Attachment 5 - NOAA Ship Oregon II Engine Overhaul.docx

NOAA Ship Oregon II Main Engine and SSDG 40,000 Hour Overhaul August 2020

NOAA Ship Oregon II Main Engine and SSDG 40,000 hour Overhauls

1.0 SCOPE This specification contains requirements for 40,000 Hour overhaul of one, Caterpillar 3512 engines (Serial number: 66Z00696; Arrangement 1W4219) and one Caterpillar 3408 ship’s service generator set (Serial number: 78Z4101, Generator 1GD00171, arrangement 4W8048) on NOAA Ship Oregon II.

2.0 References

2.1 NOAA Standard Specification AMC-000-3C, "General Requirements for Small Contract Ship Repairs"

2.2 Caterpillar Operation and Maintenance Manual (SEBU6100-02)

2.3 Caterpillar Service Manual (SENR 2371)

2.4 Caterpillar Parts Manual (SEBP 1554-05)

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 under the direct on-site supervision of a factory-trained mechanic currently certified by the engine manufacturer. Upon request, the Contractor shall submit evidence that they are a current Caterpillar Authorized Marine Dealer (A.M.D.) or other Caterpillar authorized Repair Facility, or proof of current certification of the Caterpillar factory-trained mechanic that will supervise the work on-site. All such work shall be performed in accordance with References 2.1 through 2.4 and all applicable 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 the 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 special 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 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.

3.1.7 Remove and reinstall all interferences 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.

3.1.8 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.

3.1.9 After inspections have been completed and prior to reassembling components, submit a report of all inspection findings and test results to NOAA. 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

3.1.10 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.

3.1.11 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 Main Engine 40,000 Hour Overhaul Accomplish the following work for 40,000 hour overhauls:

3.2.1 Engines will be drained of oil and jacket water by ship’s force prior to start of repairs. Any residual jacket water to be drained into bilge and will be disposed of by Government.

3.2.2 Renew the following “mandatory-renewal” parts and components. Where “remanufactured” is added in parenthesis after a component, a remanufactured component may be provided in lieu of a new component.

a. Seals, ferrules, “o”-rings, and gaskets of all removed and disassembled components and parts

b. Oil, fuel and air filters

c. Inspect Spacer Plates

d. Turbocharger cartridges (remanufactured)

e. Temperature regulators

f. Cylinder head assemblies with valves (remanufactured)

g. Fuel injectors (remanufactured)

h. Fuel transfer pump (remanufactured)

i. Jacket water pump (remanufactured)

j. Sea water pump (rebuild kit and new impeller)

k. New zinc anodes in pumps and heat exchangers. (Government will supply new zinc anodes)

l. Connecting Rods

m. Cylinder Liners

n. Inspect Cam Bearings

o. Pistons/Rings

p. Governor (remanufactured)

q. Main Oil Pump (remanufactured)

r. Inspect Crankshaft

s. Inspect Camshaft

t. Main Bearings

u. Rod Bearings

v. Valve Rotators

w. Crankshaft Seals

x. Inspect Damper

y. Inspect Fuel System Linkage

z. Inspect Gear Train and Bushings

3.2.3 Remove piping to aftercooler, send aftercoolers to local shop for cleaning and pressure test air sides. Reseal water sides.

3.2.4 Renew both Vulcan couplers.

3.2.5 Clean engine suction screen.

3.2.6 Touch-up all disturbed surfaces to standard Caterpillar paint scheme; surfaces to be painted shall be free of dirt and grease.

3.2.7 Fill coolant and lube oil systems. Government will provide lube oil. Government will fill coolant system with fresh water and same type of non-chromate corrosion inhibitor as existing.

3.3 3408 Genset 40,000 Hour Overhaul Accomplish the following work for 40,000 hour overhauls:

3.3.1 Engines will be drained of oil and jacket water by ship’s force prior to start of repairs. Any residual jacket water to be drained into bilge and will be disposed of by Government.

3.3.2 Renew the following “mandatory-renewal” parts and components. Where “remanufactured” is added in parenthesis after a component, a remanufactured component may be provided in lieu of a new component.

a. Seals, ferrules, “o”-rings, and gaskets of all removed and disassembled components and parts

b. Oil, fuel and air filters

c. Inspect Spacer Plates

d. Turbocharger cartridges (remanufactured)

e. Temperature regulators

f. Cylinder head assemblies with valves (remanufactured)

g. Fuel injectors (remanufactured)

h. Fuel transfer pump (remanufactured)

i. Jacket water pump (remanufactured)

j. Sea water pump (rebuild kit and new impeller)

k. New zinc anodes in pumps and heat exchangers. (Government will supply new zinc anodes)

l. Connecting Rods

m. Cylinder Liners

n. Inspect Cam Bearings

o. Pistons/Rings

p. Governor (remanufactured)

q. Main Oil Pump (remanufactured)

r. Inspect Crankshaft

s. Inspect Camshaft

t. Main Bearings

u. Rod Bearings

v. Valve Rotators

w. Crankshaft Seals

x. Inspect Damper

y. Inspect Fuel System Linkage

z. Inspect Gear Train and Bushings

3.3.3 Remove the generators and send out to be cleaned, dipped and baked.

3.3.4 Remove piping to aftercooler, send aftercoolers to local shop for cleaning and pressure test air sides. Reseal water sides.

3.3.5 Clean engine suction screen.

3.3.6 Touch-up all disturbed surfaces to standard Caterpillar paint scheme; surfaces to be painted shall be free of dirt and grease.

3.3.7 Fill coolant and lube oil systems. Government will provide lube oil. Government will fill coolant system with fresh water and same type of non-chromate corrosion inhibitor as existing.

4 Quality Assurance

4.1 Tests and Reports. Test operate engine after overhaul for a minimum of four hours at the dock. Test all alarm and shutdown systems prior to starting. Ship’s engineer will line up and start engine. Provide technicians to observe operation, verify joints are leak-free, make adjustments, and record data. Operate engine at no load until normal no-load operating temperatures are reached (at least 1 hour). Provide Ship’s Command and crew an opportunity to apply propeller pitch ahead and astern to ensure control systems are all operational. Monitor temperatures and pressures and compare these parameters 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.

4.2 Record the following information near the end of the test; provide test instruments as required:

4.3 Submit a report of all data obtained and include manufacturer’s recommended limit for each measured parameter.

4.4 After all work is accomplished; submit a cost breakdown of parts used for the overhauls.

4.5 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.

5 Notes

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

5.2 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.

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

5.4 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.

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

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