Attachment 1-PISCES SOW APR 23.pdf

NOAA Ship PISCES

FY24 SSDG Repairs

April 2023

NOAA SHIP PISCES FY24 ENGINE OVERHAULS

1. SCOPE

1.1.Complete a top end overhaul on the two Caterpillar 3508B engines, replacement of the

Local Control Panels, and maintenance on the 3512s and 3306 Emergency Diesel

Generator in accordance with this specification. Serial Numbers for the two CAT 3508B, two CAT 3512B engines, and the EDG on NOAA Ship PISCES are as follows:

Engine No. 1 Serial No: 8EM00549

Engine No. 2 Serial No: 8EM00550

Engine #3: 3DM00508 – 3508 Top End Overhaul

Engine #4: 3DM00509 – 3508 Top End Overhaul

EDG Model 3306 Serial Number: 6DG01939

2. REFERENCES

2.1.NOAA Standard Specification AMC-000-1F, "General Requirements for Ship Repair

Contract Work on NOAA Ships"

2.2. Technical Manual FRV40-226-028-010 “Diesel Engine Caterpillar 3508B”

2.3. Technical Manual FRV40-226-029-010 “Diesel Engine Caterpillar 3512B”

2.4. Technical Manual FRV40-226-041-010 “Kato Generator, 3 Phase Synchronous”

2.5. Technical Manual FRB40-226-039-010 “Generator Set, Emergency, Model 3306”

3. GOVERNMENT FURNISHED MATERIAL

3.1. None

4. REQUIREMENTS

General: The following requirements apply to all work.

4.1.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.

4.2.Except as specified herein, all work shall be accomplished by an authorized repair contractor 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

2.4, 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.

4.3.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.

4.4.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.

4.5.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.

4.5.1 The existing components become the property of the contractor in their as-found condition.

4.5.2 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.

4.6.Disassemble the engine components, and parts to the extent required to perform the required inspections, repairs, and parts renewal.

4.7.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.

4.8.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.

4.9.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

4.10. 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.

4.11. Prior to the start of work, Contractor shall install deck coverings on the engine room lower walkways where Contractor will transit and stage / transport equipment. Cover any equipment the Contractor will use to stage tools on. Contractor is responsible for maintaining the deck coverings throughout the completion of the work and shall remove all deck coverings upon completion of work.

4.12. 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.

4.13. Co-ordinate mechanical and electrical tag-outs with ship’s force engineering department prior to commencement of overhauls. Contractor’s locks/tags shall be installed on all equipment and signed in the Ship’s Lock-Out/Tag-Out book with the

Chief Engineer. Equipment to be LO/TO include:

4.13.1. 24V Control power for each generator

4.13.2. 600V Breakers

4.13.3. Engine Pre-lube pumps

4.13.4. Jacket Water Heaters

4.13.5. Air Shutoff valves

4.13.6. Fuel oil isolation valves

4.14. Contractor shall drain and dispose of all liquids (fuel, lube oil, and jacket water) in the engines prior to beginning work. 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.

Engine Repairs:

4.15. Coordinate draining the lube oil from the 3508 engines to the Ship’s Waste Oil

Tank. Ship’s Force will drain the oil to the Waste Oil Tank. Contractor shall stand by to assist.

4.16. Coordinate draining the Jacket Water and Aftercooler Water (CAT ELC Coolant) from the 3508 and from the two 3512 engines. Contractor shall provide Ten (QTY 10) empty 55-gallon drums. Eight (QTY 8) drums will be staged on the ship’s aft deck and two (QTY 2) in the lower engine room to aid in engine coolant removal. Ship’s Force will connect a ship’s hose to the engine drain connection and drain coolant to the 55-gallon drums staged in the lower engine room. Contractor shall supply a diaphragm pump with 1-inch hose connections to pump the engine coolant from the lower engine room to the aft deck. Hose length required is approximately 100 feet.

NOTE: Drain the Jacket Water and Aftercooler Water from the 3512 engines to aid in isolation valve installation on the engine hoses.

4.17. Contractor shall provide a pump truck to remove and dispose the coolant and lube oil from the ship’s waste oil tank and aft deck 55-gallon drums. For bidding purposes, estimate 1000 gallons of waste to be removed and disposed. Contactor shall coordinate scheduling tank discharge with ship’s force. Dispose of the used 55-gallon drums upon completion of work.

4.18. Remove all interferences and obstructions including piping, wiring, and grating as needed to conduct work.

4.19. Accomplish the work of a “Second Top End Overhaul” on SSDG 3 and SSDG 4 in accordance with Table 61 on Pages 131-133 of References 2.2. Where work directed in Paragraphs 4.2.5, 4.2.6, and 4.2.7 includes work not specified in Table 61, Contractor shall follow work directed in this specification. Where "re-manufactured" is added in parenthesis after a component, a re-manufactured component may be provided in lieu of a new component. Submit a CFR for any recommended OEM repairs differing from those directed below or for any emergent required engine repair work not called out in this specification.

4.19.1. Seals, "o"-rings, and gaskets of all removed and disassembled components and parts (new)

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

4.19.3. Fuel injectors (re-manufactured)

4.19.4. Cylinder head assemblies (re-manufactured)

4.19.5. Air inlet manifold, including all gaskets and seals (new)

4.19.6. Exhaust manifold, including all seals and bellows (new)

4.19.7. Turbochargers (re-manufactured)

4.19.8. Fuel Priming and Transfer Pumps (re-manufactured)

4.19.9. Engine Oil Pump (re-manufactured)

4.19.10. Push rods (new)

4.19.11. Aluminum spacer plates (new)

4.19.12. Rocker arms (new)

4.20. Clean, inspect, test, and reassemble the following components, parts and subassemblies of Table 61 of References 2.2. Submit a CFR for any OEM recommended differing from those called out by this specification:

4.20.1. Lube oil cooler (remove, clean, test, inspect, reinstall)

4.20.2. Oil suction screen

4.20.3. Wiring harnesses (ensure all wiring has chaffing gear where needed)

4.20.4. Camshaft inspection

4.20.5. Cylinder Bank Inspection (QTY 2 per engine)

4.20.6. Prelube Pump

4.20.7. Scavenge Oil Pump

4.20.8. Fuel pressure regulating valve

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

4.21. In addition to the overhaul work of Table 61, contractor shall replace the following with new for each engine:

4.21.1. All thermostats and water temperature regulators

4.21.2. Fresh water pumps (re-manufactured is acceptable)

4.21.3. Exhaust pyrometers for cylinders and each bank

4.21.4. Injector wiring harness for each cylinder

4.21.5. Filter elements

4.21.6. Crankcase breathers

4.21.7. Replace the twenty-five (QTY 25) fuel oil, lube oil, and engine coolant hoses.

Replacement hoses shall be pressure tested and tagged with the test pressure, date of pressure test, and facility completing the pressure test. Affix the hose tag to the hose using stainless steel wire. Install chaffing gear where needed. Submit a CFR for additional hose replacement.

4.21.8. Install isolation ball valves on Jacket Water and Aftercooler Loops on each of the

4 engines to allow for Jacket Water Heater replacement without draining the Jacket

Water and Aftercooler Systems. A total of 16 valves shall be installed. A short threaded pipe nipple may need to be installed on each engine to mount the valve for accessibility. Modify the hose lengths to suit the new isolation valves. Paint all new and disturbed surfaces.

NOTE: Affected Jacket Water and Aftercooler hoses for SSDG 1 and

SSDG 2 may need to be replaced to suit valve installation.

4.22. Upon completion of repairs, work with Ship’s Force to refill SSDG’s 3 and 4 with lube oil and all for SSDGs with engine coolant. Contractor shall provide 500 gallons of

OEM approved lubricating oil and 1,100 gallons of pre-mixed engine OEM extended life coolant. Turn over any remaining lube oil and engine coolant to the ship. Submit a CFR for any additional fluids required. Contractor shall assist Ship’s Force with refilling the engines to the proper fluid levels. Contractor shall provide 24 hours’ notice prior to refilling engines with coolant.

4.23. Inspect SSDG 1 and SSDG 2 engines and submit a CFR for any recommended repairs. Inspection shall include checking for leaks and operational performance testing.

4.24. Inspect the Model 3306 Emergency Diesel Generator (EDG) and submit a CFR for any recommended repairs above those specified below. Inspection shall include checking for leaks and operational performance testing. Notify the COR and Chief

Engineer prior to securing and starting work on the EDG.

4.24.1. Replace all air, fuel, engine coolant, and lube oil hoses. For bidding purposes, estimate replacement of twelve (QTY 13) hoses, 1-inch diameter hose, 3 feet long, rated for a minimum of 500 PSI). Replacement hoses shall be pressure tested and tagged with the test pressure, date of pressure test, and facility completing the pressure test. Affix the hose tag to the hose using stainless steel wire. Install chaffing gear where needed.

4.24.2. Replace the Alternator Belt

4.24.3. Replace the Fan Drive Belt

4.24.4. Complete a valve lash on each cylinder

4.24.5. Inspect/adjust the magnetic pick-up

4.24.6. Replace the engine crankcase oil filter

4.24.7. Replace the crankcase breather

4.24.8. Clean and inspect the radiator

4.24.9. Clean, inspect and test the fuel injection nozzles

4.24.10. Lubricate the fan drive bearing

4.24.11. Inspect the engine mounts

4.24.12. Clean and inspect the turbochargers

4.24.13. Submit a CFR with any additional recommended EDG repairs.

4.24.14. Test and run the EDG upon completion of repairs.

Local Control Panel Replacement

4.25. Replace the Local Control Panels for all 4 SSDGs. Replacement includes replacement of the local control panel and all the internal wiring backbone, controls, and monitoring as well as completion of all structural modifications as required, electrical cable replacement as required, wiring harness routing as required, painting, and testing.

New OEM Control Panels shall of the latest compatible model required for these engines. Contractor may utilize the expertise of an experienced and qualified contractor to accomplish structural and electrical modifications. All work must be completed in accordance with ABS regulations including use of ABS approved welders.

4.25.1. Replace the Local Control Panels for SSDG-3 and SSDG-4. Install using new 316

Stainless Steel hardware and any required vibration insulation.

SSDG-3 Panel SSDG-4 Panel

4.25.2. Relocate the Local Control Panel for SSDG-1 to the forward rail by Fire Station

4. Modify and extend the deck grating and platform railing to square off the deck and create an area for the Local Control Panel. Fabricate and install a new foundation for the Local Control Panel. Secure the panel to the foundation using 316

Stainless steel hardware. Route all wiring to the new control panel.

SSDG-1 Panel Relocation

4.25.3. Relocate the Local Control Panel for SSDG-2 to the forward rail over the Oily

Water Separator and adjacent to the stanchion seen in the below photograph.

Fabricate and install a new foundation to support the new Local Control Panel.

Secure the panel to the foundation using 316 Stainless steel hardware. Route all wiring to the new control panel.

SSDG-2 New Panel Location SSDG-2 Local Panel

4.25.4. For each SSDG, replace the 24V cables from the Generator Local Control Panel

J-box in the overhead of the Lower Engine Room to the Local Control Panel. 24V cable is powered from PP EP24 in the EDG Room.

24V J-Box located in overhead of Lower Engine Room

4.25.5. Route the engine wiring harnesses to each new Local Control Panel. Ensure all new and re-routed cable is properly banded and supported by cable hangers.

4.25.6. Label all new cables. New electrical cables shall have stainless steel/aluminum cable tags. Cables inside the panel may have printed and laminated tags.

4.25.7. Power on and test the new Local Control Panels.

4.25.8. Paint all new and disturbed surfaces.

4.25.9. Provide a drawing for the new Local Control Panels.

Engine Testing:

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

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

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

4.29. 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.

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

4.30.1. Cylinder exhaust temperatures

4.30.2. Lube oil temperatures

4.30.3. Coolant temperatures

4.30.4. Fuel oil pressure

4.30.5. Lube oil pressure

4.30.6. Water pressures

4.30.7. Turbo outlet air pressure

4.30.8. Electrical Load on generator prime movers

4.30.9. Other operating parameters as permitted by installed instrumentation.

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

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

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

4.34. Complete an alignment inspection on each of the four engines and generator assemblies, to include foot deflection. Submit results to COR along with any additional recommendation repairs

5. QUALITY ASSURANCE

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

6. NOTES

6.1.Work will be accomplished while PISCES is dockside at the following address:

NOAA Gulf Marine Support Facility

151 Watts Ave

Pascagoula, MS 39567

6.2.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 is required. Rigging of parts and moving of parts from aft deck into engine room shall be the responsibility of the

Contractor.

6.3.The following is engine and generator information:

Diesel Generator Sets No. 1 and No. 2

600 Volt, 1360 kW, 1700 kVA

MFG: Kato- Caterpillar

Model: 3512B DITA SCAC

Engine No. 1 Serial No: 8EM00549

Engine No. 2 Serial No: 8EM00550

Kato Generator Serial No 1: 17824-01

Kato Generator Serial No 2: 17824-02

Kato Generator Model No: AA27756000

Diesel Generator Sets No. 3 and No. 4

600 Volt, 910 kW, 1137.5 kVA

MFG: Kato- Caterpillar

Model: 3508B DITA SCAC

Engine No. 3 Serial No: 3DM00508

Engine No. 4 Serial No: 3DM00509

Kato Generator Serial No. 3: 17825-02

Kato Generator Serial No. 4: 17825-01

Kato Generator Model No: AA27757000

EDG Model Number: 3306

EDG Serial Number: 6DG01939

Generator Model: SR4B, Serial Number 6DG01939

Arrangement Number 109-3785

213 kVA, 170 kW, 440 VAC, -END OF SPECIFICATION-