-001, Rev C, Piping and Machinery Insulation Schedule and L/M (ASC508001) Coast Guard Drawing 750-WMSL-520-001, Rev H, Seawater Cooling System Diagram (ASC520001) Coast Guard Drawing 750-WMSL-635-002, Rev K, Insulation Arr & Details Thermal, Acoustic, & Fire (ASC635002) Coast Guard Drawing FL-1204-3, Rev A, Fleet Welded Padeyes And Links

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 7119, Rev A, SWBS 311, Dec 2023, Ship Service Diesel Generators Model 3512B Coast Guard Technical Publication (TP) 7368C, SWBS 311, Feb 2022, Ship Service Diesel Generators (SSDG) Model 3512B Parts Manual Coast Guard Technical Publication (TP) 14025, Rev A, Apr 2025, Ship Service Diesel Generator Sets Caterpillar 3512B Marine Auxiliary Technical Manual Volume 1 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 3041 (SFLC Std Spec 3041), 2022, Shipboard Electrical Cable Test Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2022, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, and Installation Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2022, Auxiliary Machine Systems Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

American National Standards Institute (ANSI/EASA) AR100, 2020, Recommended Practice for the Repair of Rotating Electrical Apparatus Caterpillar® Marine Model D3512 Disassembly and Assembly (Series) Manuals and/or the latest original equipment manufacturer (OEM) technical bulletins and specifications manuals as guidance Caterpillar® Guidelines for Reusability, “Index of Publications on Reusability or Salvage of Used Parts”, Caterpillar Publication SEBF8029 (series) The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2016, Solvent Cleaning

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor must submit a CIR for the inspections listed in the following paragraph(s):

3.2 Failure Investigative Work.

3.5 Additional contractor furnished equipment (CFE)

3.1.2 Tech Rep. The Contractor must provide the services of an OEM authorized/ licensed Tech Rep for the Caterpillar SSDG (Engine Model No. 3512B) to accomplish the following 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.

· Advise on manufacturer's proprietary information pertinent to the system.

· Ensure compliance with manufacturer's procedures and standards during the performance of the work item.

3.1.2.1 Ensure the Tech Rep has a résumé of demonstrated experience with the system/equipment stated above.

3.1.2.2 Submit the Tech Rep’s name and résumé to the COR at the Arrival Conference.

3.1.2.3 The Technical Representative must be present, on site, while the following engine work is being performed:

· Disassembly of Engine

· Inspection and Qualification of Parts

· Maintenance Listed in Paragraph 3.6 herein

· Re-assembly of Engine

· Engine Final Preparation for Testing

· Engine Cleaning

· Engine Testing

· Troubleshooting

· System Adjustments

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

3.1.3.1 Overhead wipe down. Prior to commencing work, the Contractor must protect the open sections of the engine with a drop cloth to prevent contamination of the engine. Wipe down the overheads above SSDG, including all framework, stiffeners, piping, intake piping, exhaust piping, and other items in the overhead to remove dirt and dust, which could fall into the engine during work.

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following:

· Piping

· Insulation

· Electrical wiring

· Overhead lights

· Catwalks will require removing handrails and placing adequate supports/shoring under, if they are intended to be used to hold heavy engine parts

· Exhaust system

· Intake system

3.1.5 Special tools. Overhaul of the engine requires the use of special tools. The Technical Manual describes the tools needed. The Contractor or the Technical Representative being supplied by the Contractor is responsible for supplying all of the special tools and any other tools needed to overhaul the engine. The Coast Guard does not have any of the special tools required for overhaul of the engine

3.1.6 Testing plan. The Contractor must submit a plan for final break-in and testing of the SSDGs in Table 1 in accordance with Tech Rep direction, Cutter Operating Procedures, requirements of Paragraph 3.3 herein and TP 7119 (both for prime mover and National Oilwell Varco or Kato generator). The test plan must include a CAMPAR test to be performed by the Tech Rep. Submit the testing plan no later than one week after the Arrival Conference via a CFR.

NOTE

Only refer to Kato Technical Publication for NSC 10.

3.1.6.1 The Contractor must obtain the Caterpillar Tech Rep’s approval of the Testing Plan.

3.1.6.2 No testing can commence before COR approval.

3.1.6.3 The plan must cover the following topics at a minimum:

· Procedures to handle emergencies during the testing process (fire, engine casualty, injury, etc)

· Method of testing E-Stop and automatic safety shutdowns (including high coolant temperature and low oil pressure automatic shutoffs)

· Load bank specification and location (final operational test only)

· Cable locations for load bank

· No-load tests

· Loaded tests

· Parallel load sharing

· All proposed connection, cable and load bank configurations

· Data to be collected during tests. At a minimum, this would include:

· Governor settings/fuel rack position

· Cylinder exhaust temperature

· Jacket water temperature

· Cylinder compression pressure

· Cylinder firing pressure

· Crank case vacuum

· Intake manifold pressure

· Exhaust back pressure

· Fuel oil consumption (total consumption over the course of the test)

· Lube oil consumption (total consumption over the course of the test)

3.1.7 Electrical work. The Contractor must accomplish all electrical work in accordance with SFLC Std Spec 3042, and test cables in accordance with SFLC Std Spec 3041.

NOTE

Lifting points or padeyes are available in the overhead to assist with lifting engine components.

3.1.8 Rigging. The Contractor is responsible for all rigging with the following considerations:

3.1.8.1 All existing padeyes that will be used for a lift must be pull tested to 1.5 times their Working Load Limit in accordance with SFLC Standard Spec 5000 Paragraph 3.2.7. All testing must occur in the presence of a Coast Guard Inspector.

3.1.8.2. If new padeyes are required, fabricate them in accordance with Coast Guard Drawing FL-1204-3 and SFLC Standard Spec 0740. Newly fabricated padeys must be pull tested to 2 times their Working Load Limit in accordance with SFLC Standard Spec 5000 Paragraph 3.2.7. All testing must occur in the presence of a Coast Guard Inspector.

3.1.8.3. Upon completion of testing, install a label plate in accordance with SFLC Standard Spec 5000 Paragraph B2.9.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.2 Investigative work. In conjunction with component removal and prior to any component disposal, the Contractor must submit a CIR providing a consolidated failure analysis investigation report of damaged components that caused the engine failure. Report must include, but are not limited to, main bearings, pistons, liners, conrod bearings, crankshaft, turbochargers, cylinder heads, filters, strainers and crankcase ventilation system. Report shall include photos of each component found defective and any future recommendations for operations.

NOTE

#2 SSDG experienced high crankcase pressure with oil/smoke vapor protruding from lube oil dipstick ports and crankcase vents. Ships Force attempted minor dynamic troubleshooting, but vapor generation was too rapid to continue operation of the engine. The SSDG was tagged out and opened (and remained open) for further investigation work and repairs.

3.3 Structural measurement After operational test and before disassembly, the Contractor must record crank thrust, web deflection, timing and any gear backlash deemed necessary by the Tech Rep. Submit a CFR with recorded data.

3.4 Alignment measurement. The Contractor must measure the shaft alignment between the shaft couplings using the two dial indicator method or Laser Shaft Alignment as described in TP 7119, Section 20 to determine the initial alignment condition between engine and generator. Record the alignment criteria specified in TP 7119, Section 20. Conduct alignment measurements in the presence of a Coast Guard Inspector. Submit CFR documenting all measurements.

3.5 Additional contractor furnished equipment (CFE). Prior to starting engine overhaul, the Contractor must submit a CIR with a list of all additional required parts that are not supplied as GFE nor explicitly listed for renewal in Table 2. The list must include the part name, part number, and date of delivery (or estimated date, if not currently received) of all CFE to ensure all material arrives on time to support the work schedule.

TABLE 2 – MINIMUM CFE RENEWAL LIST

Equivalent Caterpillar Remanufactured (ReMan) part may be substituted for any part listed above.

3.6 SSDG Overhaul (Major). The contractor must execute the Major Overhaul listed in TP 14025 (SMCS Code 7595-020-MJ).

3.6.1 The Contractor is responsible for all engine disassembly and reassembly necessary to complete these repairs and inspections.

3.6.2 The Contractor must drain and disconnect the SSDG engine assembly fluid systems including, but not limited to, fuel oil supply and return, jacket water, sea water, and lube oil systems (Approximately 200-gallons jacket water, 165-gallons lube oil, and 5-gallons fuel oil, per engine assembly). Remove the fluid systems from the Cutter and dispose of in accordance with all applicable federal, state, and local laws and regulations. The Contractor must submit a CFR for an initial wiring diagram of the pre-lube pump prior to unwiring the pump. Contractor shall not proceed to unwire the pump without COR approval.

3.6.3. The Contractor is responsible for all engine cleaning required to accomplish these repairs and inspections, as well as for any debris that migrates into the engine during work. Dispose of all residual fluids in accordance with Federal, State and Local laws and SFLC Std Spec 0000.

3.6.4 The Contractor must furnish all tools, equipment, consumable and parts required to perform the Major Overhaul. The mandatory parts that require renewal are listed in Table 2. Equivalent Caterpillar Remanufactured (ReMan) part may be substituted for any part listed if authorized by the OEM.

3.6.5. The Contractor must submit a CFR with the inspection results for all components in the “Inspection, Reconditioning or Exchanging of Components” or “Inspection of Components” section. For bidding purposes, assume that all GFP provided material and CFE furnished material in Table 2 will be renewed as a minimum. Note clearly in the CFR when any components fail their inspections in accordance with the Caterpillar Publication Reusability Manual SEBF8029 (series).

3.6.6 When reassembling the engine, components must be torqued to values given in Coast Guard TP 7119. If no torque value is given in the TP, rely on directions from the Caterpillar Technical Representative.

3.6.7 The Contractor is responsible for disconnecting and reconnecting services to the engine as required to overhaul the engine (further delineated by the full content of this specification), all associated service systems including, but not limited to, exhaust, ventilation, fuel oil, sea water, and lube oil. Reference Section 2 for more information about these systems

3.6.8 Engine components, which require removal for performance of this work item, must be labeled, and stored in a covered and protected location off-ship for reuse. If necessary, cables attached to such items may also be disconnected and pulled back per SFLC Std Spec 3042. Ensure that all reused items have been thoroughly cleaned of excess lubricants and soot.

3.6.9 Any items listed as MTI must be cleaned of excess lubricants and soot and packed in the containers that had the new components.

3.6.10 Table 3 provides information about the SMCS code for various pieces of equipment as shown in TP 7119. This is NOT an exhaustive list of all the work that must be done in the scope of this work item.

TABLE 3 – MAINTENANCE ITEMS

1907-070

1388-510

3.6.11 Driven equipment will be addressed in Paragraph 3.8 herein.

3.6.12 Submit a CFR for magnetic particle inspections of the crankshaft and camshafts in accordance with SFLC Std Spec 0740.

3.7 Diesel engine final cleaning. After completion of engine repairs and overhaul, the Contractor must open and clean the engine crankcase. Wipe out the crankcase using lint free rags. After cleaning, inspect the crankcase in the presence of the Technical Representative and the Coast Guard Inspector. Verify no foreign objects are in the crankcase. Submit a CFR.

3.7.1 Hot Lube Oil Flush. Following crankcase obstruction verification, the Contractor must perform a Hot Lube Oil Flush of the engine and ancillary equipment in accordance with Work Item “Caterpillar (CAT) Diesel Engine Hot Lube Oil Flush, Perform.”

3.8 Electrical Maintenance. Clean outside of the generator and its ventilation screen to remove dirt, dust, oil or other contamination. If necessary to remove stubborn deposits of grease, oil or similar substances, a clean cloth moistened with a non-flammable cleaning solvent can be used. Clean the inside of the generator by using a vacuum cleaner or dry low pressure compressed air, 25 PSI maximum, to remove any accumulation of dirt, dust or other gritty particles. Stubborn deposits of grease, oil or similar substances on the metal components that are located away and clear of the windings and insulating components may be cleaned using a clean cloth moistened with a nonflammable solvent.

3.8.1 Inspect the area surrounding the bearing for sign of excessive leakage of oil or grease. Submit a CFR.

3.8.2 Perform megger test on the generator in accordance with (ANSI/EASA) AR100 and submit a CFR.

3.9 Alignment. The Contractor must measure final generator shaft to engine shaft alignment using the two dial indicator method or Laser Shaft Alignment as described in TP 7119. Conduct final alignment measurements in the presence of a Coast Guard Inspector. Alignment criteria must be in accordance with TP 7119, Section 20. Submit CFR documenting all measurements.

3.9.1 In the presence of the CG Inspector, fill the engine’s jacket water with contractor furnished Caterpillar Extended Life Coolant (CAT ELC).

3.9.2 In the presence of the CG Inspector, fill the engine’s lube oil sump. Lube oil will be furnished from ship's lube oil storage tanks.

NOTE

Final filling of engine sumps with lube oil will be performed by the Coast Guard using onboard piping, valves, and lube oil storage tanks.

3.9.3 The Contractor must re-ream the holes as needed to install new alignment dowels (Pin). The dowels must be installed on each side and on the forward end (closest to coupling) of the generator.

3.9.4 After alignment is accomplished with acceptable readings, the Contractor must reconnect the coupling using a new elastomeric coupling piece and install coupling guard.

3.9.5 Check engine timing in accordance with CG TP, and the Technical Representative’s guidance.

3.9.6 The Contractor must replenish the lube oil storage tanks with approximately 165-gallons used to refill each engine. Exact quantity and type of lube oil shall be verified by Coast Guard Inspector prior to scheduling this operation.

3.10 Perform the following checks in accordance with instructions provided in the manufacturer's Technical Manual. These checks are described in the technical manual under the section on System Operation Testing and Adjusting, Section 7, TP 14025.

· Fuel System Inspection

· Fuel Injector Testing

· Engine Rotation

· Camshaft Timing

· Set Valve Clearances

· Cooling System Pressure Test

· Safety Switch Operation

3.10.1 Prior to the performance of engine testing, conduct a comparison of all gages and pyrometers that will be used to record the engine’s performance against a certified standard to ensure accuracy of reporting. Provide a CFR listing the gage readings between local and remote gages. Take final crankshaft web deflection readings and record on a CFR. Compare readings with the pre-overhaul readings taken earlier in this specification item. Show the pre-overhaul crankshaft deflection readings and the post overhaul readings to the COR and to the Technical Representative for final approval.

3.10.2 Prior to operational testing, set and adjust the engine overspeed trip in the presence of the Technical Representative and the Coast Guard Inspector. Document successful testing with a CFR before proceeding with the rest of the test.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment. Ensure a person is standing by the emergency shutdown when starting the engine after maintenance.

3.11 Operational test, post repairs. After completion of work, the Contractor must thoroughly test, in the presence of the Coast Guard Inspector and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

3.11.1 All system adjustments must be performed by the Contractor in accordance with TP 7119 and Caterpillar Technical Representative’s guidance, to provide satisfactory operation of the SSDG engines throughout the range of operation.

3.11.2 The Contractor must provide at least one (1) person to attend the ship during engine testing to record test data, and require the Tech Rep to attend the ship during engine testing and break-in.

NOTE

Machinery Control and Monitoring System (MCMS) setup will be performed by Coast Guard Personnel.

3.11.3 The Contractor must execute the final test plan.

3.11.3.1 The Contractor must provide a resistive load bank (i.e. 450 Volt, 1500 KW) with cabling (approximately 250 ft.) and accessories to test the SSDG listed in Table 1. The load bank must be placed on the pier or the cutter at the discretion of the COR. The Contractor must provide any additional labor or crane services as necessary for the setup, operation, and disassembly of the load bank and associated cabling or accessories.

3.11.3.2 The Contractor must check all piping system joints for tightness and correct, as required.

3.11.3.3 In addition to measurements taken in the test plan, the Contractor must operate the engine at no load and low idle at approximately 900 RPM. Run for 15 minutes, or until temperatures and pressures stabilize, whichever comes soonest. Stop the engine, remove crankcase covers and measure and record conrod and main bearing temperatures. Any unusual operating conditions must be corrected by the Contractor. Submit a CFR with test results.

3.11.3.4 In addition to measurements taken in the test plan, the Contractor must operate the engine at no load at 1800 RPM. Run for 15 minutes, or until temperatures and pressures stabilize, whichever comes soonest. Stop the engine, remove crankcase covers and measure and record conrod and main bearing temperatures. If any unusual readings are experienced, notify the COR. Any unusual operating conditions must be corrected by the Contractor. Submit a CFR with test results

3.11.3.5 The Contractor must provide engine diagnostic data directly from the engine for all no-load testing.

3.12 Thermal insulation installation. The Contractor must renew any disturbed insulation in accordance with Coast Guard Drawings 750-WMSL-508-001 and 750-WMSL-635-002.

3.13 Touch-up preservation. The Contractor must prepare and coat all new and disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, (Touch-ups and minor coating repairs).

3.14 Preservation and compartment restoration. Upon completion of assembly and all testing, wipe down and clean the engine exterior. Solvent wipe the exterior surfaces in accordance with SSPC-SP 1 and SFLC Std Spec 6310.

4. NOTES

4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests.

4.2 Coast Guard Inspector responsibilities. Although the Contractor is responsible for applying appropriate quality assurance measures, the Coast Guard will witness the accomplishment of these measures. Therefore, a Coast Guard Inspector will:

4.2.1 Monitor the assigned work items to keep informed of progress and to ensure that the specifications are being followed.

4.2.2 Witness all tests as required by the specification.

4.2.3 Be guided by the work item and seek immediate clarification when necessary.

4.2.4 Immediately bring to the attention of the Contracting Officer any work which appears to be contrary to the work item requirements.

4.2.5 Document all work performed in the Machinery History Log.

4.2.6 Ship’s force is responsible for post-repair verifications per Coast Guard instructions.

NOTE

When there is overwhelming documentation to record. The Engineer Officer/Engineer Petty officer may state in the Machinery History Log, “All overhaul documentation is located (indicate where) for reference.

4.3 Definitions.

4.3.1 Tools - Common tools normally contained in a standard toolbox (screwdrivers, wrenches, pliers) etc.

4.3.2 Special Tools/Test Equipment - Such as torque wrenches, calibrated electronic meters, computer devices, etc. not normally found in a standard toolbox.

4.3.3 Consumables - A non-reusable item such as a rag, disposable gloves, paint, oil, grease, solvent, adhesive, sealant, corrosion preventive product, cleaner, jacket water, etc.

26200_CAT Engine LO-Flush IDIQ_AKW_0126_IBCT Caterpillar (CAT) Diesel Engine Hot Lube Oil Flush, Perform

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a Hot Lube Oil Flush of the Ship Service Diesel Generator (SSDG) Caterpillar 3512B Diesel Engines listed in Table 1.

TABLE 1 – NAME PLATE DATA