REV. 1 Attachment 4 - PISCES FY21 SSDG Repairs.docx

REVISION 1

NOAA Ship PISCES FY21 PISCES SSDG Repairs August 2020

NOAA Ship PISCES FY21 SSDG Repairs

1. SCOPE

1.1. Complete miscellaneous repairs and jacket water flexible joint replacement on the two Caterpillar 3508 engines, resilient mount replacement on the two 3512 SSDGs, and generator inspection in accordance with this specification. Serial Numbers for the four engines on NOAA Ship PISCES are as follows:

Engine #1: 8EM00549 – 3512 Resilient Mount Replacement Engine #2: 8EM00550 – 3512 Resilient Mount Replacement Engine #3: 3DM00508 – 3508 Engine #4: 3DM00509 – 3508

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”

2.6. Drawing M282-073-FP22 “Generator Intermediate Mass Raft Details”

2.7. Spreadsheet M283-FR05 “Resiliently Mounted Equipment”

2.8. Drawing M282-259-FP06 “Exhaust System Diagram”

3. GOVERNMENT FURNISHED MATERIAL

3.1. Resilient Mounts Christie & Grey Mounts Model 10.103.70 (QTY 48) and 10.103.75 (QTY 8). Total Cost: $12,500.

3.2. Flexible Joints – 3-inch flexible joints (QTY 12), 5-inch flexible Joints (QTY 12) – estimated value: $24,000

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 2.8, 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. Prior to the start of work, Contractor shall install deck coverings on the engine room lower and upper levels, EOS, Trawl Winch Room, and the Oceanographic Winch Room walkways where Contractor will transit and stage / transport equipment. Contractor is responsible for maintaining the deck coverings throughout the completion of the work and shall remove all deck coverings upon completion of work.

4.1.12. 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.

4.1.13. Co-ordinate mechanical and electrical tag-outs with ship’s force engineering department prior to commencement of overhauls.

4.1.14. Contractor shall drain and dispose of all liquids (fuel, lube oil, and jacket water) in the engines prior to beginning work. Contractor shall drain and dispose of all liquids using contractor supplied containers, hoses, and pumps. Ship’s Waste Oil Tanks shall NOT be used. If necessary, coordinate removal of waste oil containers from the aft deck with COR using Ship’s Cranes.

4.1.15. Upon completion of work, Contractor shall restore engine coolant and lube oil levels to the recommended levels using contractor provided lubricating oil and coolant. Replacement coolant shall be an OEM approved pre-mixed engine coolant.

Miscellaneous 3508 Specific Repairs (SSDG 3 and SSDG 4)

4.2. Accomplish the following work on SSDG 3 and SSDG 4:

4.2.1. Contractor is responsible for draining all jacket water, lube oil, and fuel as necessary to accomplish the work of this specification. Contractor shall drain and dispose of all liquids using contractor supplied containers, hoses, and pumps. Contractor shall remove and dispose of all waste from the ship.

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 comprehensive inspection of each engine and submit a CFR for any required repairs that are not identified by this specification.

4.2.4. Replace all fuel, oil, and jacket water temperature and pressure sensors on each engine.

4.2.5. Replace all coolant hoses and inspect all other hoses on the engine for wear. Install chaffing gear where needed.

4.3. After draining the jacket water from each engine, Contractor shall replace all flexible joints on SSDG 3 and 4 using GFM provided flexible joints. Each engine is outfitted with six (QTY 6) three-inch (3-in) flexible joints and six (QTY 6) five-inch (5-in) flexible joints.

4.4. After refilling the jacket water systems, Contractor shall inspect each flexible joint for leakage and verify all joints are leak-free.

SSDG 1 and SSDG 2 Specific Repairs

4.5. Repair miscellaneous leaks and other discrepancies on SSDG 1 and 2. Contractor shall estimate twenty-four (QTY 24) hours of labor onsite for additional miscellaneous repairs and $1,000 of parts & materials. Additional labor and materials will be the subject of additional work.

4.6. Contractor shall inspect SSDGs 1 and 2 and submit a CFR if additional repairs are required.

4.7. Contractor shall replace the upper and lower raft resilient mounts on SSDG 1 and SSDG 2. Contractor may elect to complete this work in-house or use a qualified contractor to complete the work under OEM supervision.

4.8. Measure and record the shim heights on all the generator mounting bolts. Provide the COR with a condition report stating all of the measurements.

4.9. Contractor shall remove the existing engine foundation vibration mounts and install new GFM provided resilient mounts on both 3512 Engines; using Reference 2.6 and Reference 2.7 as a guide to ensure that the correct mounts are installed in the correct locations and as follows:

4.9.1. The generator/engine set base frame must be supported independently and leveled in position but approximately 35 mm (1.4”) higher than as found condition. Install the upper mountings directly to the generator/engine frame with no shims and with no load on the mountings.

4.9.2. The rafts must be supported independently and leveled but approximately 18 mm (0.71”) higher so as to leave a clearance of about 6 mm (0.25”) between the upper mountings and the raft top surface. Install the lower mounting to the rafts without shims. There should be a clearance of about 6 mm (0.25”) below the lower mountings at this stage.

4.9.3. Measure and record the clearances below each mounting. Take a reading at each corner of the base and average these. If the difference across a base is more than 2 mm consideration should be given to using taper shims.

4.9.4. For the upper mountings, subtract the smallest clearance of any of the upper mountings from each of the other upper measurements. The remainder is the shim thickness to be used below that mounting.

4.9.5. For the lower mountings, subtract the smallest clearance of any of the lower mountings from each of the other lower measurements. The remainder is the shim thickness to be used below that mounting.

4.9.6. Round the shim thickness calculated to the nearest millimeter (0.040”) and record. This is the shim thickness for that mounting. If taper shims are used record the thickness at each corner.

4.9.7. Prepare shims with the two bolt clearance holes for fitting below the mountings. Each shim shall be a single piece covering the whole of the mounting base. Install the shims and insert the fixing bolts loosely to ensure that the mounting are not strained horizontally.

4.9.7.1. At this stage there should be clearance below the mountings. Transfer the weight onto the mountings by first lowering the rafts. The lower mountings should not compress significantly (perhaps 2 mm (0.080”) under the weight. When the rafts are free lower the generator/engine set onto the upper mountings.

4.9.7.2. Allow to settle for 48 hours before measuring the “installed” mounting heights. These must be recorded with details of the positions and shims used at each position.

4.9.8. Tighten all mounting bolts to their correct torque valves.

4.9.9. Accomplish a complete engine and generator alignment inspection by an OEM certified technician (CAT) after the mounts have had the final torque. Ensure proper alignment and a provide report as a CFR. Provide readings for radial, axial, and angular misalignment, and inspect for soft foot conditions.

4.10. Contractor shall also inspect and validate alignment, including any soft foot deflection, on SSDGs 3 and 4. Contractor shall align SSDG 3 and 4 and provide a CFR to COR verifying proper engine and generator alignment.

Miscellaneous SSDG Repairs

4.11. Replace the pneumatic air starters on SSDGs 2, 3 and 4. One suggested replacement is the TDI Pneumatic Starter Model Number T6C, Part Number T6C63761 or approved equal. Contractor shall dispose of the old starters.

4.12. Replace the insulation blankets around each SSDG Exhaust bellows. See below photographs for example and Reference 2.8 for insulation material requirements.

Generator Inspection

4.13. Contractor shall remove the drive and free-end SSDG shrouds. Contractor shall inspect the Vulcan Couplings and engine bearings.

4.14. Contractor shall flush the lubricating grease in each generator bearing.

4.15. Contractor shall remove the exciter from SSDG-3 and transport to a factory approved machinery shop. Contractor shall remove the broken fastener from the exciter and rethread all tapped holes. Contractor shall machine the inside diameter to remove any surface roughness and restore to OEM specifications. Contractor shall polish the generator shaft as needed to aid in exciter removal / reinstallation.

4.16. Contractor shall inspect the armature, rotor, and exciter, and test all engine operating parameters including the armature, rotor, and exciter insulation resistance tests, and testing of all diodes.

4.17. Provide a CFR to the COR of Vulcan coupling and bearing conditions and generator assessment including all inspection results before and after cleaning.

SSDG Testing (Post Engine Repairs)

4.18. Upon completion of all engine repairs, Contractor shall refill all SSDGs 3 and 4 with Lube Oil and OEM approved pre-mixed Engine Coolant. Contractor shall provide all pre-mixed extended life engine coolant. Contractor shall provide 24 hours’ notice prior to refilling engines with oil and coolant.

4.19. Conduct the following tests on all four SSDGs after all components have been reassembled.

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

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

4.19.3. 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.

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

4.19.4.1. Cylinder exhaust temperatures

4.19.4.2. Lube oil temperatures

4.19.4.3. Coolant temperatures

4.19.4.4. Fuel oil pressure

4.19.4.5. Lube oil pressure

4.19.4.6. Water pressures

4.19.4.7. Turbo outlet air pressure

4.19.4.8. Electrical Load on generator prime movers

4.19.4.9. Other operating parameters as permitted by installed instrumentation.

4.19.5. Prepare and submit to COR a report of all data taken during the test period. Include Caterpillar’s recommended limits for the applicable parameter.

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

4.20. Paint all new, disturbed, and re-manufactured parts with OEM paint.

5. QUALITY ASSURANCE

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

6. NOTES

6.1. Contractor is responsible for providing all PPE, personal cleaning agents, and personal cleaning stations.

6.2. Unless precluded by task related PPE (such as welding), all Contractor personnel are required to wear face coverings that cover the nose and mouth while on the ship at all times. Face coverings are required for all interior and exterior areas of the vessel.

6.3. To the maximum extent practicable, and not to interfere with production work, Contractor shall practice social distancing while on NOAA property.

6.4. Contractor personnel shall clean hands immediately after boarding the vessel and prior to proceeding to the work area. Hands shall be cleaned each time the vessel is boarded.

6.5. Work will be accomplished while PISCES is dockside at the NOAA Gulf Marine Support Facility: 151 Watts Ave; Pascagoula, MS 39567.

6.6. 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.

6.7. The following is engine and generator information:

END OF SPECIFICATION

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