ME_Cylinder_Head_Inspection_and_Repairs_SOW_0302274.docx
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- TS GOLDEN BEAR ME Cylinder Head Repair
- Solicitation number
- 6991PE19Q000028
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Statement of Work
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TITLE: Main Engine Cylinder Head Inspection and Repairs NSE SR: 0302274 and 0302153
1. ABSTRACT:
1.1 The intent of this item is to transport and overhaul Ten (10) each of the Main Engine Cylinder Heads including all attachments and sensors (Except Injectors). Contractor is to provide for packaging and transportation of the cylinder heads from the vessel and from the MARAD Warehouse to contractor facility and return to the MARAD Warehouse. All costs for transportation and packaging are to be included.
2. REFERENCES:
2.1. Technical manuals for Enterprise Engines, Engine Model: R5-V16
2.2 CONTRACTOR TO USE ALL THREE (3) REFERENCED ATTACHEMENTS IN PREPARATION OF THEIR BID AND TO PERFORM THE REPAIRS ON THE HEADS TO BE OVERHAULED
2.2.1 Transamerica Delaval Service Information Memo No 249
2.2.2 Hans Mueller – AALBORG 1993 Paper -Part No 1
2.2.3 Hans Mueller - 1993 Paper -Part No 2
3. ITEM LOCATION AND DESCRIPTION:
3.1. Qty Six (6) Heads to be taken from the Vessel (four (4) to be taken following ME Inspection) at CSUM Pier, 200 Maritime Academy Dr., Vallejo, CA 94590
3.2. Qty Four (4) Heads to be taken from the MARAD Alameda Warehouse, 1651 Viking Street, BLDG 168, Alameda, CA 94501
3.3 Cylinder heads are to be returned to the MARAD Alameda Warehouse, 1651 Viking Street, BLDG 168, Alameda, CA 94501
4. OWNER FURNISHED EQUIPMENT, MATERIALS, AND SERVICES:
4.1 Ten (10) each Main Engine Cylinder Heads (Serial Number to be identified during disassembly)
4.2 Contractor is to provide a CFR with pricing and availability for parts identified as worn or non-usable, bulk pricing is to be included as required. CFR approval for supplemental funding for this line item will be required.
4.3 Once part requirements are identified, contractor is to coordinate with COR and vessel to identify which parts will be supplied from vessel spares. Once parts are identified contractor is to provide a CFR to package and transport parts to contractor facility. CFR approval for supplemental funding for this line item will be required.
5. STATEMENT OF WORK:
All work must be in accordance with standard marine practice and be in compliance with ABS and USCG rules. All dimensions are estimated.
| 5.1 | GENERAL CRITERIA |
| 5.1.1 | Supply all labor, equipment, parts, materials and transportation/lifting services to accomplish work described in abstract. Contractor is responsible for removing and returning any material or parts requiring off-site repair or servicing. |
| 5.1.2 | Contractor is responsible for all rigging, packaging and transport associated with shipping the ten (10) main engine cylinder heads in the quantities and locations as specified in above Section 3. Contractor is responsible for all crating and strapping and securing of the cylinder heads to prevent any damage during shipment. Contractor is responsible for the same precautions during any shipment, to and from the vessel, the contractor facility or MARAD Warehouse. |
Qty Six (6) Heads to be taken from the Vessel (four (4) to be taken following ME Inspection) at CSUM Pier, 200 Maritime Academy Dr., Vallejo, CA 94590 Qty Four (4) Heads to be taken from the MARAD Alameda Warehouse, 1651 Viking Street, BLDG 168, Alameda, CA 94501 All heads to be returned are to be sent to the MARAD Alameda Warehouse, 1651 Viking Street, BLDG 168, Alameda, CA 94501
5.1.3 Contractor must have a minimum of five (5) years of experience working on Enterprise R5 16V Engine and Cylinder Heads. Supply proof of this experience at time of bid submittal. Contractor must supply specific proof of their past repairs to R5 – 16V cylinder heads including the ship’s name and the cylinder number and the ABS reports for same.
Note: All parts and materials are to be contractor supplied unless called out otherwise in specification. All parts and materials shall be OEM or equivalent pre-approved by COTR. All tolerances and limits referred to in this overhaul specification shall be defined as those that the OEM delineates as “suitable for reuse or reassembly” or “acceptable” in the Enterprise Maintenance and Repair manual for these engines. These tolerances and limits shall not be those the OEM describes as “as new” or “as delivered” unless specifically referred to in this specification and in no case shall the contractor deliver reports calling out tolerances as “out of spec” when within the “suitable for reuse” tolerances.
| 5.1.4 | All work shall meet USCG, ABS or other appropriate regulatory standards. Contractor is responsible for contacting the ABS when the Heads are ready to be inspected both prior to repairs and after the repairs are completed and to be tested and inspected after the valve seat repairs. Shop and contractor must supply MARAD with all shop notes and ABS Approval of same plus all heads must have an ABS stamp on each head to show that it has passed ABS inspections |
| 5.1.5 | Any Contractor recommendations or requests to deviate from OEM repair guidelines/specifications shall be submitted in writing in a timely manner to the COTR and shall not be acted on prior to COTR authorization |
| 5.2 | TRANSPORTATION AND INITIAL INSPECTION: |
| 5.2.1 | Contractor is to provide all needed rigging and transportation to remove the used cylinder heads to/from the MARAD Warehouse, to/from the vessel, and to/from the contractor facilities. |
| 5.2.2 | Contractor to provide all needed transportation and rigging to return the repaired cylinder heads from the contractor facility to the MARAD Warehouse. |
| 5.2.3 | Contractor is to prepare heads for an owner’s representative visit following the cleaning and inspection process and prior to repairs being performed. Contractor is to notify COR 30 days prior to expected inspection date to allow for travel plans to be made. Due to travel requirements, all heads and associated parts are to be stripped and cleaned, ready for inspection. Contractor is to coordinate owner’s representative visit inspection, such that overall inspection and any testing to be performed will be accomplished during a one-time visit. Contractor to coordinate with vessel representative regarding scheduling and if more than one day is required note the number of consecutive days required to complete the inspection. |
| 5.3 | CYLINDER HEAD OVERHAUL: |
| 5.3.1 | Contractor to provide all necessary technical labor and material to overhaul the Enterprise Cylinder Heads to return them to usable condition and within manufacturers specifications and/or Regulatory requirements |
| 5.3.2 | Completely disassemble and clean each cover detaching valve gear, etc. Check fire-decks, and valve seats for cracks using either dye penetrant or magnetic particle method. Clean and inspect all parts including: exhaust and intake valve spindles, rotators, guides, air-start valves, safety valves, indicator cocks, etc. |
| 5.3.3 | Provide as found report to COTR and with recommendations for cylinder heads to continue with service as per specification. |
| 5.3.4 | Of the Ten (10) cylinder heads removed from the engine that need to be overhauled: |
| 5.3.5 | Repair all cracked valve seats following OEM Transamerica Delaval Service Information Memo No. 249 Cylinder Head Valve Seat Repair and other procedure as required by ABS or other Regulatory Agencies. Review all attachments that refer to procedures for the pre-heat, repair and post-heat processes. Three (3) separate sets of instructions are attached and must be followed to insure the proper repair and reliable operation. Relief at the Outside Diameter of the valve seat is especially important to prevent possible damage to the valve seat during operation. |
| 5.3.6 | Grind all non-cracked intake and exhaust valves and seats to bring back to within manufacturer’s tolerances. Take and record clearances as per manufacturer’s Inspection and Maintenance Records. |
Note:
DO NOT lap or blue the valves with the head in a vertical position. Grinding should be done using a Chris Marine seat grinder or equivalent technology followed by bluing to prove proper seating.
5.3.7 Following OEM recommended procedures, repair all firing and jacket water head gasket seating surfaces to meet manufactures acceptable tolerances.
5.3.8 Rejected Exhaust/Intake Valves shall be replaced per Section 4, above. Either from vessel spares or from parts purchased thru approved CFR by Contractor. All valves shall be installed with new keepers.
| 5.3.9 | One (1) Fuel Injector will be supplied with the four (4) heads to be used for measurements and tolerance checks |
| 5.3.10 | All Start Air Valves shall be completely disassembled, cleaned, inspected, lapped and reassembled with contractor furnished all new seals and O-rings and re-installed in Cylinder Heads with new O-rings and joint rings. Contractor is to supply and install all O-rings and Joint rings. |
| 5.3.11 | Re-assemble cylinder heads. Hydro-test ring and gauge test cover to 125 psi |
| 5.3.12 | Once the Heads are completely repaired, paint the exterior surfaces with paint color and type to match the existing paint scheme and that is compatible with service of the equipment location to heat and other operating conditions. |
| 5.3.13 | ABS surveyor to witness above inspections as required. |
5.3.14 Provide two (2) final typewritten copies to Chief Engineer of all measurements, clearances and readings taken during work this item in manufacturer’s format as per Inspection and Maintenance Record of service manual and provide for review during ABS attendance. This report shall include serial numbers of all cylinder heads, etc.
Provide electronic copies of all documents to COTR
| 5.4 | SCHEDULING & REGULATORY DEMONSTRATION |
| 5.4.1 | Contractor is responsible scheduling the overhaul of the Cylinder Heads so that they can be shipped back to the MARAD Warehouse prior to 8/15/2020. If this date cannot be accomplished, alert the MARAD COTR via email giving an approximate date for completion a minimum of 2 weeks before the contract completion date |
| 5.4.2 | Contractor is to coordinate all transportation and give a weekly update to the COTR all progress and of any problems encountered that might delay the delivery of the overhauled heads to the MARAD Warehouse. |
6. PERFORMANCE CRITERIA AND DELIVERABLES:
6.1. Contractor is to provide two (2) hard copies and one (1) electronic (pdf) copy to the Chief Engineer of all measurements, clearances, readings and pictures taken during work this item in manufacturer’s format as per Inspection and Maintenance Record of service manual. This report is also to include the serial numbers of all rods, pistons, cylinder heads, etc., associated with the work scope. Additionally, contractor is to provide a historical Mapping of overhauled cylinders and the dates / years in which they were overhauled. An additional one (1) electronic (pdf) copy is to be supplied to the governments representative.
6.2. Any work items outside of this work scope are to be submitted via CFR. All CFR’s are subject to approval. Any additional costs will require approval and additional costs are only to be incurred following an approval by the ACO which may be dependent on a review and the amount.
7. ADDITIONAL WORK AND SUPPLEMENTARY:
7.1 Additional work and Supplemental labor and materials are to be used for additional requirements which are identified during the accomplishment of the scope of work however were not in the original SOW. To establish an estimate for supplemental labor and materials contractor is to supply a supplemental labor rate for the number of hours shown below with supplemental material costs per below.
7.2 Any additional items that are required which are considered within the scope of work, or are required to complete the scope of work but were not reasonably known and are not listed in the statement of work (SOW) above are to be submitted as a CFR. The written CFR is to be approved prior to the contractor incurring any additional costs for associated CFR.
7.3 Contractor is not to proceed with a CFR until it is approved by the ACO or COR with ACO permission. A verbal from the ACO may be given at the ACO’s discretion. CFR’s under $2500 may be approved by vessel COR.
7.4 If approved, the contractor is to provide labor, material and equipment to accomplish the CFR.
7 A) Supplementary Labor = 80 hrs @ $____/Hr = Total $___________
7 B) Supplementary Parts and Materials = $28,000.00
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