Attachment 1 - Detailed Work Specifications.pdf

NOAA Standard Specification

CATERPILLAR 3512C MARINE ENGINE TOP END OVERHAULS (9,000 hr)

1.0 SCOPE: This specification contains requirements for the top end overhauls (9,000 hr.) for Caterpillar 3512C marine engines on NOAA Fisheries Survey Vessels (FSV).

2.0 REFERENCES:

2.1 Technical manual 235-01-00002-010 Rev A - 1360 Generator

2.2 Technical manual 235-01-00002-020 Rev A - 1360 Generator

2.3 Caterpillar 3512C Disassembly and Assembly Manual (KENR6055-05)

2.4 Caterpillar 3512C Systems Operation Testing and Adjusting Manual (KENR5403-05)

2.5 Caterpillar 3512C Parts Manual (SEBP4674)

2.6 Caterpillar Operation and Maintenance Manual (SEBU8224-03)

2.7 Caterpillar Torque Specifications Manual (SENR3130-12)

3.0 REQUIREMENTS:

3.1 General. The following requirements apply to all work.

3.1.1 Except as otherwise specified, the contractor shall provide all labor, material, services, tools, supervision, manuals and technical expertise needed to accomplish the work required by this specification within the specified time limits. Unless otherwise specified, 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 the manufacturer’s engine specifications, clearances, tolerances, and procedures.

3.1.2 All work shall be performed by an authorized repair facility of the engine manufacturer or by a factory-trained mechanic with over15 years’ experience servicing the 3500 series marine diesel engines. Work shall be shall be performed in such a manner that the manufacturer's warranty on parts and labor is not voided. All parts and labor supplied by the Contractor shall be fully warranted.

3.1.3 American Bureau of Shipping (ABS) survey of the overhaul is required for credit toward the ship’s Continuous Machinery Survey. Contractor shall inform ABS of progress and arrange for inspections as required by the local office. The government will pay for all ABS surveyor cost.

3.1.4 Provide and install "mandatory-renewal" parts and components as required by this specification. Other parts found to be in need of renewal may be provided by Government (if available) and installed by the contractor. Such additional parts or components which are not provided by the Government will be negotiated by the Contracting Officer as an additional cost.

3.1.5 Except where rebuilt components are authorized or specified, all components and parts used in the engines shall be new original equipment manufacturer (OEM) non-surplus components and parts.

Prior to installing new or rebuilt components or parts, perform visual and dimensional inspections to verify that the components or parts are acceptable for use.

3.1.6 Engines will be drained of jacket water and oil (to the lowest level allowed by the installed piping arrangement) by ship’s force prior to start of repairs. Any residual jacket water drained into bilge and will be disposed of by Government. The contractor shall be responsible for removing and disposing of any residual fuel and lube oil. Upon reassembly, the contractor shall clean all filter housings and install new Government-furnished filters, using new gaskets and O-rings.

Attachment I

3.1.7 Where remanufactured components are provided (as authorized or specified), existing components shall be replaced on an exchange basis with components remanufactured at the Caterpillar factory, and the existing components become the property of the Contractor in their as-found condition. When factory-remanufactured components are not available, the existing components shall be disassembled, cleaned, inspected, repaired (including renewal of all parts needed), reassembled, and calibrated at the Caterpillar factory or Caterpillar-authorized repair facility. Rebuilt components shall meet the manufacturers rebuild 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.

3.1.8 Disassemble the engine components, and parts to the extent specified herein and in other procurement documents. Whenever the extent of disassembly is not specified, disassembly shall be to the extent required to perform the required inspections, repairs, and parts renewal.

3.1.9 Interferences shall be removed and reinstalled, as required, at no additional cost to the Government. Contractor is responsible for removing piping to or from the engine, engine heat exchangers, air motors, etc.

3.1.10 Thoroughly clean, then conduct visual inspections of all disassembled parts, checking 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.

3.1.11 After inspections have been completed and prior to reassembling components, submit a report of all inspection findings and test results to NOAA. Report shall include a record of all measurements and readings taken as well as recommendations for additional repairs, inspections or testing. Do not proceed with any additional work until authorized by the Contracting Officer.

3.1.12 After the report has been accepted and all additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed. Reinstallation of all components throughout will be with new gaskets, seals, grommets, and O-rings.

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

3.2 Top End Overhaul (9,000hr) - Accomplish following work for the top end overhaul per references 2.1 to 2.7:

3.2.1 Install new or Caterpillar re-manufactured, in accordance with paragraph 3.2, and for the following components:

3.2.1.1 Seals, "o"-rings, & gaskets of all removed and disassembled components/parts

3.2.1.2 Turbocharger cartridges (re-manufactured)

3.2.1.3 Thermostats and water temperature regulators

3.2.1.4 Cylinder head assemblies (re-manufactured)

3.2.1.5 Fuel injectors (re-manufactured)

3.2.1.6 Fresh water pumps (re-manufactured)

3.2.1.7 Aftercooler cores (remove, clean, pressure test)

3.2.1.8 Filter elements

3.2.1.9 Crankcase breathers

3.2.2 Clean, inspect, test, and reassemble the following components, parts and subassemblies:

3.2.2.1 Wiring harness (ensure all wiring has chaffing gear where needed)

3.2.2.2 Visually inspect all hoses for signs of deterioration; insure hoses are fitted with chaffing gear where needed

3.2.2.3 Rocker arms

3.2.2.4 Fuel pressure regulating valve

3.2.2.5 Push rods

3.2.2.6 Aluminum spacer plates

3.2.2.7 Cam shaft inspection

3.2.2.8 Exhaust pyrometers for cylinders and each bank

3.2.2.9 Oil suction screen and oil pump

3.2.2.10 Exhaust manifold bellows and gaskets

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

Ship’s force will refill the coolant and lube oil systems. Contractor to provide 24 hours’ notice. to the Chief Engineer and vendor technicians shall be on-hand during re-filling procedures.

3.2.3 Touch-Up Paint. Touch-up paint all disturbed surfaces to standard Caterpillar paint scheme;

surfaces to be painted shall be free of dirt and grease prior to application.

4.0 TESTING & REPORTS:

4.1 Testing - The contractor shall notify the Chief Engineer and the COR when the overhauled engine and generator unit is ready to be tested under ship's electrical load. The Chief Engineer or his representative will be responsible for actually engaging the unit on the vessel’s main bus. The ABS surveyor shall be informed by the contractor in order to attend the final testing so credit can be given for the Continuous Machinery Survey on the unit. Conduct the following test of the engine after all components have been reassembled.

4.1.1 Test all shutdown systems prior to starting the engine.

4.2.2 Conduct a preliminary tune-up of the engine.

4.2.3 Monitor engine operations as the ship's engineers start/run the engine. Observe operation, verify joints are leak-free, make adjustments, and record data.

4.2.4 Perform operational test of the engine using the ships Hotel load for two (2) hours.

4.2.5 Operate engines at no-load until normal no-load operating temperatures are reached, then increase load incrementally up to full load and operate for one hour. Temperatures and pressures shall be monitored and compared to manufacturer's recommended limits. If a temperature or pressure exceeds or falls below manufacturer's recommended upper or lower limits, testing shall be stopped and the cause determined and corrected before continuing.

ships force will add equipment to the bus to increase load.

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

Cylinder exhaust temperatures Lube oil temperatures Water temperatures Fuel oil pressures Lube oil pressures Electrical load on generator Other operating parameters as permitted by installed instrumentation

4.2.7 Final Adjustments and Tune-up. After satisfactory completion of operational test, reset valves and accomplish final adjustments and tune-ups as required to provide smooth, efficient, and reliable operation.

4.2 Reports - Submit separate reports of all work completed, parts used, and all test data collected.

Reports shall include manufacturer's recommended limits for each measured parameter.

5.0 NOTES

Ship’s force is available to provide shipboard crane service during normal working hours to lift parts between the pier and aft deck. 24-hour notice is required. Actual rigging of parts and moving parts to/from the aft deck and engine room shall be the arranged by the government.

END OF SPECIFICATION