Inactive

Scope of Work: CGC MUNRO; #1 and #2 Generator Alignment/Pinning/Load Bank Testing The CTR shall provide technical services and labor to complete load testing, laser alignment, and pinning and machine ... Scope of Work: CGC MUNRO; #1 and #2 Generator Alignment/Pinning/Load Bank Testing The CTR shall provide technical services and labor to complete load testing, laser alignment, and pinning and machine work for #1 SSDG and #2 SSDG. The #1 and #2 SSDGs were lifted by Coast Guard personnel to replace the oil pan gaskets. Following these replacements, both SSDGs need to be laser aligned, pinned (machining may be required) and load bank tested. The CTR shall provide the following: Attend Daily Production Meeting to include Review of plan and requirements with Ship’s personnel Completion of OEM checklist if available First and last names of all personnel. Completion of a daily COVID survey before gaining access to Mare Island Dry Dock Facility. Perform all work IAW SFLC Standard Specification 0000 Certified technicians to supply all equipment needed to perform a load test IAW provided instruction Provide at least 250’ of cable Provide Load Bank and operating personnel Provide detailed service report on findings and observations CTR shall perform shaft alignment and 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. Submit CFR documenting all measurements. After alignment is accomplished with acceptable readings, the Contractor shall reconnect the coupling using a new elastomeric coupling piece and install coupling guard. The CTR shall re-ream the holes as needed to install new alignment dowels (Pin). The dowels shall be installed on each side and on the forward end (closest to coupling) of the generator. The CTR shall submit the alignment data in accordance with TP 7119, Section 14, Paragraph 7.5. Coast Guard will provide the following: GFE: N/A Tagouts of all interfering equipment Remove interferences Electrical Power Removal and installation of bearing Clean work environment Period of Performance: 11-15 October 2022 to accomplish laser alignment, pinning, and machine work. The Contractor is expected to quote for and provide services for 5 total days. If there are any questions, reach out to MUNRO Port Engineer, LTJG Stephen Bruno, (203) 868-9139. Place of Performance: U.S. Coast Guard Base Alameda, Berth 3 Load Testing Procedures: Testing plan. The Contractor shall submit a plan for break in and testing of the new SSDG in accordance with Caterpillar Publication SEBF9011-26, Cutter Operating Procedures, requirements of Paragraph 3.3 herein and TP 7119 (both for prime mover and National Oilwell Varco generator). Submit the testing plan no later than one week after the Arrival Conference in a CFR. See previous Load Bank Testing Plan below for an example. The Contractor shall obtain the Caterpillar Tech Rep’s and the Generator Tech Rep’s approval of the Testing Plan. No testing shall commence before COR approval and official acceptance by the Contract Officer (KO). The plan shall cover the following topics at a minimum: Emergency shutdown procedures Load bank specification and location Cable locations for load bank No-load tests Loaded tests Data to be collected during tests All proposed connections, cable and load bank configurations Load Banking. The Contractor shall provide a resistive load bank (i.e. 450 Volt, 1500 KW) with cabling and accessories to test the SSDG, estimate 250’ of cabling for bidding purposes. The CTR must hook up to Bus Bar in the respective switchboard. The load bank shall be placed on the pier or the ship at the discretion of the COR. The Contractor shall run cables in overheads as much as possible to avoid trip hazards. The Contractor shall provide any additional labor or crane services as necessary for the setup, operation, and disassembly of the load bank and associated cabling or accessories. Loaded Operational Test. The Contractor shall execute the loaded portion of the Test Plan. During the tests, all measured parameters shall be recorded and be within acceptable ranges. Submit a CFR. During the operational test, record all engine and generator parameters on a log sheet (to be provided by ships force). If any unusual readings are experienced, immediately secure the engine and troubleshoot to determine the cause. Any unusual operating conditions caused by work on this item shall be corrected by the Contractor. The Contractor shall provide engine diagnostic data directly from the engine. Coast Guard personnel will operate all shipboard machinery and equipment. Previously Used Load Bank Testing Procedure: Safety: At any point in the load test or operational testing period if the need presents its self the engine – Prime mover may be shut down by the Tech rep with communication to the USCG operational Engineer utilizing the local EOS, E stop or shut down from the switch gear. Any of the three options will automatically open the SSDG buss breaker. The cool down of the load bank will not be a consideration of a life safety event or mechanical failure. Load bank cables will be connected at USCG#2 main buss breaker. Accessed from the back side of the switch gear after proper LOTO procedures have been performed and dead buss is verified. 6 – 8 cables per phase are to be utilized and connected to the buss with mechanical lug blocks bolted to the existing buss access door in the back side of the switch board. All cables and blocks are to be insulated after installation with rated arc flash blanket – wrap. Load bank cables will be routed out of the engine room via hallway utilizing ladder 2-45-1 rescue hatch door. Load bank cables will be at or under 250 foot length specified. 1500KW Load bank will be set on the pier closest to the rescue hatch. If proper external power is available for load bank fan operation external power will be utilized however not required. Running no load testing. No load testing will consist of running the engine at idle rpm until the engine coolant temperature reaches 140 deg. F during that warm up time safety testing will be performed for oil psi and temp warning and shut down and coolant temp. warning and shutdown. Ship board alarm verification will be observed at that time as well. Load bank test It is proposed that the load bank test be done to the following: Warmup until coolant temp reached 140 deg F. Thirty minutes at 25% load Thirty minutes at 50% load Thirty minutes at 75% load Two hours at 90-100% load Fifteen minute cooldown Load bank readings will be taken every 15 minutes of the following. Engine, Coolant temp, oil pressure, battery voltage, boost, intake air temp after the aftercooler, exhaust stack temp left and right bank if available and fuel rate GPH. In addition to the generator load test form a Caterpillar steady state engine performance file will be recorded off of the engine ECM to record all related available information. Generator information, voltage reading per phase, amperage readings per phase, HZ, bearing and winding temps if installed. Pre and post-test PSSRP will be saved off of the ECM to provide verification of all available diagnostic codes and events. All electronic files and reports will be sent to the COR and distributed through proper channel.