23-062_PWS_Redacted.pdf

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Performance Work Statement (PWS) Overhaul of Detroit Diesel 8V92 Engine for Westmont Portal Crane

1.0 Description of Service: Pearl Harbor Naval Shipyard & Intermediate Maintenance Facility (PHNSY & IMF) has a diesel engine that requires overhaul. The engine is required for use on Westmont portal cranes. The engine needs to be overhauled and dyno tested prior to installation on the portal crane.

The engine is a Detroit Diesel 8V92 engine model number 80837K05, serial #08VF175942.

2.0 Work Specifications: The contractor shall provide all management, labor, materials, tools and machinery to overhaul the engine and dyno test the engine.

2.1 Contractor workmanship shall provide a standard of quality consistent with that of OEM specifications. Contractor shall ensure that all personnel assigned to this contract possess suitable professional skills, qualifications, and certifications to accomplish the overhaul of the engine.

2.2 The engine shall be overhauled within all specifications of the OEM and the requirements of this PWS. The Contractor shall be responsible for following all OEM specifications using OEM drawings, documents, and service publications during the performance of the engine overhaul.

2.3 All components and parts to be replaced shall be approved OEM parts. Where the OEM has substituted parts or components with a newer model or identification number, a record of superseded model numbers and designations shall be provided to the Government for its records. For OEM components or parts not available, an equivalent component or part shall be provided. Components or parts not sourced through the OEM require submittal of documentation to the Government to include the following:

2.3.1 Manufacturer’s part name and full part number to be listed and identified.

2.3.2 Confirmation of compatibility to OEM component specifications and/or system design parameters. Location of the component or part on the engine.

2.4 Overhaul of the engine shall include all work elements necessary to access, and assess the condition of all components of the engine. All wearing elements shall be assessed for condition and replaced if not within OEM criteria for new machine tolerances of fit, function, and finish. Components subject to environmental degradation (UV sunlight, moisture, corrosion, rust, etc.) shall be replaced, or cleaned and refinished as applicable.

2.5 Surface preparation shall include media blast of all painted surface areas and cosmetic repairs to metal surfaces as needed. Primer and paint specifications and colors shall be In Accordance With (IAW) OEM specifications.

NOTE: Material Restrictions: Lead paint, Polychlorinated Biphenyl’s (PCB’s), and asbestos (in any form) shall not be used in the overhaul of the engine.

2.6 OEM required Non-Destructive Testing (NDT) such as Magnaflux inspection to structural members shall have documentation of NDT inspections and provided to the Government. All defects shall be corrected IAW OEM specifications.

2.7 The newly overhauled engine shall be dynamometer tested per manufacturer requirements upon completion of the overhaul.

3.0 Work Description:

3.1 Contractor shall replace non-rebuildable components with new.

3.2 The contactor shall break down the engine to bare block. The block and crank shall be cleaned, checked, bored, mag tested, polished and balanced.

3.2.1 Cylinder blocks shall be checked for surface cracks using Magnaflux or OEM approved procedure.

3.2.2 Cylinder bores, counter bores and crank bores shall be checked for wear and damage, and repaired if required to restore OEM standards.

3.2.3 Water passages of the cylinder blocks shall be pressure tested.

3.2.4 Serial numbers, cylinder bore size and work performed shall be recorded and submitted to the Government for record keeping.

3.2.5 Crankshafts shall be checked for bends and cracks using a Magnaflux procedure and shall be measured and polished or machine ground to OEM specifications.

3.3 Engine block shall be rebuilt using new liners, pistons, skirts, rings, wrist pins and liner seals. Updated block plugs shall be used.

3.4 Cylinder heads shall be assembled using new valves, springs, spring retainers and seats, rocker arm shafts, guides, seals, cam follower rollers, push rods. Rocker arms and valve bridges may be reclaimed or overhauled to OEM specifications as needed. Cylinder heads shall be supplied with new plugs. New fuel injectors and head bolts shall be used.

3.4.1 Cylinder heads shall be checked for straightness in accordance with OEM specifications, and re-faced as needed. All critical dimension shall be checked and corrected if re-facing is needed.

3.5 Connecting rods and bearings shall be replaced with new OEM approved parts.

3.6 Fuel pump and water pump shall be new using new seals, new bearings and shafts.

3.7 Camshaft end bearings shall be new using new bushings and bearings. Camshafts shall be cleaned and checked for damage/wear and adherence to OEM specifications.

Overhauled camshafts may be purchased from outside vendors as long as the vendor’s service and experience ensure the highest quality components available.

3.8 Oil pump, and oil cooler shall be new using new valves and springs.

3.9 Turbochargers, vibration dampener, thermostat and seals, blower, starter, and flywheel assembly shall be new.

3.10 DDEC-3 control unit wiring harness shall be new with all sensors (sending unit) replaced.

3.11 All refurbished/reused items shall be shall be cleaned/polished and/or pressure checked prior to reinstallation, and/or checked for deformation or warpage (such as thermostat housing, rocker cover, end plates, covers, etc.). In the event that a reused part is found to not meet OEM standards and specification, the Contractor shall notify the Contract Specialist. A modification to this contract may be performed; additional work shall not proceed until authorization from the Contracting Officer is granted.

3.12 Engine shall be assembled by qualified technicians who verify the correct components and acceptable measurements of all overhauled components, subassemblies and reclaimed components. Engine shall be assembled using all new bearings, seals, gaskets, hoses, belts, fuel lines, high pressure injection lines, block fasteners, and all other consumable parts, including replacement of engine lube oil and oil filters.

3.13 Complete engine shall be dynamometer tested to OEM standards. Horsepower output, rpm, oil pressure, crankcase pressure and air box pressures shall be recorded along with engine specifications and supplied with a start-up inspection report that shall be submitted to the Government for record keeping.

3.14 Engine shall be painted IAW OEM specifications.

3.15 Reports documenting all work performed, including NDT inspection reports and dynamometer test results shall be submitted in .pdf format to the TPOC via e-mail.

4.0 Period of Performance: Contractor shall coordinate work with PHNSY & IMF Code 700. The Engine will be available for delivery after the contract award. POP: 06/01/2023 – 11/30/2023.

5.0 Place of Performance: Overhaul of the Detroit Diesel 8V92 Engine, will take place at the contractors facility.

Shipping: PHNSY &IMF will be responsible for shipping and transportation of the equipment to the contractor’s facility. The contractor is responsible for shipping and transportation of the equipment back to the government FOB destination via traceable means. Contractor must ship to the following address and POC.

Pearl Harbor Naval Shipyard and IMF

667 Safeguard Street

JBPHH, HI 96860

6.0 Safety: The Contractor shall comply with all applicable Federal and State of Hawaii Occupational Safety and Health Administration (OSHA) requirements.

7.0 Security Requirements: Work will be performed outside of shipyard property and no additional security requirements are applicable.

8.0 Contractor Qualification: Contractor shall have a minimum of 10 years of experience overhauling Detroit Diesel engines.

9.0 Quality Assurance: The Contractor is responsible for implementing and maintaining a Quality Control Program (QCP) to ensure that the work performed meets or exceeds contract requirements and results in the correction of potential and actual problems. The QCP shall be implemented on the first day of contract performance. Contractor shall also warranty his work (materials and workmanship) for 90 days.

10.0 Working Hours: Regular working hours shall consist of an 8-hour period, between 6:30 AM - 3:00 PM Monday through Friday, excluding Federal holidays and weekends. The shipyard is also closed between December 25 through January 1.

11.0 FEDERAL HOLIDAYS:

New Year's Day 1st of January Dr. Martin Luther King's Birthday 3rd Monday in January President's Day 3rd Monday in February Memorial Day 5th Monday in May Independence Day 4th of July Labor Day 1st Monday in September Columbus Day 2nd Monday in October Veteran's Day 11th of November Thanksgiving Day 4th Thursday in November Christmas Day 25th of December

If the federal holiday falls on a Saturday, the holiday is observed on the preceding Friday. If the federal holiday falls on a Sunday, the holiday is observed on the following Monday.

12.0 ENTERPRISE-WIDE CONTRACTOR MANPOWER REPORTING APPLICATION:

The contractor shall report ALL contractor labor hours required for performance of services provided under this contract via a secure data collection site. Contracted services excluded from reporting are based on Product Services Codes (PSCs). The excluded PSCs are:

(1) W, Lease of Equipment;

(2) X, Lease/Rental of Facilities;

(3) Y, Construction of Structures and Facilities;

(4) S, Utilities ONLY;

(5) V, Freight and Shipping ONLY.

The contractor is required to completely fill in all required data fields using the following web address https://doncmra.nmci.navy.mil.

13.0 POINT OF CONTACT: