SH_FY19_SSDG_Topend_Overhaul_SOW.pdf

1. Item 233: Ship’s Service Diesel Generator Top End Overhaul

1.1. Scope:

1.1.1. Provide all labor, material, services, tools, supervision, manuals and technical expertise needed to accomplish top end overhauls on two (2) 3512B Ship Service

Diesel Generator Engines (SSDG) #1 & #2, in accordance with this specification.

1.2. References:

1.2.1. NOAA Ship Bell M Shimada technical manual, SH-233-02

(FRV40-225-029-010), “Diesel Engine Caterpillar 3512B”

1.3. Government Furnished Material:

1.3.1. Lubricating oil and engine coolant

1.4. Requirements:

1.4.1. All work shall be accomplished by an authorized repair facility of Caterpillar Tractor Company, in accordance with

Caterpillar service, maintenance, and overhaul technical manuals, including all current and applicable amendments and service bulletins, in such a manner that the manufacturer's warranty on parts and labor is not voided. 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 Caterpillar engine specifications, clearances, tolerances, and procedures.

1.4.2. Provide and install "mandatory-renewal" parts and

components as required by this specification. Additional components requiring renewal may be provided by the Government

(if available) or by the Contractor. Procurement and installation of additional parts and components will be negotiated by the Contracting Officer as additional work.

1.4.3. Except where re-manufactured components are authorized or specified, only new, original Caterpillar non-surplus components and parts shall be used. Prior to installing all parts, perform visual and dimensional inspections to verify components and parts are acceptable for use.

1.4.4. Where re-manufactured components are provided, existing components shall be replaced on an exchange basis with components which have been re-manufactured at Caterpillar

Tractor Company’s factory or a Caterpillar-authorized repair facility; all remanufactured components shall meet Caterpillar’s re-manufactured 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.

a. The existing components become the property of the contractor in their as-found condition.

b. When factory re-manufactured or new components are not available, existing components shall be disassembled, cleaned, inspected, repaired (including renewal of all parts needed), reassembled, and calibrated by a Caterpillar authorized repair facility using Caterpillar parts.

1.4.5. Disassemble the engines, components, and parts to the

extent required to perform the required inspections, repairs and parts renewal.

1.4.6. Thoroughly clean, then conduct visual inspections of all disassembled parts to be re-used for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability.

1.4.7. After inspections and tests have been completed, and

prior to reassembling components, submit a typed report of all inspection findings and test results, including a record of all measurements and readings taken, to the Contracting Officer's

Representative (COR). Include recommendations for additional repairs, inspections, tests, and part renewals needed. Do not proceed with any additional work (i.e., work not identified in the original specification) until authorized by the Contracting

Officer.

1.4.8. After the report has been accepted and all additional

work has been negotiated, reassemble and reinstall all components that were previously disassembled or removed.

1.4.9. Remove and reinstall interferences as required to

accomplish the required work.

1.4.10. Accomplish daily clean-up of debris incidental to the performance of the required work. Clean all work sites to their as-found condition upon completion of all work.

1.4.11. Ship’s force will drain and dispose of all liquids in the engines prior to overhauls.

1.4.12. Coordinate mechanical and electrical tag-outs with

ship’s force engineering department prior to commencement of overhauls.

1.5. Tasks: Accomplish the following work for the top end

overhaul of both engines:

1.5.1. Renew all of the following "mandatory-renewal" parts and components. Where "re-manufactured" is added in parenthesis after a component, a re-manufactured component may be provided in lieu of a new component.

a. Seals, "o"-rings, and gaskets of all removed and disassembled components and parts

b. Turbocharger cartridges (re-manufactured)

c. Thermostats and water temperature regulators

d. Cylinder head assemblies (re-manufactured)

e. Fuel injectors (re-manufactured)

f. Fresh water pumps (re-manufactured)

g. Aftercooler cores (remove, clean, pressure test)

h. Filter elements

i. Crankcase breathers

j. Visually inspect all hoses for signs of deterioration;

ensure hoses are fitted with chaffing gear where needed.

1.5.2. Clean, inspect, test, and reassemble the following

components, parts and subassemblies:

a. Wiring harness (ensure all wiring has chaffing gear where needed)

b. Rocker arms

c. Fuel pressure regulating valve

d. Push rods

e. Aluminum spacer plates

f. Cam shaft inspection

g. Exhaust pyrometers for cylinders and each bank

h. Oil suction screen and oil pump

i. Exhaust manifold bellows and gaskets

j. Check Engine Control Module (ECM) software; enter and review system; advise if updates are needed

1.5.3. Ship’s force will refill the coolant and lube oil

systems. Contractor to provide 24 hours’ notice. Contractor to be on hand during re-filling procedures.

1.6. Testing:

1.6.1. Conduct the following test of the engine after all

components have been reassembled.

a. Test all shutdown systems prior to starting the engine. Conduct a preliminary tune-up of the engine.

b. Monitor engine operations as the ship's engineers start the engine. Check all joints for leaks.

c. Perform operational tests of the engine using ship’s hotel load for two hours. Ship’s force to add equipment to bus for testing purposes. Make adjustments, correct leaks, and continuously monitor performance of the engine. If at any time a temperature or pressure exceeds or falls below Caterpillar’s recommended upper or lower limits, the test shall be stopped and the cause determined. After the cause has been corrected, the test shall be restarted from the beginning.

d. Near the end of the test period, take and record the following information. Provide test instruments as required:

1. cylinder exhaust temperatures

2. lube oil temperatures

3. water temperatures

4. fuel oil pressures

5. lube oil pressures

6. electrical load on generator prime movers

7. other operating parameters as permitted by installed instrumentation

1.6.2. Prepare and submit to COR a report of all data taken

during the test period. Include Caterpillar’s recommended limits for the applicable parameter.

1.6.3. After satisfactory completion of the operational test, make final adjustments as required to provide smooth, efficient, and reliable operation of the engine.

1.6.4. Paint all re-manufactured parts with OEM paint.

1.7. Quality Assurance:

1.7.1. COR inspection/witness of post-overhaul testing, along with submittal of documentation called out in specification.

1.8. Period of Performance:

1.8.1. 26 November 2018 – 14 December 2018

1.9. Place of Performance:

1.9.1. NOAA Ship Bell M. Shimada, dockside at NOAA Marine

Operation Center, Pacific; 2002 SE Marine Science DR, Newport, OR.

1.10. Notes:

1.10.1. Engine Information:

a. #1 SSDG

MAKE: CATERPILLAR

MODEL: 3512B

SERIAL #: 3EM00558

ARRANGEMENT #: 174-4947

b. #2 SSDG

MAKE: CATERPILLAR

MODEL: 3512B

SERIAL #: 3EM00557

ARRANGEMENT #: 174-4947