Attachment 1 Statement of Work .pdf

CATERPILLAR D398 20,000 HOUR ENGINE OVERHAUL

1.0 SCOPE: This specification contains requirements for

the 20,000 hour overhaul of two, Caterpillar D398 engines on NOAA Ship Okeanos Explorer. Serial Numbers: Engine #3:

35Z01558; Engine #4: 35Z01555.

2.0 REFERENCES

2.1 Technical manual T9312-AG-MM0-010/11083 Engine

Generator Set Model D398B T-AGOS 13-18

2.2 Caterpillar Maintenance Management Schedule for Marine

Engines (SEBU6102)

2.3 Caterpillar Operations and Maintenance Manual

(SEBU5698)

2.4 Caterpillar Service Manual (SEBR0511)

2.5 NOAA Standard Specification AMC-000-1F, “General

Requirements for Ship Repair Contract on NOAA Ships”

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 accomplished by a Caterpillar-

authorized repair facility, be under the direct on-site supervision of a factory-trained mechanic currently certified by the engine manufacturer or have at least 15 years of relevant Caterpillar experience. Submit evidence prior to start of work. All such work shall be performed in accordance with Caterpillar service, maintenance, and overhaul technical manuals (including all current and applicable amendments and service bulletins), and in such a manner that the manufacturer's warranty on parts and labor is not voided.

3.1.3 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.

3.1.4 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.

3.1.5 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 manufacturer’s 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.

3.1.6 Prior to commencing disassembly of engines or

generator removals, engage the services of a vibration analysis service to take vibration readings of the diesel engines and generators above and below each mount while they are operating dockside under load. Repeat vibration readings upon completion of all work. Provide ship’s force a minimum of 24 hours’ notice of need to run engine(s).

Provide COR a report of before and after vibration readings.

3.1.7 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.

3.1.8 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.

3.1.9 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.

3.1.10 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.

3.1.11 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.

3.1.12 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 20,000 Hour Overhaul: Accomplish following work for the 20,000 hour overhaul for Engine #3: 35Z01558 and Engine #4: 35Z01555.

3.2.1 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.

3.2.2 Perform an inspection for wear by checking all

dimensions and tolerances on the following components. All components shall be properly cleaned and prepared for inspection and re-installation. Submit a written condition report stating each component’s condition and recommendations for renewal due to the component being out of Caterpillar specification. Include material and labor costs to renew that component.

a. Pre-lube pump

b. Fuel injection system and governor

c. Main oil pump and relief valve

d. Governor drive group, Woodward EG-3P actuator and linkages, manual shutdown linkages

e. Vibration damper

f. Gear train

g. Drive unit alignment, generator

h. Rocker arm assembly and bushings

3.2.3 Take and record crankshaft deflection readings

and end thrust readings.

3.2.4 Renew the following "mandatory-renewal" parts and

components on each engine, except as noted. Where "remanufactured" is added in parenthesis after a component, a remanufactured or “unit exchange” component may be provided in lieu of a new component.

a. Complete turbo cartridges

b. Governor linkage

c. Actuator (remanufactured)

d. Thermostats and water temperature regulators

e. Cylinder head assemblies with valves

(remanufactured)

f. Cylinder packs (remanufactured)

g. Dampers

h. Fuel nozzles

i. Fuel pump assemblies (exception: #3 SSDG fuel pump assemblies were replaced June 2022)

j. Fuel transfer pump (remanufactured)

k. Oil relief valve and spring

l. Fuel injection pump group yoke screw and lock nuts

m. Main bearings, (complete, including thrusts)

n. Rod bearings, complete

o. Front and rear cover seals and gaskets

p. Front and rear hydromechanical seals – directional

q. Jacket water pumps (remanufactured)

r. Jacket water heater hoses

s. Jacket water thermostats

t. Sea water pumps; No removal; provide rebuild kit and new impeller to the Chief Engineer

u. Lube oil coolers, non-removable core

(remanufactured)

v. All fuel injection pump to fuel nozzle fuel tubing, with fittings; new fuel tubing shall be double-walled.

w. All thermocouples and thermocouple wiring. Install new wiring to thermocouple box on bracket on aftercooler.

x. New zinc anodes in pumps and heat exchangers (Government to provide zincs)

3.2.5 The procedure to renew the rear seal requires

disconnecting the attached generator from the flywheel and engine block and skid. Before disassembly, take and record generator shaft runout readings and deflection readings of the generator fan to flex plate. Upon reassembly, readings are once again to be taken and the generator adjusted in accordance with Caterpillar specifications. Provide the ship’s Chief Engineer and the COTR at least 24 hours prior notification so they may witness these readings.

3.2.6 Reseal pre-lube pumps.

3.2.7 Remove piping to aftercooler. Remove cores for

industrial cleaning. Clean the cores. Reinstall/reseal water sides.

3.2.8 Adjust all piston cooling jets to proper spray

angle.

3.2.9 Reset tappets, check valve rotators, check and

adjust fuel timing. Adjust fuel rack actuator by setting turnbuckle adjustment to middle of range. Adjust position of arm on actuator spine such that when engine is running at rated speed under no load, voltage at actuator is 1.5 VDC. Voltage is best measured in switchboard, however the voltage drop across the fuse must be considered.

3.2.10 Inform the Chief Engineer, in a timely manner, when the engine jacket water system is ready to be refilled and tested for water-tightness. Re-fill coolant system with fresh water and the appropriate amount of jacket water treatment (to be supplied by ship’s force).

3.3 Quality Assurance

3.3.1 Tests and Reports: Notify the Chief Engineer in

a timely manner when the overhauled engines are ready to be tested under electrical load. Test operate engines after overhaul using available ship’s dockside hotel load for a period of not less than two hours. Test all alarm and shutdown systems prior to starting. Ship’s force will line up and start engines. Provide technicians to observe operation, verify joints are leak-free, make adjustments, and record data. 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 the manufacturer's recommended upper or lower limits, testing shall be stopped and the cause determined and corrected before continuing.

3.3.2 Record the following information near the end of

load test; provide test instruments as required:

a. cylinder exhaust temperatures

b. lube oil temperatures

c. water temperatures

d. fuel oil pressure

e. lube oil pressure

f. water pressures

g. electrical load on generator prime mover

h. turbo outlet air pressure

3.3.3 Submit a report of all test data collected.

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

3.3.4 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.

3.3.5 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.

3.4 Notes

3.4.1 American Bureau of Shipping (ABS) survey of the

20,000 hour overhauls 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. Government will pay ABS fees associated with the survey under a separate purchase order.

3.4.2 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 responsibility of the Contractor.

3.4.3 The Government anticipates award of a firm fixed-

price order for the 20,000 hour overhaul of the two D398 SSDG’s on board NOAA Ship Okeanos Explorer. The price for the work is based on return of useable like-cores for the unit exchange items. For evaluation purposes, the contractor shall submit as part of their quote the unit prices that will apply to cores in the event that they may be determined not re-buildable.

END OF SPECIFICATION