Attachment 1 - DY FY21 SSDG Topend Overhaul SOW.docx

1. Item 233: Ship’s Service Diesel Generator Top End Overhaul

1.1. Scope:

1.1.1. Provide all labor, material, services, tools, supervision, manuals, and technical expertise needed to accomplish top end overhauls on two (2) 3512B Ship Service Diesel Generator Engines (SSDG) #1 & #2, in accordance with this specification. As well as replace the resilient mounts on SSDG #1.

1.2. References:

1.2.1. NOAA Ship Oscar Dyson technical manual, DY-233-02 (FRV40-224-029-010), “Diesel Engine Caterpillar 3512B”

1.2.2. NOAA Ship Oscar Dyson drawing DY-073-FP22, “Generator intermediate mass raft details”

1.3. Government Furnished Material:

1.3.1. Lubricating oil and engine coolant

1.3.2. Engine Mounts

1.4. Requirements:

1.4.1. All work shall be accomplished by an authorized repair facility of Caterpillar Tractor Company, in accordance with Caterpillar service, maintenance, and overhaul technical manuals, including all current and applicable amendments and service bulletins, 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.

1.4.2. 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 by the Contractor. Procurement and installation of additional parts and components will be negotiated by the Contracting Officer as additional work.

1.4.3. 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.

1.4.4. 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.

1.4.5. Disassemble the engines, components, and parts to the extent required to perform the required inspections, repairs and parts renewal.

1.4.6. Thoroughly clean, then conduct visual inspections of all disassembled parts to be re-used for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability.

1.4.7. After inspections and tests have been completed, and prior to reassembling components, submit a typed report of all inspection findings and test results, including a record of all measurements and readings taken, to the Contracting Officer's Representative (COR). Include recommendations for additional repairs, inspections, tests, and part renewals needed. Do not proceed with any additional work (ie., work not identified in the original specification) until authorized by the Contracting Officer.

1.4.8. After the report has been accepted and all additional work has been negotiated, reassemble and reinstall all components that were previously disassembled or removed.

1.4.9. Remove and reinstall interferences as required to accomplish the required work.

1.4.10. Accomplish daily clean- up of debris incidental to the performance of the required work. Clean all work sites to their as-found condition upon completion of all work.

1.4.11. Ship’s force will drain and dispose of all liquids in the engines prior to overhauls.

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

1.5. Tasks: Accomplish the following work for the top end overhaul of both engines:

1.5.1. 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.

a. Seals, "o"-rings, and gaskets of all removed and disassembled components and parts

b. Turbocharger cartridges (re-manufactured)

c. Thermostats and water temperature regulators

d. Cylinder head assemblies (re-manufactured)

e. Fuel injectors

f. Fresh water pumps (re-manufactured)

g. Aftercooler cores (remove, clean, pressure test)

h. Filter elements

i. Crankcase breathers

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

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

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

b. Rocker arms

c. Fuel pressure regulating valve

d. Push rods

e. Aluminum spacer plates

f. Cam shaft inspection

g. Exhaust pyrometers for cylinders and each bank

h. Oil suction screen and oil pump

i. Air inlet manifold

j. Exhaust manifold bellows and gaskets

k. Connecting rod bearings

l. Cylinder liners

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

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

1.6. Replace SSDG #1 resilient engine mounts

1.6.1. Measure and record the shim heights on all the generator mounts. Provide the COR with a condition report stating all of the measurements.

1.6.2. Remove the existing engine foundation vibration mounts and install the new government furnished mounts on SSDG 1 and 2; use Reference (a) as a guide to ensure that the correct mounts are installed in the correct locations and as follows:

1.6.3. The generator/engine set base frame should 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.

1.6.4. The rafts should 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.

1.6.5. 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.

1.6.6. 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.

1.6.7. 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.

1.6.8. 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.

1.6.9. Prepare shims with the two bolt clearance holes for fitting below the mountings. Each shim should 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.

1.6.10. 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.

1.6.11. 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.

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

1.6.13. Provide generator alignment inspection after the mounts have had the final torque. Ensure proper alignment provide report as a CFR, note condition and wear. Provide readings for radial, axial, and angular misalignment, and inspect for soft foot conditions.

1.7. Testing:

1.7.1. Conduct the following test of the engine after all components have been reassembled.

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

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

c. Perform operational tests of the engine using ship’s hotel load for two hours. Ship’s force to add equipment to 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.

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

1. cylinder exhaust temperatures

2. lube oil temperatures

3. water temperatures

4. fuel oil pressures

5. lube oil pressures

6. electrical load on generator prime movers

7. other operating parameters as permitted by installed instrumentation

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

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

1.7.4. Paint all re-manufactured parts with OEM paint.

1.8. Quality Assurance:

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

1.9. Period of Performance:

1.9.1. 28 October – 15 November 2020

1.10. Place of Performance:

1.10.1. NOAA Ship Oscar Dyson, dockside at NOAA Marine Operation Center, Pacific; 2002 SE Marine Science DR, Newport, OR.

1.11. Notes:

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

b. 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.

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

d. 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.

1.11.2.

1.11.3. Engine Information:

a. #1 SSDG

MAKE: CATERPILLAR

MODEL: 3512B

SERIAL #: 8EM00441

ARRANGEMENT #: 174-4947

b. #2 SSDG

MAKE: CATERPILLAR

MODEL: 3512B

SERIAL #: 8EM00442

ARRANGEMENT #: 174-4947