ATT_5-PISCES_SOW.pdf

NOAA Ship PISCES

3512 SSDG Top-End Overhaul

June 2019

NOAA Ship PISCES 3512 SSDG Top End Overhaul

1. SCOPE

1.1. Complete a top end overhaul on the two Caterpillar

3512B engines in accordance with this specification and repairs as specified to the two 3508B engines. Serial

Numbers for the four engines on NOAA Ship PISCES are as follows:

Engine #1: 8EM00549 – 3512 Top End Overhaul

Engine #2: 8EM00550 – 3512 Top End Overhaul

Engine #3: 3DM00508 – Repairs as specified

Engine #4: 3DM00509 – Repairs as specified

2. REFERENCES

2.1. NOAA Standard Specification AMC-000-1F, "General

Requirements for Ship Repair Contract Work on NOAA Ships"

2.2. Technical Manual FRV40-226-029-010 “Diesel Engine

Caterpillar 3512B”

2.3. Technical Manual FRV40-226-028-010 “Diesel Engine

Caterpillar 3508B”

2.4. Technical Manual FRV40-226-030-010 “Diesel Engine, Parts Manual Model: 3508B”, Volumes 1 and 2

2.5. Technical Manual FRV40-226-041-010 “Kato Generator, 3

Phase Synchronous”

3. GOVERNMENT FURNISHED MATERIAL

3.1. Lubricating Oil. Estimated Quantity: 400 Gallons, Estimated Cost: $8,000

4. REQUIREMENTS

4.1. General: The following requirements apply to all work.

4.1.1. Except as otherwise specified, the contractor

shall provide all labor, material, services, tools, consumables, supervision, manuals, and technical expertise required to accomplish the work detailed in this specification.

4.1.2. All work shall be accomplished by an authorized

repair facility of Caterpillar Tractor Company. All work shall be performed in accordance with Caterpillar service, maintenance, and overhaul technical manuals, including all current and applicable amendments and service bulletins, and References 2.1 through 2.5, 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.

4.1.3. 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 contractor and installed by the contractor. Procurement and installation of additional parts and components will be the subject of additional work negotiated by the Contracting Officer.

4.1.4. 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.

4.1.5. 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 remanufactured 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.

4.1.6. Disassemble the engine components, and parts to

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

4.1.7. Thoroughly clean, then conduct visual inspections

of all disassembled parts retained for re-use. Inspect for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability. 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.

4.1.8. Remove and reinstall all interferences as

required, at no additional cost to the Government.

Contractor is responsible for removing and reinstalling electrical cabling and piping to or from the engine, engine heat exchangers, air motors, etc. Contractor shall provide proper termination and support for all removed interferences.

4.1.9. After inspections have been completed and prior

to reassembling components, submit a report of all inspection findings and test results to the COR.

Include a record of all measurements and readings taken as well as recommendations for additional repairs, inspections or testing. Contractor shall not proceed with any additional work until authorized by the

Contracting Officer

4.1.10. After the report has been accepted and all

additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed using all new gaskets, seals, grommets, and O-rings.

4.1.11. At the end of each work day, accomplish a clean-

up of all debris incidental to the performance of the required work. Upon completion of all work, clean all work sites to their as-found condition.

4.1.12. Co-ordinate mechanical and electrical tag-outs

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

4.1.13. Contractor shall drain and dispose of all liquids

(fuel, lube oil, and jacket water) in the engines prior to beginning work. Upon completion of work, Contractor shall restore engine coolant levels to the recommended levels using contractor provided coolant. Replacement coolant shall be an OEM approved pre-mixed engine coolant.

Top End Overhauls on SSDG 1 and SSDG 2

4.2. Accomplish the following work for the Top End

Overhauls on SSDG 1 and SSDG 2:

4.2.1. Coordinate draining all fuel, lube oil, and

jacket water from SSDG 1 and SSDG 2 with Ship’s Force.

Contractor shall provide a pump truck to remove and dispose the coolant and lube oil from the ship’s waste oil tank. For bidding purposes, estimate 600 gallons of waste to be removed and disposed. Contactor shall coordinate scheduling tank discharge with ship’s force.

4.2.2. Remove all interferences and obstructions

including piping, wiring, and grating as needed to conduct work.

4.2.3. Contractor shall perform a Top-End overhaul on

SSDG 1 and SSDG 2 in accordance with Table 61 on Pages

132-133 of Reference 2.2 and as specified in Paragraphs

4.2.4 and 4.2.5.

4.2.4. Contractor shall 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.

4.2.4.1. Seals, "o"-rings, and gaskets of all removed

and disassembled components and parts

4.2.4.2. Turbochargers (re-manufactured)

4.2.4.3. Thermostats and water temperature regulators

4.2.4.4. Cylinder head assemblies (re-manufactured)

4.2.4.5. Fuel injectors (re-manufactured)

4.2.4.6. Fresh water pumps (re-manufactured)

4.2.4.7. Aftercooler cores (remove, clean, pressure

test)

4.2.4.8. Filter elements

4.2.4.9. Crankcase breathers

4.2.4.10. Visually inspect all hoses for signs of

deterioration. Ensure hoses are fitted with chaffing gear where needed and install if missing.

4.2.5. Clean, inspect, test, and reassemble the

following components, parts and subassemblies:

4.2.5.1. Wiring harness (ensure all wiring has

chaffing gear where needed)

4.2.5.2. Rocker arms

4.2.5.3. Fuel pressure regulating valve

4.2.5.4. Push rods

4.2.5.5. Aluminum spacer plates

4.2.5.6. Cam shaft inspection

4.2.5.7. Exhaust pyrometers for cylinders and each

bank

4.2.5.8. Oil suction screen and oil pump

4.2.5.9. Exhaust manifold bellows and gaskets

4.2.5.10. Cylinder Bank Inspection (QTY 2 per engine)

4.2.5.11. Fuel Priming Pump

4.2.5.12. Fuel Transfer Pump

4.2.5.13. Pre-lube Pump

4.2.5.14. Scavenge Oil Pump

4.2.5.15. Check Engine Control Module (ECM) software;

enter and review system; advise if updates are needed

SSDG 3 and SSDG 4 Repairs

4.3. Replace the leaking Engine Aft Crankshaft seal (Drive

End coupled to KATO Prime Mover) on both SSDG 3 and SSDG 4.

4.4. Repair leaks miscellaneous leaks on SSDG 3 and 4.

Contractor shall estimate eight (QTY 8) hours of labor onsite for repairs. Government shall provide materials.

Additional labor and materials will be the subject of additional work.

SSDG Testing

4.5. Upon completion of repairs, Ship’s Force will refill

engines with Lube Oil. Contractor shall assist Ship with refilling the engines to the proper coolant levels.

Contractor shall provide 24 hours’ notice prior to refilling engines with coolant.

4.6. Conduct the following tests on all four SSDGs after

all components have been reassembled.

4.6.1. Test all shutdown systems prior to starting the

engine. Conduct a preliminary tune-up of the engine.

4.6.2. Monitor engine operations as the ship's engineers

start the engine. Check all joints for leaks.

4.6.3. Perform operational tests of each engine using

ship’s hotel load for two hours. Ship’s 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 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.

4.6.4. Near the end of the test period, take and record

the following information. Provide test instruments as required:

4.6.4.1. Cylinder exhaust temperatures

4.6.4.2. Lube oil temperatures

4.6.4.3. Coolant temperatures

4.6.4.4. Fuel oil pressure

4.6.4.5. Lube oil pressure

4.6.4.6. Water pressures

4.6.4.7. Turbo outlet air pressure

4.6.4.8. Electrical Load on generator prime movers

4.6.4.9. Other operating parameters as permitted by

installed instrumentation.

4.6.5. Prepare and submit to COR a report of all data

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

4.6.6. After satisfactory completion of the operational

test, make final adjustments as required to provide smooth, efficient, and reliable operation of the engine.

4.7. Paint all new, disturbed, and re-manufactured parts

with OEM paint.

4.8. Complete an alignment inspection on each of the four

engines and generator assemblies, to include foot deflection. Submit results to COR along with any additional recommendation repairs

5. QUALITY ASSURANCE

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

6. NOTES

6.1. Work will be accomplished while PISCES is dockside at

the NOAA Gulf Marine Support Facility: 151 Watts Ave;

Pascagoula, MS 39567.

6.2. Ship’s force is available to provide crane service

during normal working hours to lift parts between the pier and aft deck; 24 hour notice required. Rigging of parts and moving of parts from aft deck into engine room shall be the responsibility of the Contractor.

6.3. The following is engine and generator information:

Diesel Generator Sets No. 1 and No. 2

600 Volt, 1360 kW, 1700 kVA

MFG: Kato- Caterpillar

Model: 3512B DITA SCAC

Engine No. 1 Serial No: 8EM00549

Engine No. 2 Serial No: 8EM00550

Kato Generator Serial No 1: 17824-01

Kato Generator Serial No 2: 17824-02

Kato Generator Model No: AA27756000

Diesel Generator Sets No. 3 and No. 4

600 Volt, 910 kW, 1137.5 kVA

MFG: Kato- Caterpillar

Model: 3508B DITA SCAC

Engine No. 3 Serial No: 3DM00508

Engine No. 4 Serial No: 3DM00509

Kato Generator Serial No. 3: 17825-02

Kato Generator Serial No. 4: 17825-01

Kato Generator Model No: AA27757000

-END OF SPECIFICATION-