Attachment_1_Specification_for_6000-hour_Engine_Maintenance_for_the_RV_Kaho.pdf

Attachment A Specification

SPECIFICATION FOR

6000-HOUR ENGINE MAINTENANCE FOR THE

USGS RV Kaho

US DEPARTMENT OF THE INTERIOR

US GEOLOGICAL SURVEY

GREAT LAKES SCIENCE CENTER

1451 Green Road • Ann Arbor, MI 48105

TABLE OF CONTENTS

1 GENERAL INFORMATION pg. 3

2 GENERAL REQUIREMENTS pg. 4

3 WORK ITEMS – GENERAL pg. 11

4 WORK ITEMS pg. 11

1 GENERAL INFORMATION

The USGS Great Lakes Science Center’s research vessel Kaho requires 6000-hour maintenance to be completed on Port and Starboard main engines. The vessel is equipped with (2) MTU 8V-2000, diesel engines serial numbers 531101413 and 531101414. The contractor will be required to provide all labor, materials, and marine repair resources for the work described herein.

The work will be conducted dockside at the RV Kaho’s home port at 17 Lake St., Oswego, New York unless otherwise specified by the government. Work will be conducted during May 4 – June 5, 2026.

1.1 Vessel Particulars

USGS owns and operates the R/V Kaho. Vessel particulars are included herein. Where possible, the work items reference drawings, specifications, or other reference material; however, the Contractor is responsible for verifying the accuracy of any information provided.

R/V Kaho

Year Built

Builder Great Lakes Towing

Hull Number 104

Location Oswego, New York

Length Overall feet 71’

Length Waterline feet 65’ 11”

Breadth feet 18’

Depth feet 7.8’

Loadline Draft feet – in. 5’

Full Speed knots 14.7

Cruising Speed Knots 12.5

Full Load Displacement long tons 72.35

Lightship Displacement long tons 53

Regulatory Tonnage GRT 67

Class

ABS ID

USCG Inspected No

USCG Documentation No

Operated As Uninspected, Undocumented Research Vessel

1.2 Definitions

Whenever used herein or in other documents which invoke this specification by reference, the following definitions of terms apply:

Inspect. Visually evaluate the specified surface, item, part, or component for evidence of contamination, damage, excessive wear, scoring, and any other condition which could interfere with the proper operation or functioning of the surface, item, part or component.

Install. Place the specified item in position for service and make all connections needed to insure proper use, service, appearance, and operation. Except as may otherwise be specified, this shall include the following:

• Provide new or modify existing foundations. Securely mount equipment and components using new

Stainless-steel fasteners. Align connected equipment and components to meet manufacturers’ specifications.

• Modify piping to suit the new equipment, including the rerouting of existing piping and adding of new piping as needed to properly connect equipment and components. New piping is required only to the extent necessary to accommodate modifications of existing piping.

Piping. A system of pipe, tube, elbows, tees, valves, couplings, and other pipe fittings.

Rebuild. Disassemble, clean, inspect, repair (including renewal of all parts needed), reassemble, test, and calibrate the specified part, component, system, or machine to restore it to a condition of reliability and functionality equivalent to a new part, component, system, or machine. Components and parts shall meet the manufacturer’s applicable rebuild specifications.

Reinstall. Return the same item which was previously removed to its previous configuration, location and full functionality.

Renew. Provide and install a new item as replacement for an existing item previously removed or to be removed. The new item must be the same as or comparable in material, functionality, performance and configuration to the item removed.

Replace. Same as “renew”, defined above.

2 GENERAL REQUIREMENTS

2.1 Safety Requirements

Safety Plan

Prior to starting work on the ship, prepare and provide to the USGS Technical Representative a written Safety Plan. As a minimum, the Safety Plan shall contain the following as applicable to the Work Items or as otherwise required by OSHA regulations:

• Procedures for obtaining and posting of gas free certificates.

• Designation of the certified Marine Chemists authorized to issue gas free certificates.

• A copy of Department of Labor Form OSHA 73, “Designation of Competent Person” containing names of persons designated as a “Competent Person”.

• Procedures to be followed should any disruption occur to a temporary service or ship’s system which affects the safety of the ship or personnel.

• Description of the procedures to be followed prior to performing any hot work, including the procedures to be followed to ensure the presence of a properly outfitted fire watch stander.

• Description of the duties and responsibilities related to fire prevention of personnel performing hot work.

• Methods of rigging hoses, welding leads, and temporary lighting to avoid restricting escape passages and to minimize tripping and other safety hazards.

• Whenever the work is being performed at the Contractor’s facility, include a detail description of the fire protection system which will be in effect during the contract. Include the method for reporting fires, the shipyard fire- fighting facilities, equipment, and organization, the procedures for maintaining clear fire lanes in the shipyard and on the piers, and the nearest municipal fire-fighting organization.

• An inventory listing of and copies of material safety data sheets (MSDS) for all hazardous chemicals covered by 29 CFR 1910.1200 which will be brought onto the ship or which USGS personnel may be exposed to under normal conditions or in a foreseeable emergency.

• Procedures to be followed for cleanup should a spill occur of a hazardous chemical.

• A description on the Contractor’s Lock-Out/Tag-Out procedures and affected systems.

• Other safety procedures as required by OSHA regulations.

Fire Watch Standers

Hot work is permitted only when fire watch standers are provided by the Contractor. A fire watch stander is required whenever welding, flame cutting, or other hot work is performed where combustible materials are present or when combustible materials are adjacent to the opposite side of metal partitions exposed to hot work and could be ignited by conduction or radiation. In the latter case, a fire watch stander is required on both sides of the partition.

Each fire watch stander shall be outfitted by the Contractor with a fire extinguisher of a suitable size and type.

Each fire watch stander shall remain at their work site for at least 30 minutes after completion of the hot work. Prior to leaving the work site, the fire watch stander shall verify with the worker performing the hot work that no further hot work will be performed.

Insulation, sheathing, or other materials which limit access to either side of a partition or structure on which hot work is being performed shall be considered to be an interference and shall be removed and restored by the Contractor.

Written Hot Work Notice

Prior to starting hot work on any job or separate area of the ship, provide a written notice to the USGS Technical Representative and the ship’s Master.

Hazardous Materials

The Contractor is responsible for compliance with all local, state, and federal regulations, laws, and ordinances regarding handling and use of hazardous materials.

The Contractor shall provide to the USGS Technical Representative an inventory listing of and copies of MSDS’s for all hazardous materials which will be brought onto the ship. The inventory listing and MSDS shall be provided at least 24 hours in advance of any hazardous material being brought onto the ship.

The Contractor shall remove all hazardous materials used and shall properly dispose of all hazardous waste produced during the performance of work under the contract.

Lock-Out/Tag-Out

The Contractor is responsible for all Lock-Out/Tag-Out requirements and shall coordinate the de-energizing and re-energizing of equipment and machinery with the USGS Technical Representative and ship’s Master or Engineer. The Contractor shall maintain a program consisting of energy control procedures, employee training and periodic inspections to ensure that before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing, startup or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from the energy source and rendered inoperative. The Contractor shall provide all protective materials and hardware including labels, signage, locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware for isolating, securing or blocking of machines or equipment from energy sources. The Contractor shall notify the USGS Technical Representative and ship’s Master or Engineer in writing that the installation, maintenance, repair, alteration or servicing action is complete, and that system, equipment, machinery or system is ready for use and operation.

Miscellaneous Safety Requirements

Oxygen, acetylene, and gas supply manifold systems shall be located off the ship and have a shutoff valve to the gas supply located on the dock. The shutoff shall be in addition to the master shutoff valve at the inlet to each portable outlet header.

Material brought onto the ship shall be stored until used in areas which do not interfere with access to fire-fighting equipment or personnel access. Crating and packing shall be removed prior to bringing the equipment or material aboard the ship, unless needed to protect the equipment or material from damage during handling. In that case, the crating and packing shall be removed from the equipment or material, and shall be removed from the ship, immediately after being brought aboard.

Rigging of hoses, welding leads, and temporary lights shall be kept clear of the decks on temporary “trees” or brackets and be arranged so as to minimize tripping and other safety hazards. Passageways shall be kept as clear of obstructions as possible.

2.2 Reports and Documentation

The contractor is responsible for providing all relevant plans, calculations, reports and documentation prior to final acceptance of the Work Item. Documentation shall be provided in hard copy and MS Office, .dwg or .pdf format as applicable. Documentation shall include full description of all work accomplished, materials used, and man-hours expended.

As applicable to vessel modifications, vessel drawings shall be updated to reflect “as-built/modified” condition and applicable calculation summaries and regulatory body approval certificates are to be provided. “As found” readings, photographs and other amplifying information are to be included where applicable.

In addition, vendor catalog cut sheets, material certificates, manuals, operating instructions, maintenance routines and vendor contact information shall be provided where applicable.

2.3 Condition Found Reports

A Condition Found Report shall be prepared and submitted by the Contractor to the USGS Technical Representative on all the following occasions:

1. Whenever specifically required by the Work Item or other documents.

2. Whenever the Contractor determines or notes that additional work or material or other deviation is necessary to produce a reliable or complete repair.

3. Whenever defect or deficiencies are noted in Government-furnished Property.

4. Whenever measurements, tests or inspections are required by other specifications or procurement documents, the results and findings shall be documented on a Condition Found Report.

Condition Found Reports shall contain, as a minimum, the following:

• Name of the ship.

• Contract number and related work item number.

• Detailed description of conditions observed, including a record of all measurements taken and other supporting data, documents or photographs.

• Recommendations of additional work and materials deemed to be needed, if any. Recommendations are to include the following items as necessary o Additional man-hours and/or materials required o Supporting documentation from vendors o Any other supporting documentation needed to define the scope of the recommendation

• Estimate of the impact on the completion of the contract, if any.

• Estimate total cost impact, if any.

Submit Condition Found Reports to the USGS Technical Representative within 24 hours after completing the measurements, inspections, or tests, or after the need for additional work or material is noted.

2.5 Personnel Information

The Contractor shall provide to the USGS Technical Representative a list of the Contractor’s supervisors, including shop supervisors, and a list of telephone numbers where the supervisors can be reached during non-working hours in event of an emergency.

2.6 Restricted Access

Access by the Contractor’s personnel to the ship’s compartments shall be restricted to those in which work is being performed or through which passage is necessary to reach the work site. The USGS Technical Representative shall designate those paths authorized for passage by workers. All other compartments shall be considered off-limits to workers.

2.7 Shipboard Storage

No space or compartment on the ship shall be used for storage by the Contractor of materials or tools. The materials allowed at the work site shall be limited to those which will be installed, consumed, or otherwise used during the work shift in progress. When needed or required, the Contractor may provide a temporary dockside storage area to store materials and tools.

2.8 Daily Clean-Up

Good housekeeping practices will be maintained on the vessel at all times, particularly after the end of the workday. If work is required to be conducted inside the vessel, special care will be required to maintain a neat and clean vessel condition. The Contractor shall clean-up and remove from the ship all dirt, debris, scrap, and other materials incident to Contractor’s work at the end of each workday; all oil, or other fluids, shall be cleaned off all surfaces. The work site shall be left “broom-clean”.

All necessary precautions will be taken with work involving cutting, welding, grinding, blasting, painting, etc., so as to cause minimal disturbance to the vessel. All disturbed areas will be brought back to an original “existing condition” by the Contractor. Whenever abrasive blasting or other operations on or near the ship causes collection of blasting residue or other foreign particles to collect on exterior decks of the ship, the Contractor shall vacuum or sweep the decks to remove the residue and particles prior to the end of the day on which the contamination occurred. The Contractor shall not wash the residue or particles through the ship’s deck drains unless specifically authorized by the USGS Technical Representative.

Prior to final acceptance and departing the shipyard, the vessel will be returned to the original “existing condition” by the Contractor.

2.10 Disruption of Ship’s Systems

Except as otherwise authorized, none of the ship’s fire main, electrical, steam, heating, potable water, drainage, or other systems which are vital to crew safety or comfort shall be shut off or disrupted. If necessary, to shut off or disrupt any of the systems to perform contract work, the Contractor shall submit a written Condition Found Report to the USGS Technical Representative requesting authorization. The USGS Technical Representative must receive the Condition Found Report at least 4 hours in advance of the desired disruption.

For purposes of this specification, a “disruption” occurs whenever a large section of a system will be unusable. If the only section of the system affected is that on which work is being performed and the remainder of the system can be operated, a “disruption” has not occurred, and the requirements of this paragraph do not apply.

2.11 Access for Work / Inspection

Access for all work, staging, cleaning, and inspection that are necessary to complete work including, but not limited to, removal of bulkheads, overheads, joiner, piping, ducting, outfitting, and other interferences are the responsibility of the Contractor. All material removed for access shall be reinstalled in, or better than, the condition found unless otherwise specified. All disturbed coatings, insulation, lagging and joiner shall be repaired and re-installed and or replaced with new coatings and materials in order to provide an as new appearance to material surfaces and in accordance with the material manufacturer recommendations.

Contractor shall provide temporary lighting and ventilation to all required areas for the purpose of performing work, cleaning, and inspections.

2.12 Interferences and Restorations

The Contractor shall remove all interferences and obstructions necessary to complete the required work.

This shall include the disassembly and removal of machinery, piping, ducts, cable, wiring, insulation, structures, and anything else which interferes with the proper accomplishment of work. Except as otherwise specified, this does not include relocations made necessary by new installations which physically prevent an interference from being returned to its existing location.

Whenever an interference to be removed involves a structural strength member, temporary supports shall be provided to compensate for the strength loss. Whenever watertight integrity is violated by a removed interference, a temporary means of maintaining watertight integrity shall be provided except when work is being performed or the space is otherwise manned.

Prior to removing any interference, the Contractor shall meet with the USGS Technical Representative at the work site to discuss the nature, condition and extent of interferences to be removed. The Contractor shall record all damage or deterioration which exists prior to removal.

The Contractor shall install tags on removed interferences to indicate the nomenclature of the item, ship, and location to enable proper reinstallation. Treat all removed interferences as government-furnished property. The Contractor shall store interferences to protect from damage, loss, and contamination.

The Contractor shall restore all interferences to their existing configuration and condition. Install new gaskets and fasteners. In place of material which is rendered unsuitable for reinstallation during removal or storage, provide and install new materials which are equal in composition, strength, design, type, and size as existed prior to removal. All insulation, including removable blankets, shall be considered to be unsuitable for reinstallation and shall be renewed with new insulation.

Material containing asbestos which is removed as an interference shall not be reinstalled. Instead, renew the asbestos-containing material with a new non-asbestos material which provides the same function and general appearance as that removed.

Align and conduct strength, tightness, and operational tests to ensure that the reinstalled interferences safely perform their normal functions.

The Contractor shall be responsible for identifying all interferences involved in accomplishing required work.

Interferences are not normally identified in the detail specifications of the work item. Therefore, prospective bidders are encouraged to perform a site inspection whenever possible before submitting a bid.

2.14 Disposition

Whenever the detail specifications indicate that removed materials are to be scrapped or properly disposed of, title to the property is hereby transferred to the Contractor for disposal or scraping scrapping.

2.16 Brackets and Supports

All pipe, cables, ducts, furniture, equipment, machinery installed by the Contractor shall be bracketed, supported, and secured so as to carry the weight, prevent vibration, and withstand inertia forces resulting from rolling and pitching of the ship.

2.17 Gaskets, Packing, Seals and Fasteners

New gaskets, packing, seals or and fasteners shall be installed whenever the Contractor performs work which disturbs existing gaskets, packing, seals or fasteners. All material shall comply with the design service requirements of the systems or components for which they are installed.

2.18 Standard Parts and Materials

Unless otherwise specified in this document, all materials, equipment, services, and labor shall be furnished by the Contractor. All material shall be new and of commercial marine quality. Where required, all material shall comply with the standards of the applicable regulatory bodies.

All articles, fittings, equipment, machinery, supplies, and materials used shall be the highest grade, free from defects and imperfections and unused.

2.25 Installation

Materials and equipment shall be installed in accordance with the approved recommendations of the manufacturer, and in compliance with the contract documents. The installation shall be accomplished by workmen skilled in this type of work.

2.26 Manufacturer’s Representative

The services of a manufacturer’s Representative are required only when specified in other specifications or procurement documents. The services of the Representative shall be provided by the Contractor unless otherwise stated in the other specifications or procurement documents.

The manufacturer’s Representative shall be specially trained by the manufacturer of the equipment or material and shall be certified by the manufacturer as authorized to represent the manufacturer in performing the prescribed tasks. If requested by the USGS Technical Representative, provide written documentation from the manufacturer attesting that the Representative is authorized to represent the manufacturer.

The Representative shall be considered to be an on- site technical consultant to provide technical advice to the Contractor and the USGS Technical Representative. When specified, the Representative is also required to take measurements and conduct inspections. However, nothing herein shall be construed as relieving the Contractor of the responsibility to satisfactorily perform all required work.

Whenever the manufacturer’s Representative is required to be “on-site”, the Representative shall be at the worksite during all times that work is being performed.

The Contractor shall obtain from each manufacturer’s Representative a detailed service report which outlines all inspections, observations, and recommendations provided by the Representative. If measurements were taken by the Representative, a record of the measurements shall be included in the report. Submit a copy of the service report to the USGS Technical Representative prior to completion of the contract.

In the event that any work to be performed deviates from the Representative’s guidance, the Contractor shall submit a Condition Found Report to the USGS Technical Representative which outlines the guidance provided and the reasons for the proposed deviation. The Contractor shall proceed with the deviation only after the USGS Contracting Officer has reviewed the Condition Report and accepted the proposed deviation. Whenever the Contractor deviates from the Representative’s guidance, any and all increased costs resulting from the deviation shall be borne by the Contractor.

2.27 Tests and Inspections

The Contractor shall perform an operational test of all newly installed, overhauled, and repaired equipment to demonstrate proper operation. Shipboard equipment will be operated by the ship’s crew.

At least 48 hours, in advance of conducting each required test and inspection, the Contractor shall notify the USGS Technical Representative in order to allow the USGS Technical Representative the opportunity to witness the tests and inspections. If the USGS Technical Representative is not present at the scheduled time of the test or inspection, and if the required 48-hour advance notification was furnished to the USGS Technical Representative, the Contractor may proceed with the test or inspection.

All tests and inspections shall be witnessed by the Contractor’s supervisor responsible for the work. A Condition Found Report shall be prepared to document the results of all tests and inspections.

To the extent possible, all tests and inspections shall be scheduled during the normal weekday work shift.

Tests and inspections may be scheduled for other times only when necessary to avoid a delay in the contract completion. When necessary to schedule a test or inspection after the normal day shift or on a weekend, the USGS Technical Representative shall be notified of the test or inspection at least 4 hours before the end of the last preceding regular work shift.

3 WORK ITEMS – GENERAL

3.1 Lay Berth

A suitable berth alongside an accessible pier shall be furnished by the government. The berth will have access for service trucks.

3.1 Fuel Oil and Lube Oil Offloading

Lube oil will be removed from the engines and disposed of by the contractor in accordance with all local governmental regulations.

New oil will be supplied by the government.

4 WORK ITEMS –

4.1 MTU 8V-2000 6000 Hour Maintenance.

The vessel is equipped with (2) MTU 8V-2000, diesel engines serial numbers 531101413 and 531101414.

The Contractor shall provide a MTU qualified technician to provide parts and labor for the required 6000-hour maintenance as specified in the manufacturer’s engine Maintenance Schedule (# MS50105/04E 2021- 06).

Three tasks associated with the 4000-hr maintenance (W1006, W1011, and W1178 in the manufacturer’s engine Maintenance Schedule (# MS50105/04E 2021-06)) also need completing.

Three optional work items in the manufacturer’s engine Maintenance Schedule (# MS50105/04E 2021-06), W1009 and W2009 related to centrifugal oil filters and W2112 related to a bilge pump, do not apply to the RV Kaho’s engine configuration and will not be required.

Maintenance includes but is not limited to:

MTU Maintenance Schedule Service Task Description

MTU Maintenance Schedule task number.

Overhaul exhaust turbochargers. W2075 Reinstall of turbochargers to include replacement of O-Rings that seal the exhaust elbow to the bellows.

Not in the MTU maintenance schedule but required service

Replace fuel filter or fuel filter element. W1001 Check valve clearance, adjust if necessary. W1002 Check belt condition and tension, replace belt(s) if necessary.

W1003

Replace air filters. W1005 Replace fuel injection valves / injectors W1006 Inspect cylinder chambers using an endoscope. W1011 Replace pressure pipe neck (bayonet) in cylinder head.

W1178

Replace fuel injection pump(s). W1007 Before starting maintenance work, drain coolant and flush coolant systems, and restore coolant prior to restarting engines.

W2000

Clean air pipework. W2002 Clean intercooler and inspect for leaks. W2003 Inspect vibration damper. W2011 Clean wire meshes of crankcase ventilation.

Replace diaphragm of crankcase ventilation.

W1140 & W2014

Clean engine coolant cooler and check for leaks. W2017 Clean engine oil heat exchanger and check for leaks.

W2018

Check engine alignment. W2036 Clean fuel cooler. W2059 Check thermostats. Replace coolant thermal actuators.

W2073

Check rocker arms, valve bridges, pushrods and ball joints for wear.

W2074

Replace sealing material for all disassembled components.

W2062

Overhaul engine coolant pump. W2110 Overhaul raw water pump. W2111 Replace engine oil filters and engine oil (One 55-gallon drum of Amsoil 15W40 HD Deisel and Marine Oil will be provided by USGS).

W1008

Maintenance specifications may be found in MTU service manual for the above engines.

All maintenance shall be performed by a qualified MTU technician. All parts shall be OEM spec unless specifically approved by USGS Technical Representative and MTU.

An operational test shall be conducted after the maintenance is performed. A Condition Found Report shall be provided to the USGS Technical Representative documenting the results of the operational test.