Scope of Work

USCGC POLAR STAR (WAGB-10)

NR3 SSDG Cylinder Bore Repair and Lower Sleeve Installation

1. Purpose

Contractor must provide services for the installation of one .044” oversize cylinder liner. Contractor must provide labor, supervision, tools, on-site machining, technical support, and incidental materials necessary to install the new cylinder liner and restore the NR3 Ship Service Diesel Generator (SSDG) cylinder block bore seating area and install the lower sleeve aboard USCGC

POLAR STAR.

2. Place of Performance:

USCGC POLAR STAR (WAGB-10)

Vigor Industrial – Seattle 1801 16th Ave SW Seattle, WA 98134

3. Affected Equipment

NR3 Ship Service Diesel Generator ALCO Model: 251E8MGS Serial: 16232070 Cylinder 1R.

4. Background

On 13 Jul 2026, while conducting corrective maintenance on NR3 SSDG, it was determined that cylinder 1R could not satisfactorily pass pressure testing after installation of a new liner, and rust was observed on the crankshaft in way of 1R. NED Seattle replaced the upper and lower sleeves with negative results. After removal of the lower sleeve, marring and damage were observed on the block where the lower sleeve seats, resulting in improper fit-up and allowing jacket water to bypass the sleeve and enter the sump.

Current temporary conditions indicate that new lower sleeves pressed in with retaining compound can hold pressure, but a permanent repair path is required. Loss of NR3 SSDG would further degrade readiness because NR2 SSDG is already not mission capable, and loss of NR3 SSDG would prevent the asset from meeting safe-to-sail requirements.

5. Scope

The contractor must inspect the affected cylinder block bore and seating area, determine machining requirements, bore or machine the damaged seating surface as required, and install the lower sleeve repair configuration to restore correct fit, sealing, and serviceability of the affected cylinder location.

The contractor must furnish all labor, tools, equipment, machining equipment, specialty tooling, and precision measuring instruments required to perform the work specified herein, unless specifically identified in writing by the Government as Government-furnished equipment.

6. Contractor Tasks

The contractor must:

• Inspect the affected NR3 SSDG cylinder location and verify the condition of the block bore, sleeve seating area, and adjacent mating surfaces.

• Review available measurements, fit-up conditions, and prior repair attempts associated with the lower sleeve installation.

• Perform machining necessary to install the specified .044-inch oversize lower liner in accordance with OEM-approved repair procedures and restore cylinder block bore and liner seating area to required dimensions

• Bore, machine, or otherwise restore the affected cylinder block lower sleeve bore and seating area to accept the repair sleeve configuration.

• Furnish and install the required lower sleeve, including the .044 oversize sleeve identified in this scope.

• Installation and machining must be done in accordance with applicable OEM repair procedure, OEM engineering guidance, or an engineering repair procedure approved by

USCG SFLC.

• Apply the appropriate retaining or sealing compound during installation if required by the selected repair method.

• Verify proper sleeve fit, alignment, and seating after installation.

• Perform pre- and post-repair dimensional inspections.

• Record final liner fit, protrusion, and sealing surface measurements.

• Support or perform pressure testing of the repaired cylinder location to confirm jacket water sealing integrity.

• Support or perform a post-repair hydrostatic test using the applicable OEM procedure or other Government-approved repair and testing standard. to verify sealing integrity and repair acceptability.

• Inspect for evidence of jacket water bypass into the sump following repair.

• Identify and document any deviations from OEM repair procedures or specifications.

• Evaluate and recommend whether permanent etching, stamping, or nameplate marking is required on the block, affected cylinder location, or associated nameplate to identify any deviation from standard configuration, repair condition, or OEM baseline.

• Recommend the proposed marking location, wording, and method for any permanent identification of non-standard condition.

• Perform permanent etching, stamping, or nameplate marking only if specifically authorized in writing by the Government.

• Handle, contain, collect, and properly dispose of fluids and waste generated during performance, including jacket water, lube oil, fuel oil, contaminated absorbents, and other residuals, in accordance with applicable federal, state, and local requirements.

• Provide recommendations for any additional corrective action required before return to service if deficiencies remain.

• Provide a written summary of work performed, as-left condition, measurements taken, and test results.

7. Material and Part Information

Contractor-furnished required part:

• Sleeve, liner to block, lower (.044 oversize), P/N 2501083, Qty 1

8. Period of Performance

The period of performance must start within 72 hours after award. Exact onboard work dates must be coordinated between USCG SFLC, USCGC POLAR STAR, and the contractor based on vessel availability and repair sequencing.

9. Deliverables

The contractor must provide:

• On-site inspection and repair support.

• Machining and installation of the lower sleeve repair configuration.

• Pre- and post-machining dimensional inspection results documentation of: Bore diameter, Bore roundness, Bore taper, Surface finish, Counterbore dimensions, Sleeve interference fit, Sleeve protrusion, Liner protrusion.

• Final liner fit, liner protrusion, and sealing surface measurements.

• Successful completion and documentation of a post-repair hydrostatic test.

• Any deviation from OEM repair procedures, dimensions, materials, tolerances, or repair methods must be submitted to USCG SFLC for review and approval prior to implementation.

• Recommendation as to whether permanent etching, stamping, or nameplate marking is required to document any deviation from standard configuration, repair condition, or OEM specification.

• Proposed marking location, wording, and method, if applicable.

• Documentation of any permanent marking accomplished with Government authorization.

• Final fit and condition verification.

• Written service report documenting findings, repair actions, parts used, measurements, test results, fluid handling/disposal actions, and final status.

10. Government-Furnished Support

The Government will provide:

• Access to USCGC POLAR STAR and the affected NR3 SSDG.

• Shipboard coordination and escort as required.

• Available maintenance history and discrepancy information related to the casualty.

• Available casualty documentation and prior repair information.

• Unit points of contact for scheduling and execution.

No engine-specific tooling or repair parts are Government-furnished unless specifically identified in writing by the Government prior to performance.

11. Acceptance Criteria

Work must be considered complete when:

• The damaged cylinder block bore and seating area have been machined or repaired as required for proper lower sleeve installation.

• The lower sleeve is properly installed and seated.

• Final liner fit, protrusion, and sealing surfaces are measured and documented.

• The repaired location successfully holds pressure without evidence of jacket water leakage or bypass.

• No jacket water intrusion into the sump is observed at the repaired location following testing.

• A post-repair hydrostatic test is successfully completed and documented.

• Any deviations from OEM repair procedures or specifications are identified and documented.

• Any authorized permanent marking is completed and documented, if directed by the Government.

• Fluids and waste generated during performance are properly handled and disposed of.

• The contractor provides a final service report documenting the repair and test results.

12. Constraints and Assumptions

• This scope is limited to repair of the affected NR3 SSDG cylinder block lower sleeve bore and seating area and installation of the lower sleeve at the identified casualty location.

• Any additional block damage, cracking, dimensional instability, or internal engine damage discovered during execution that exceeds this scope must require immediate suspension of work pending review and authorization by the Government.

• Final repair dimensions and exact machining method must be based on field inspection and actual condition of the block.

• Any follow-on work outside this scope must require separate Government authorization.

• No Government-furnished oversized sleeve, engine-specific tooling, or repair consumables are included unless specifically identified in writing prior to performance.

13. Government Points of Contact

LCDR Joshua Hearing Joshua.C.Herring@uscg.mil

CWO Matthew Tuten matthew.r.tuten@uscg.mil

CWO Matthew Temple matthew.temple@uscg.mil mailto:matthew.r.tuten@uscg.mil mailto:matthew.temple@uscg.mil