EX_FY_19_10k_Engine_Overhaul_Specs.pdf

NOAA Ship Okeanos Explorer (R-337)

FY 2019

Caterpillar D398 SSDG’s - 10,000 Hour Overhauls – Engines #3 and #4 http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=imgres&cd=&cad=rja&uact=8&ved=0ahUKEwjdidX4zpHZAhWp8YMKHUYZDnYQjRwIBw&url=http://hawaiipublicradio.org/post/bytemarks-caf-okeanos-research-nw-hawaiian-islands&psig=AOvVaw2iGlZYe_tNc077EAlvyuRn&ust=1518017752532835

FY 2019 10k Caterpiller SSDG Overhauls

TABLE OF CONTENTS

DESCRIPTION/TITLE PAGE

1. SCOPE 3

2. GENERAL 3

3. BASE ITEMS 8

3.10 10,000 Hour Overhauls on SSDGs #3 and #4 8

1.0 SCOPE

1.1 The National Oceanic and Atmospheric Administration (NOAA) operates a fleet of 16 research vessels that supports research and mapping for the National Marine Fisheries Service, National Ocean

Service, Office of Atmospheric Research and the National Weather

Service, as well as provides support to other Federal agencies. These research missions are time sensitive and therefore the data must be collected at specific times during the sailing season to be meaningful.

At the end of each sailing season the vessels enter a repair period

(drydock or dockside) to address repairs, maintenance and equipment overhauls that have been previously identified, in addition to performing upgrades to mission systems or ship systems that either extend the life of the ship or provide new data collection capabilities or for safer operations of ships systems as well as address any emergent work that would adversely affect the ships ability to safely perform its mission on schedule, while meeting all regulatory body requirements (American Bureau of Shipping and United States Coast

Guard) and all habitability requirements, including any that may be required as a result of contracts for personnel to augment ship staff.

1.2 The work items in the repair and overhaul specification are identified well in advance of the performance period in order meet the contracting lead times.

1.3 These Detail Specifications contain the requirements the 10,000 hour overhauls to NOAA Ship Okeanos Explorer SSDG Engine’s #3 and #4

2.0 GENERAL

2.1 References

2.1.1 NOAA Standard Specification No. MOC-000-1G, “General

Requirements for Ship Repair Work on NOA Ships.”

2.1.2 Drawing No. OE-601-101, “NOAA Ship Okeanos Explorer General

Arrangement.”

2.2 Requirements

2.2.1 Reference 2.1.1 forms a part of these Detail Specifications.

All provisions and requirements contained therein are applicable to all work items, including all additional work items which are authorized by the Contracting Officer.

2.2.3 Some of the ship’s drawings have not been updated to reflect modifications to the ship during activation and conversion in 2007.

These drawings and reference documents are for planning purposes only.

Actual shipboard configurations and conditions may be different from what is listed. Contractor shall be responsible for verifying all current configuration, construction, and arrangement changes, as necessary, to comply with and perform the work requirements of these specifications. Contractors are encouraged and expected to review ship’s drawings and to perform a field inspection to inspect the locations and shipboard conditions where services are to be performed aboard the Okeanos Explorer prior to submitting a bid proposal. This inspection should satisfy potential contractors regarding all general and local conditions, (including locations, interferences, tolerances and necessary “work-arounds”, etc.) that may affect the cost of contract performance, to the extent that the information is reasonably obtainable. In no event shall failure to inspect the sites constitute grounds for a change order or claim after contract award.

2.2.4 Ship’s drawings and technical publications may be borrowed during the performance period. It would be preferable for the contractor to make copies of these drawing and technical publications if their intended use will be outside an office environment. All reference materials borrowed by the Contractor shall be signed for, and then returned to the COR after no further use of the reference materials is required.

2.2.5 Provide and maintain a status report of all American Bureau of

Shipping (ABS) inspections and technical reviews required by ABS, during the course of this contract, to ensure the ship’s ABS certification requirements are in compliance. Submit weekly ABS status reports to the COR, along with the preliminary progress reports.

2.2.6 All visual examination, hydrostatic testing, and non-

destructive testing shall be in accordance with ABS Rules for

Building and Classing Steel Vessels, Survey After Construction 2005, Part 7. All contractors performing NDT and hull gauging shall be certified under the ABS external specialists program.

2.2.7 On the first day of the contract performance period, provide the COR a detailed production schedule. Then, on a daily basis provide the COR a revised and updated production schedule reflecting actual work progress. These deliverables shall be in Microsoft

Project electronic format and 1 paper copy.

2.2.8 Safety and housekeeping walkthrough inspections of the work area and other productions areas shall be conducted on a regular basis by the contractor.

2.2.9 All new equipment and furnishings purchased by the Contractor for installation on the vessel shall be provided with factory or vendor supplied certificates, technical manuals, and data sheets, complete with parts listings. Faxed copies of this information are not acceptable. This documentation shall be turned over to the COR after installation is completed. Equipment technical manuals shall provide detailed information necessary to operate, maintain, troubleshoot, and repair the equipment. The manuals shall include detailed procedures for disassembly of equipment, parts lists, drawings, inspection criteria, troubleshooting, and test procedures. Provide four paper copies of each manual, plus one electronic copy in Abode Acrobat .pdf format.

2.2.10 Submit all inspection, test, and quality reports to the COR in Corel WordPerfect or Microsoft Word electronic software formats, in addition to providing hard paper copies.

2.2.11 Weigh all materials and items removed, installed, or relocated on the ship. Provide a summary report to the COR indicating the total weight in pounds of items and a breakdown of their locations by space, deck, frame, distance from centerline, and height above the deck. .

2.2.12 Unless otherwise stated in the individual work items, prepare and coat all new steel, all existing steel surfaces identified to be cleaned and painted, and all paint systems disturbed while accomplishing work items. Finish coat colors and paint type shall match those of the surrounding, unmodified area.

2.2.13 Ship’s force will maintain a minimal presence during

accomplishment of work to these specifications. Their availability to operate ship’s equipment will be limited. Crew availability is generally limited to the hours of 0800 and 1500 local time, Monday through Friday. Unless otherwise specified, provide a minimum of two working days’ prior notice for any equipment operations.

2.2.14 All new and disturbed machinery and services shall be

operated for a period sufficient to indicate satisfactory performance, but not less than one hour, after all adjustments and deficiency corrective actions have been made, without further adjustment.

2.2.15 Provide manufacturer’s technical representatives where required in the individual work items, to witness and to provide technical guidance during operational testing of equipment and systems. All tests and trials of equipment or systems shall be witnessed by the COR, ABS, and/or USCG as applicable, to ensure compliance with regulatory body requirements to maintain the ship’s

ABS class certification, and to complete all requirements of these specifications.

2.2.16 These Detailed Specifications are a combination of “performance specifications” and “design specifications.” Whenever possible, the

Government has provided performance specifications, giving the

Contractor the opportunity to accomplish the work requirements as best as he or she sees fit, while providing a fully functional repair and/or equipment/system installation in accordance with all work requirements.

When specific details are required, the Government will provide design/detail specifications; this will be more the exception, than the rule.

2.2.17 Frame numbers and space names are derived from ship’s drawings.

All equipment changes and space modifications over the ship’s life span may not all be reflected in the referenced drawings. Contractors are encouraged to review all referenced drawings and to perform a field inspection of the ship prior to submitting a bid. Copies of drawings and technical manuals not included herein may be made available for review during any scheduled pre-bid inspection and during the performance period. Contractors may review available drawings and technical manuals on board ship.

2.3 Notes

2.3.1 The following descriptive data of the ship is provided for information:

Length, Overall......................................224’ 0”

Length, BP...........................................194’ 0”

Beam, Molded..........................................43’ 0”

Mean Draft, Loadline..................................15’ 1”

Displacement, Loadline.............................2311.5 LT

Displacement, Lightship............................1591.2 LT

Cruising Speed......................................11 knots

Officer & Crew Size

Scientists and Technicians

Electric Service.......450 VAC, 60 Hz, 3 PH, 800 Amp Service

Propulsion.......................Diesel electric, twin screw

2.3.2 NOAA Ship Okeanos Explorer is classed A1, E, AMS, and ACCU and identified with the following:

http://upload.wikimedia.org/wikipedia/commons/thumb/9/97/Cross-Pattee-Alisee.svg/600px-Cross-Pattee-Alisee.svg.png http://upload.wikimedia.org/wikipedia/commons/thumb/9/97/Cross-Pattee-Alisee.svg/600px-Cross-Pattee-Alisee.svg.png http://upload.wikimedia.org/wikipedia/commons/thumb/9/97/Cross-Pattee-Alisee.svg/600px-Cross-Pattee-Alisee.svg.png

Official Number - CG023672

ABS ID - 901987

IMO NUMBER – 8835114

2.3.3 GOVERNMENT FURNISHED MATERIAL/EQUIPMENT

2.3.3.1 None

3.0 BASE ITEMS

3.1 CATERPILLAR D398 10,000 HOUR OVERHAUL SSDGs #3 and #4

3.1.1 Scope

3.1.1.1 This specification contains requirements for the 10,000 hour

(top-end) overhaul of two Caterpillar D398 diesel engines on NOAA Ship

Okeanos Explorer. The serial numbers of the engines are as follows:

Engine #3: 35Z01558; Engine #4: 35Z01555.

3.1.2 References

3.1.2.1 Technical manual T9312-AG-MM0-010/11083 Engine Generator Set

Model D398B T-AGOS 13-18

3.1.2.2 Caterpillar Maintenance Management Schedule for Marine Engines

(SEBU6102)

3.1.2.3 Caterpillar Operations and Maintenance Manual (SEBU5698)

3.1.2.4 Caterpillar Service Manual (SEBR0511)

3.1.2.5 Generator alignment procedure (attached).

3.1.3 Requirements

3.1.3.1 General. The following requirements apply to all work.

3.1.3.1.1 Except as otherwise specified, the contractor shall provide all labor, material, services, tools, supervision, manuals, and technical expertise needed to accomplish the work required by this specification within the specified time limits. NOTE: The 9-day performance period shall be strictly adhered to. This work shall not be done while the ship is in drydock.

3.1.3.1.2 All work shall be performed by an authorized repair facility of the engine manufacturer or under the direct on-site supervision of a factory-trained mechanic currently certified by the engine manufacturer.

3.1.3.1.3 All work shall be in accordance with the manufacturer’s service, maintenance, and overhaul technical manuals, including all current and applicable amendments and service bulletins. Unless otherwise specified, the contractor shall provide a copy of the applicable manuals, amendments, and service manuals at the job site.

All repairs shall be made according to the manufacturer’s engine specifications, clearances, tolerances, and procedures.

3.1.3.1.4 All parts and labor provided by the contractor shall be fully warranted. Work shall be performed in such a manner that the manufacturer’s warranty on parts and labor is not voided.

3.1.3.1.5 Provide and install “mandatory renewal” parts and components as required by this specification and other procurement documents.

Other parts found to be in need of renewal may be provided by the

Government (if available) and installed by the contractor. Such additional parts or components which are not provided by the Government will be negotiated by the Contracting Officer as an additional cost.

3.1.3.1.6 Except where rebuilt components are authorized or specified, all components and parts used in the engines shall be new original equipment manufacturer (OEM) non-surplus components and parts. Prior to installing new or rebuilt components or parts, perform visual and dimensional inspections to verify that the components or parts are acceptable for use.

3.1.3.1.7 Where rebuilt components or parts are provided (as

authorized or specified), existing components and parts shall be replaced on an exchange basis with components and parts which have been manufactured at the engine manufacturer’s factory, and the existing components shall become the property of the contractor in their as-found condition. When factory re-manufactured components are not available, the existing components shall be disassembled, cleaned, inspected, repaired (including renewal of all parts needed), reassembled and calibrated by the manufacturer’s factory or a manufacturer-authorized repair facility. Rebuilt parts and components shall meet the manufacturer’s rebuild specifications and shall be restored to a condition of reliability equivalent to new components and parts. The only parts renewal for which additional costs will be negotiated are component bodies and casings.

3.1.3.1.8 Interferences shall be removed and reinstalled, as required, at no additional cost to the Government. Contractor is responsible for removing piping to/from the engine, engine heat exchangers, air motors, etc.

3.1.3.1.9 Disassemble the engines, components and parts to the extent specified herein and in other procurement documents. Whenever the extent of disassembly is not specified, disassembly shall be to the extent required to perform the required inspections, repairs, and parts renewal.

3.1.3.1.10 Thoroughly clean and conduct a thorough visual inspection of all disassembled parts checking for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability of the engine. Ensure all passages and holes are open and clear. Whenever hydraulic, fuel, lube oil, water, or air lines are disconnected, clean the point of disconnection and cap or plug the hoses or pipes and their connection points.

3.1.3.1.11 After inspections and tests have been completed and prior to reassembling the components, submit a report of all inspection findings and test results to the COR. Report shall include a record of all measurements and readings taken, as well as recommendations for additional repairs, parts renewals, inspections, or tests needed to ensure continued reliable operation of the engine. Do not proceed with any additional work until authorized by the Contracting Officer.

3.1.3.1.12 After the report has been accepted and all additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed. Reinstallation of all components throughout shall be with new gaskets, seals, grommets, and o-rings.

3.1.3.1.13 At the end of each work day, clean up all debris incidental to the performance of the required work. Upon completion of all work, clean all worksites to their as-found condition.

3.1.3.2 Mechanical/Fluid

3.1.3.2.1 Perform the 10,000 hour top-end overhaul on both engines as specified in References 3.1.2.1 through 3.1.2.5.

3.1.3.2.2 Renew the following parts and components on each engine.

Where “remanufactured” is added in parenthesis after a component, a remanufactured or “unit exchange” component may be provided in lieu of a new component. Quantities listed are per engine.

a. Cylinder head assemblies, complete with valves, springs, guides and prechambers (remanufactured), 6 ea.

b. Fuel nozzle injectors with o-rings, 12 ea.

c. Jacket water pump (remanufactured), 1 ea.

d. Turbocharger cartridges with seals and gaskets

(remanufactured).

e. Jacket water thermostats with seals and gaskets.

f. Camshaft kit (which includes lifters).

g. Camshaft bearings.

h. All cylinder thermocouples and thermocouple wiring.

3.1.3.2.3 Rebuild the existing salt water pump on each engine using the following parts:

a. Impeller, P/N 4L6220

b. Rebuild kit, P/N 1W7066

c. Elbow assembly, P/N 5L1549

d. New seals and gaskets

3.1.3.2.4 Clean turbo aftercooler cores; reseal and re-gasket. If cores require industrial cleaning, it will be the subject of additional work.

3.1.3.2.5 Clean and check all valve mechanism assemblies in accordance with Reference 3.1.2.4.

3.1.3.2.6 Test and adjust the fuel nozzles in accordance with

Reference 3.1.2.4 prior to installation.

3.1.3.2.7 Check and adjust the fuel timing, reset all tappets and check valve rotators in accordance with Reference 3.1.2.4.

3.1.3.2.8 During reinstallation of all parts, new gaskets, grommets, o-rings, and joints are to be used throughout and all items shall be torque to specifications listed in Reference 3.1.2.3.

3.1.3.2.9 Check engine-to-generator alignment in accordance with the

Reference 3.1.2.5. If realignment or adjustments are required, such work will be negotiated by the Contracting Officer as an additional cost.

3.1.3.3 Electrical

3.1.3.3.1 Test low lube oil pressure and high jacket water temperature safety shutdown devices. Inspect all electrical connections, exhaust pyrometer leads and readouts, wire standoffs and chafing protections installed on the engines and generators. Provide a condition report detailing general conditions found, as well as any abnormal findings, along with recommended corrective action, if any. Such corrective action will be negotiated by the Contracting Officer as an additional cost.

3.1.3.4 Electronics

3.1.3.4.1 Make known to all personnel working on the engines and generators that electrical and electronic devices and controls are present. These components must be protected from damage during the overhaul period and may require special precautions, isolation, etc.

3.1.3.5 Painting

3.1.3.5.1 Restore all disturbed surfaces to standard Caterpillar paint scheme. Surfaces to be painted shall be free of dirt and grease prior to paint application.

3.1.3.6 Testing

3.1.3.6.1 Notify the ship’s Chief Engineer and COR 24 hours prior to the engine/generator units being ready for testing under the ship’s electrical load. Test operate the engines after overhaul using the ship’s dockside hotel load for a period not less than two hours. Test all alarm and shutdown systems prior to starting. Ship’s force will line up and start engines and engage the generators on the ship’s main bus. Operate engines at no-load until normal no-load operating temperatures are reached, then increase load incrementally up to available load and operate for two hours. Provide technicians to observe operation, verify joints are leak-free, make adjustments, and record teat data.

3.1.3.6.2 Monitor temperatures and pressures and compare to

manufacturer’s recommended limits. If a temperature or pressure exceeds or falls below manufacturer’s recommended upper or lower limits, testing shall be stopped and the cause determined and corrected before continuing.

3.1.3.6.3 Record the following information near the end of the full-load test; provide test instruments as required:

a. cylinder exhaust temperatures

b. lube oil temperatures

c. water temperatures

d. fuel oil pressure

e. lube oil pressure

f. electrical load on generator prime mover

3.1.3.6.4 Submit a report of all test data collected. Report shall include manufacturer’s recommended limits for each parameter measured.

3.1.3.7 Final Adjustments and Tune-up

3.1.3.7.1 After satisfactory completion of operational testing, reset valves and accomplish final adjustments and tune-ups as required to provide smooth, efficient, and reliable operation.

3.1.3.8 Notes

3.1.3.8.1 Ship’s force is available to provide shipboard crane service during normal working hours (M-F 0830-1530) to lift parts between the pier and the ship’s aft deck. 24 hours advance notice is required.

Actual rigging of parts and moving parts to/from the aft deck and generator room shall be the responsibility of the contractor.

3.1.3.8.2 Reference 3.1.2.1 will be available for review during scheduled pre-bid inspection and during the performance period of the contract. References 3.1.2.2 through 3.1.2.4 shall be contractor furnished. Reference 3.1.2.5 follows this specification as an attachment.

Reference 3.1.2.5 GENERATOR ALIGNMENT PROCEDURE

The Contractor shall take the following readings before disassembly:

a. generator fan angular deflection,

b. generator shaft runout (TIR),

c. crankshaft end play,

d. crankshaft deflection.

Above readings shall be taken again upon reassembly, after the generator to engine alignment relationships have been re-established.

Record all results on condition reports and report the results to the attending NOAA Port Engineer, or assigned representative.

Before performing the parallel and angular alignment checks, ensure that the natural clearance between the base and its foundation is properly gapped with shims at all mounting locations and check that all base-to-foundation bolts are tightened to their final torque. If deflection of the base is noted, loosen base-to-foundation bolts at affected locations, shim as necessary to eliminate deflection, and re-tighten base-to-foundation bolts to their final torque.

Inability to attain repeatability of readings may be due to cocking of the flywheel by the turning tool. An end-supporting turning tool has proven to be superior to free-gear types for taking these particular reading. If an end-supported tool is not available, good results are attainable with a free-gear type if tooth engagement is reduced to the bare minimum necessary to turn the flywheel.

The deflection dial indicator must not have a leash attached since it may change readings.

PARALLEL ALIGNMENT (SHAFT RUNOUT)

Ensure that the generator shaft surface, which is to be measured with the dial indicator, is clean. Solvent and or light sanding with emery cloth should remove any dirt or rust accumulation.

Place the base of a dial indicator on the uppermost generator adaptor frame rib and position the indicator finger, which requires extensions, on the generator shaft. Preliminary readings can be taken on the coupling; final readings will be taken on the shaft only. Zero the dial indicator at the 12 o'clock position. It is essential to ensure that the dial indicator base does not move during the run-out check.

Any movement will result in erroneous readings.

Rotate the shaft one revolution starting at the 12 o'clock position, checking and recording the dial indicator readings every 90 degrees.

To validate the readings, at the completion of the revolution, the dial indicator must return to 0 at the original 12 o'clock starting position. In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft.

Desired reading is 0.000 inch. Total indicator readings shall not exceed .005 inches. Adjust drive flex plate pack (discs) to flywheel installation as necessary to bring parallel alignment into tolerance.

Adjustment is accomplished by changing the diesel engine flywheel to generator drive flex plate pack relationship. If total indicator readings exceed 0.005 inches, adjustment is accomplished by removing the drive flex plate pack to flywheel bolts and turning the engine flywheel with the turning gear. The generator can be prevented from rotating with the engine by installing a capscrew in the generator coupling and then holding the generator with a 36" long pinch bar or angle iron placed on the capscrew and generator web. The engine to flywheel relationship is changed one or more bolt holes at a time.

Reinstall the drive flex plate pack to flywheel bolts and take runout readings. Adjust as necessary to bring TIR readings into tolerance.

GENERATOR ANGULAR ALIGNMENT

Place a deflection dial indicator at the 12 o'clock position between the forward face of the fan and the drive flex plate at a point as far away as possible from the centerline of the shaft. The contact points for the deflection dial indicator fingers should be lightly punch marked.

Starting at the 12 o'clock position, rotate the shaft one revolution checking and recording readings every 90 degrees. To validate readings, at the completion of the revolution, the deflection dial indicator must return to zero at the 12 o'clock starting position. In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft.

Desired generator angular alignment readings are as follows:

12 O'CLOCK: 0.000 (starting point)

3 O'CLOCK: 0.000 TO +0.004

6 O'CLOCK: 0.000 TO +0.008

9 O'CLOCK: 0.000 TO +0.004

12 O'CLOCK: 0.000 (original starting point)

Adjust as necessary to bring angularity readings into compliance with paragraph 3 above. If adjustment is affected, a final set of angularity readings must be obtained after all bolts securing the generator to the engine and the generator to base are tightened to their final torque.

CRANKSHAFT DEFLECTION

Measure between faces of connecting rod throws of the crankshaft next to the center main bearing #4 and within .250 in. of the counterweight in accordance with Caterpillar Instructions. Record readings.

CRANKSHAFT END PLAY

Measure crankshaft end play in accordance with Caterpillar instructions. Record readings.

END OF ITEM