ATT_1-SHIMADA_SOW.pdf

1. Item 233: Ships’ Service Diesel Generator Major Overhaul

1.1. Scope:

1.1.1. Provide all labor, material, services, tools, supervision, manuals and technical expertise needed to accomplish major overhauls on two (qty 2) 3508B Ship

Service Diesel Generator Engines (SSDG) #3 & #4, in accordance with this specification.

1.2. References:

1.2.1. NOAA Ship Bell M Shimada technical manual, SH-233-01

(FRV40-227-028-010), “Diesel Engine Caterpillar 3508B”

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 contractor 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 manufacturers’ 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 Companys’ factory or a Caterpillar-authorized repair facility; all re-manufactured components shall meet Caterpillars’ 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. Ships’ force will drain and dispose of all liquids in the engines prior to overhauls.

1.4.12. Co-ordinate mechanical and electrical tag-outs with

ships’ force engineering department prior to commencement of any work.

1.5. Tasks: Accomplish the following work for the major

overhaul of both SSDG 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. Rocker arms (re-manufactured)

f. Piston cylinder pins

g. Piston connecting rods (re-manufactured)

h. Fuel priming and transfer pumps (re-manufactured)

i. Cylinder liners (re-manufactured)

j. Pistons (re-maufactured)

k. Piston rings

l. Camshaft thrust washers, lifters and bearings

m. Push rods and spacer plates

n. Oil pump

o. Intake and exhaust manifolds, including gaskets and bellows

p. Fuel injectors (re-manufactured)

q. Fresh water pumps (re-manufactured)

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

s. Engine wiring harness

t. Filter elements

u. Crankcase breathers

v. All other components as recommended by Caterpillar to accomplish a Major overhaul in accordance with Table 58 of Reference 1.2.1.

w. 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. Cam shaft inspection

b. Crankshaft inspection

c. Oil suction screen

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

1.5.3. Ships’ force will refill the coolant and lube oil

systems. Contractor to provide 24 hours’ notice for commencement and completion of work, and must 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 ships’ engineers start the engine. Check all joints for leaks.

c. Perform operational tests of the engine using ships’ hotel load for two hours. Ships’ force will add equipment to the 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

Caterpillars’ 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 Caterpillars’ 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 this specification.

1.8. Period of Performance:

1.8.1. 27 August – 10 September 2019

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. #3 SSDG

MAKE: CATERPILLAR

MODEL: 3508B

SERIAL #: 3DM00526

ARRANGEMENT #: 173-6953

b. #4 SSDG

MAKE: CATERPILLAR

MODEL: 3512B

SERIAL #: 3DM00525

ARRANGEMENT #: 173-6953