SOW__Main_Engine_and_SSDG_.docx

TS GOLDEN BEAR- MAIN ENGINE AND SSDG -- 2017

TS GOLDEN BEAR- MAIN ENGINE & SSDG

Item No 1 – SR No 0301968 SSDG Cylinder Heads SR No 0301968 - SSDG Cylinder Head Annual Overhaul

ABSTRACT

This item describes the annual overhaul of SSDG Cylinder Heads including the transportation to/from the ship and all shop work and parts to overhaul heads to manufacturer’s specifications. Heads to be removed and reinstalled by ship’s crew.

REFERENCES

Manufacturer’s instruction books and prints in ship’s files Engine Specifications: MaK Four Stroke Type 6M332 engine, single acting non-reversing/solid injection, turbocharged. Engine Numbers: 33616, 33617, 33618

ITEM LOCATION / DESCRIPTION

Location Contractor picks-up and delivers to CMA pier after scheduling with Chief Mate.

Engine Room – Six (6) Heads to be removed by ship’s crew Description:

Inspection, servicing and Reconditioning or MAK SSDG Cylinder Heads.

GOVERNMENT FURNISHED EQUIPMENT / MATERIAL / SERVICES

Forklift assistance for loading / unloading heads.

STATEMENT OF WORK

Annual SSDG Cylinder Head Overhaul For bidding purposes Contractor to use the following:

1) Rig six (6) each Ship-removed SSDG cylinder heads from ship to shop

2) Survey each head and note any missing parts or fittings - Supply needed missing parts

3) Once the heads are stripped and cleaned, report findings in shop notes and any needed repairs

4) Perform needed repairs to the heads such as valve seats, injector seating surface or other wear items using proper methods and materials compatible with engine design and OEM approved procedures.

5) Supply new valves and springs and keepers as necessary

6) Repair all injectors but if individual injector cost exceeds 50% of new, then renew same. Report status of injectors and those that are renewed in shop notes

7) Clean and coat final repaired heads and supply same with all new O-rings and Seals necessary for installation

8) Transport and rig reconditioned heads back to ship

DELIVERABLES

Contractor to provide Chief Engineer and COTR with original and two (2) copies of inspection and shop work completed for each head.

Chief Engineer and COTR to receive electronic form

Item No 2 – SR No 0301968 Main Engine Cylinder Heads SR No: 0301967 - Main Engine Cylinder Head Overhaul Note:

CONTRACTOR TO USE ALL ATTACHEMENTS IN PREPARATION OF THEIR BID AND TO PERFORM THE REPAIRS ON THE FOUR (4) HEADS TO BE OVERHAULED

1.0 ABSTRACT

This item describes the overhaul of Four (4) of the Main Engine Cylinder Heads including all attachments and sensors (Except Injectors) that were removed from the Engine (Stbd Main Engine Cylinders 7,8,15 & 16). Transportation and rigging from the ship to the shop and from the shop to the MARAD Warehouse is to be included in the job. Job also includes the rigging and transportation of four (4) reconditioned heads from the MARAD Warehouse to the ship and put in the rack as spares in place of those to be shipped to the shop

2.0 REFERENCES –

Use the attachments for reference as to the exact methods required to do the valve seat repairs and all other procedures required Attachments are as follows:

1) Transamerica Delaval Service Information Memo No 249

2) Hans Mueller – 1993 Paper -Part No 1

3) Hans Mueller - 1993 Paper -Part No 2

3.0 LOCATION / DESCRIPTION

Location:

Spare ME Cylinder Heads (that were removed from SME) Four (4) spare ME Cylinder Heads from MARAD Warehouse to be picked up and transported and rigged into rack as spares aboard ship

Description:

Heads were removed from Stbd Main Engine as part of the 2016 Emergent Repair. Heads are to be rigged and transported to the shop for inspection and needed repairs then rigged and transported to the MARAD Warehouse. To replace those spares contractor to pick up four (4) ME Cylinder Heads from the MARAD Warehouse and transport to ship and rig into spares rack.

4.0 GOVERNMENT FURNISHED EQUIPMENT / MATERIAL / SERVICES

Four (4) each Main Engine Cylinder Heads (Serial Number to be identified during disassembly) Once a survey is taken for each head and the worn or non-usable parts are identified, the Ship will send parts enough to rebuild the heads after the valve seats are repaired.

Note: All parts and materials to be contractor supplied unless called out otherwise in specification. All parts and materials shall be OEM or equivalent pre-approved by COTR. All tolerances and limits referred to in this overhaul specification shall be defined as those that the OEM delineates as “suitable for reuse or reassembly” or “acceptable” in the Enterprise Maintenance and Repair manual for these engines. These tolerances and limits shall not be those the OEM describes as “as new” or “as delivered” unless specifically referred to in this specification and in no case shall the contractor deliver reports calling out tolerances as “out of spec” when within the “suitable for reuse” tolerances.

Note:

DO NOT lap or blue the valves with the head in a vertical position. Grinding should be done using a Chris Marine seat grinder or equivalent technology followed by bluing to prove proper seating.

5.3.7 Following OEM recommended procedures, repair all firing and jacket water head gasket seating surfaces to meet manufactures acceptable tolerances.

5.3.8 Rejected Exhaust/Intake Valves shall be replaced from Ship’s spares. All valves shall be installed with new keepers

5.3.14 Provide two (2) final typewritten copies to Chief Engineer of all measurements, clearances and readings taken during work this item in manufacturer’s format as per Inspection and Maintenance Record of service manual and provide for review during ABS attendance. This report shall include serial numbers of all cylinder heads, etc.

Provide electronic copies of all documents to COTR

5.5 DELIVERABLES

5.5.1 Contractor to supply hard copy shop notes of work completed with each head that is shipped back to the MARAD Warehouse

5.5.2 Contractor to supply two hard copies of the shop notes to the Ship and electronic copy to the ship and the MARAD COTR

5.5.3 The cylinder heads will not be deemed finished unless each one has an ABS stamp that verifies it has been inspected and passed inspection by an ABS Surveyor Item No 3 – SR No 0301985 Five (5) Each ME Cylinder Heads SR No 0301985 - Main Engine Cylinder Heads Overhaul Note:

CONTRACTOR TO USE ALL ATTACHEMENTS IN PREPARATION OF THEIR BID AND TO PERFORM THE REPAIRS ON THE FIVE (5) HEADS TO BE OVERHAULED

1.0 ABSTRACT

This item describes the overhaul of FIVE (5) each of the Main Engine Cylinder Heads including all attachments and sensors (Except Injectors). Transportation to and from the MARAD Warehouse is to be included in the job.

Cylinder Head Nos: To be supplied at the time of the Solicitation Note: Five (5) Additional Heads to be picked up from MARAD Warehouse and transported to shop for disposal as these have been found to be damaged and beyond repair Cylinder Head Nos: To be supplied at the time of the Solicitation

2.0 REFERENCES –

Use the attachments for reference as to the exact methods required to do the valve seat repairs and all other procedures required

3.0 LOCATION / DESCRIPTION

Ten (10) Used Main Engine Cylinder Heads are located in the MARAD Warehouse in Alameda, CA

4.0 GOVERNMENT FURNISHED EQUIPMENT / MATERIAL / SERVICES

Five (5) each Cylinder Heads including all attachments and sensors and one (1) fuel Injector for measurement purposes.

Original shipment will be only the cylinder heads themselves Once a survey is taken for each head and the worn or non-usable parts are identified, the Ship will send parts enough to rebuild the heads after the valve seats are repaired.

Note: All parts and materials to be contractor supplied unless called out otherwise in specification. All parts and materials shall be OEM or equivalent pre-approved by COTR. All tolerances and limits referred to in this overhaul specification shall be defined as those that the OEM delineates as “suitable for reuse or reassembly” or “acceptable” in the Enterprise Maintenance and Repair manual for these engines. These tolerances and limits shall not be those the OEM describes as “as new” or “as delivered” unless specifically referred to in this specification and in no case shall the contractor deliver reports calling out tolerances as “out of spec” when within the “suitable for reuse” tolerances.

5.3.8 All of the deficiencies noted in the old Worldwide shop notes must be addressed and corrected and noted as being completed

5.3.16 Dispose of properly the five (5) damaged heads properly

5.5 DELIVERABLES

5.5.1 Contractor to supply hard copy shop notes of work completed with each head that is shipped back to the MARAD Warehouse

5.5.2 Contractor to supply a hard copy of the shop notes to the Ship and electronic copy to the ship and the MARAD COTR Item No 4 – SR No 0301989 SSDG Fuel Pumps SR No 0301989 - SSDG Fuel Pumps

ABSTRACT

This item describes the overhaul of the eighteen (18) SSDG Fuel Pumps to be overhauled. Contractor to provide all labor and material and rigging and transportation and crating to ship fuel pumps from Vallejo, CA to contractor’s shop for overhaul. Upon completion of repairs, Contractor to ship fuel pumps from repair shop to ship in Vallejo and rig to engine room for reinstallation.

REFERENCES

Manufacturer’s instruction books and prints in ship’s files Engine Specifications: MaK Four Stroke Type 6M332 engine, single acting non-reversing/solid injection, turbocharged. Engine Numbers: 33616, 33617, 33618

ITEM LOCATION / DESCRIPTION

Location – Engine Room Description:

Fuel pumps to be removed by ship’s crew Inspection, servicing and reconditioning of MAK SSDG Fuel Pumps at Contractors Shop Transport and crating and rigging all to be done by Contractor from/to ship and to/from shop

GOVERNMENT FURNISHED EQUIPMENT / MATERIAL / SERVICES

Crane and Forklift assistance for loading / unloading fuel pumps

.STATEMENT OF WORK

Contractor to provide all necessary labor, material, transportation and rigging to transport eighteen (18) SSDG Fuel Pumps from Vallejo, CA to contractor’s shop. Contractor is responsible for protecting all pumps to prevent any damage during rigging and transportation from the ship to the shop and back Contractor to supply a technician who has a minimum of five (5) years of experience repairing similar fuel pumps using OEM parts and procedures Contractor to open and inspect each fuel pump and list the deficiencies as found and necessary parts renewal and any associated costs for repair.

Contractor to supply new balanced delivery valves for each fuel pump and final test of each repaired fuel pump will be conducted with the new delivery valve Contractor to perform operational tests on each repaired fuel pump and supply the final shop test results as a deliverable Contractor to crate the repaired fuel pumps for shipment from shop to ship located at California Maritime Academy in Vallejo, CA

DELIVERABLES

Contractor to supply all shop notes for each fuel pump showing original open and inspect and parts needed to repair plus the final test data All notes can be sent to Chief Engineer and COR via email in electronic format Item No 5 – SR No 0301966 Main Engine Turbo-Charger & Deflection Readings SR No 0301966 MAIN ENGINE TURBO-CHARGER & DEFLECTION READINGS

ABSTRACT

Contractor to provide all labor, material, transportation and rigging to perform the following:

· Remove in service Turbo-Charger on

· Rig spare Turbo Charger from storage space in Furniture Room to Engine Room for installation

· Install spare Turbo-Charger

· Take Deflection Readings PME and SME prior to operation when at operating temperature

· Test run both PME and SME

· Take Deflection Readings PME and SME after test run of Turbo Charger and other component checks for both engines

· Rig and Transport removed Turbo-Charger to Shop

· Overhaul Turbo-Charger per Manufacturer’s guidelines

· Rig and Transport overhauled Turbo-Charger to ship and rig into storage area as directed by CE

· Provide all shop notes for all work completed both hard copy for CE and electronic copy for COR and CE

REFERENCES

Technical manuals for Enterprise Engines.

ITEM LOCATION / DESCRIPTION

Item Location: Main Machinery Space – Turbo Charger .

Item description: Main Engine Turbo-Charger Change and PME and SME Deflection Readings

GOVERNMENT FURNISHED EQUIPMENT / MATERIAL / SERVICES:

Spare overhauled Turbo-Charger stored in Furniture Room below the Gym by Fwd MSD Note: Contractor responsible for rigging spare from Furniture Room to Engine Room for Installation and Transportation and Rigging removed turbo-charger from the ship to the shop

MAIN ENGINE TURBOCHARGER OVERHAUL

ABSTRACT

This item describes the Overhaul and Inspection of one DeLaval C17-180CA turbocharger for ABS machinery survey. Main Engine Turbo-Chargers must be opened and inspected and repaired as necessary. The Continuous Engine Survey requires this change out and open and inspect and overhaul.

REFERENCES

DeLaval Enterprise technical manuals available on vessel.

ITEM LOCATION / DESCRIPTION

Item Location: Main Machinery Space.

Item description: Open, Inspect, overhaul and service of a Delaval C-17-180CA turbocharger.

GOVERNMENT FURNISHED EQUIPMENT / MATERIAL / SERVICES:

None

STATEMENT OF WORK

GENERAL CRITERIA & INITIAL INSPECTION AND PLANNING

All dimensions are estimated. Contractor is responsible for ship checking and verifying dimensions and Data prior to bid submission and notice to proceed.

Contractor shall employ and have on site during all work this item a Lead Man/Technician with a minimum of five (5) years experience in the Overhaul and Repair of DeLaval C17 Turbochargers. Award vendor may use his own labor force to complete the work cited in the CLIN provided that the lead man is on site during critical phases of disassembly and assembly. Critical phases include all checkpoints and measurements cited in contract, actual rigging out of and into engine of components, inspection of and guidance for surface preparations (such as honing), and during inspection & testing phases.

Furnish labor, material, and equipment to accomplish the following. Note: All parts and materials to be contractor supplied unless called out otherwise in specification. All parts and materials shall be OEM or equivalent pre-approved by COTR. All tolerances and limits referred to in this overhaul specification shall be defined as those that the OEM delineates as “suitable for reuse or reassembly” or “acceptable” in the Enterprise Maintenance and Repair manual for these engines. These tolerances and limits shall not be those the OEM describes as “as new” or “as delivered” unless specifically referred to in this specification and in no case shall the contractor deliver reports calling out tolerances as “out of spec” when within the “suitable for reuse” tolerances.

All work shall meet USCG, ABS or other appropriate regulatory standards. At the earliest opportunity during the first week of the project the contractor and/or sub-contractor shall tour the sight and review the project with the Chief Engineer, COTR, and regulatory body representative(s) to discuss expectations and check-points. Vessel’s Chief Engineer and COTR shall be given at least 48 hours notice prior to expected regulatory check points. Contractor is not responsible for surveyor fees, but must make every effort to minimize required surveyor visits by scheduling multiple inspections whenever possible.

DISASSEMBLY, INSPECTION AND CLEANING

Disconnect and detach interferences to allow removal of the turbocharger from the main engine.

Disconnect and detach C17 turbocharger from main engine. Retain and identify all connections, shims and mounts to allow for later re-assembly.

Note any abnormalities, stresses or damage in as found installations and provide “As Found” report to COTR and Chief Engineer. Note: particular attention shall be paid to “wrinkle belly” expansion joints. If any cracks or stress is noted, expansion joint shall be replaced with one from vessel’s spares.

Rig the detached turbocharger out of machinery space, off ship, and to contractor’s facility for overhaul, cleaning, balance, and inspection.

Upon arrival at contractor’s facility visually inspect unit for signs of leaks, cracks or misalignment. Document and photograph general condition of units and provide report to COTR.

Completely disassemble turbocharger as per OEM procedures. Photograph and record any areas of wear, scoring or abnormalities. Verify and document that rotor, shroud, nozzle ring, and casings are within OEM design specification. Verify and document all operating clearances as per OEM specification.

Thoroughly clean compressor casing, inlet, diffuser and shroud. Shot or silica blast, as appropriate, the turbine case, exhaust cone, partition, inlet cover, the nozzle ring, shroud, compressor wheel, turbine wheel, divider shield and diffuser.

Perform the following inspections, and take and record measurements as per OEM specifications noting tolerances where appropriate:

· Measure shaft for straightness, and measure seal and journal diameters and condition.

· Measure concentricity of bearing journal to bore.

· Measure & inspect radial bearings and report on suitability for reuse.

· Measure & inspect thrust bearing assembly and report on suitability for reuse.

· Compare bore inside diameter and depth to OEM specification.

· Measure compressor wheel conical washer for diameter and crush.

· Measure and inspect bearing cartridge for concentricity.

· Inspect casings for cracks, damage, and bolt hole condition.

· Inspect and measure compressor inlet housing for bore, shaft seal groove condition, and labyrinth seal diameter.

· Measure exhaust cone bore diameter.

· Verify partition flange is within specified tolerances.

· Measure and inspect partition.

· Verify divider shield tab groove width and thickness.

· Perform a liquid penetrant inspection of compressor wheel and turbine exhaust wheel. Measure and record all dimensions and compare to OEM specification.

· Measure and record nozzle ring groove clearance, nozzle ring dimensions, and nozzle ring flow area. Compare to OEM tolerances and nameplate data.

RECONDITIONING, REASSEMBLY AND REINSTALLATION

Recondition parts for proper reassembly. Remove any broken bolts and re-tap threaded holes, checking for proper thread engagement. Machine critical mating surfaces. Balance rotating assemblies to within .01 oz./in. Provide balance report to COTR. Paint interior and exterior surfaces as per OEM specification.

Reassemble units with all new radial bearings & fasteners. Apply sealant, & locking compound to mating faces and fasteners as per OEM specifications. Verify and document proper bearing size, clearances and conditions. Confirm and document proper clearances, seal run-out, shim pack thickness, total rotor travel, and end-thrust.

Reinstall all oil and air piping as per OEM specification and supplemental seal air modifications.

Identify overhaul date, facility, model and serial number on new nameplate for ease of reference. Seal off all openings and skid mount units for delivery to vessel.

Transport and deliver overhauled units to vessel and rig into place.

Replace any damaged exhaust side expansion joint with vessel’s spare obtained through Chief Engineer.

Re-install overhauled C17 turbocharger delivered above, or previously overhauled vessel’s spares on Main Engines as designated by COTR. Previously overhauled spares are located in vessel storeroom below gym. . Note: If using vessel’s spare Turbocharger which were rebuilt under a previous contract, it is not necessary to disassemble these vessel’s spares as condition was acceptable in previous report. It is understood that the contractor will not be held responsible for any defect or delay under this contract caused by any fault associated with prior repairs contract.

Reconnect all detached interferences including all connections, shims, mounting supports, and flex joints. Leave ready-for-sea.

Test run engines and turbocharger with vessel’s crew.

NOTES

Particular care shall be put into shimming and mounting turbo to minimize thermal and mechanical stresses. Vessel has spare casings and rotors at MARAD warehouse facility, but these casings have been discovered with transitions cracked in past services. Spare casings have ABS approved metal-stitch repair.

If damaged expansion joints or wrinkle-bellies are found at delivery inspection, the contractor shall at no additional cost to the government replace the damaged expansion joint with a vessel spare or new joint provided under a separate item. It is imperative that all due diligence be expended to insure that expansion joints are replaced at overhauls due to difficulty in addressing between overhauls.

ENGINE DATA

DELIVERY INSPECTIONS

When Turbo-charger reinstalled, prepare for testing with ship’s crew assistance.

Perform a set of deflections on PME and SME prior to running engine (after engine has reached operating temperature). Perform the hot set of deflection readings after engines have been run Install crankcase doors and have ship’s crew run lube oil pumps to check for flow to bearings and valve and running gear. Bar engine over while running pump.

Vessels crew will test run PME and SME which will be followed by contractor performed bearing checks.

Contractor shall be responsible for demonstrating that all Vessel supplied special tools, i.e. lifting brackets, hydraulic jacks, hydraulic pump…, are stowed away in full working condition.

DELIVERABLES

Provide 2 final hard copies to Chief Engineer of all measurements, clearances and readings taken during work this item in manufacturer’s format as per Inspection and Maintenance Record of service manual within 30 days of contract completion. Provide the Shop notes for the Turbo-Charger initial open and inspect of same and the parts that are necessary for reassembly . Provide COR and CE with electronic copies of all reports

Item No 6 – SR No 0301980 SSDG Cylinder Bore & Reassembly SR No 0301980 SSDG Cylinder Bore Repairs Phase 2 of 3

ABSTRACT

Contractor to supply all labor, materials, transportation and rigging to dismantle one (1) Ship Service Diesel Generator (SSDG) engine to gain access to the individual cylinder bores. Contractor to remove all pistons and interferences to allow the cylinder liners to be removed on each cylinder. Contractor to use OEM approved methods to bore the engine block and insert sleeves to correct wasted sections of the block behind the liners. Contractor to do each cylinder and fit with a sleeve and the reinsert the liners with new o-rings then reassemble engine for operational testing.

Note: Engine may have been torn down by crew and will have to be reassembled by Contractor.

REFERENCE

Engine Specifications: MaK Four Stroke Type 6M332 engine, single acting non-reversing/solid injection, turbocharged. Engine Numbers: 33616, 33617, 33618

LOCATION AND DESCRIPTION

Location:

SSDG #2

Description:

Crew has dismantled one (1) SSDG to allow for inserting of contractor-supplied sleeves in the individual bores of each cylinder and then reassembly including the liners and pistons and all heads and attachments. Final assembled engine to be tested under the direction of the Chief Engineer. After engine has run up to temperature, Contractor to do an internal inspection to insure that there is no leakage past the new sleeve to block or liner to sleeve locations on any of the cylinders. Final approval by Chief Engineer and COR

STATEMENT OF WORK

Contractor to supply all labor, materials, transportation and rigging necessary to complete the cylinder block inserts in one (1) SSDG including the boring of the cylinder block and removal of any interferences and insertion of contractor supplied sleeves and reassembly of the engine including liners, pistons and attachments.

Contractor to supply all needed materials to prevent any machining debris or work materials from falling into the crankcase during the time the engine is opened for repairs.

Contractor is responsible for all tooling and equipment necessary to do the boring of the engine blocks to receive the sleeves in each cylinder. Procedure must agree with OEM procedures relative to the sleeve materials and thickness and other dimensions.

Procedure to include but is not limited to the following work:

1) Contractor to isolate engine with ship’s crew to prevent engine from turning over and any fuel or coolant loss.

2) Remove Cylinder Heads and attachments and stow on wood or other materials to protect seating areas

3) Pull pistons from each cylinder and stow on wood or other materials to protect same

4) Line area below the cylinders to prevent any debris from falling into the crankcase

5) Remove liners and label cylinder locations and stow on wood or other materials to prevent damage to same

6) Take pictures of the liner seating area to show deteriorated locations in each cylinder

7) Set up and bore each cylinder to receive the contractor supplied sleeves

8) Press in the sleeves to the machined cylinder locations

9) Clean and fit with new O-Rings all liners and press into new sleeved cylinders

10) Install pistons and heads and attachments

11) Fill engine with coolant to test the new sleeve to liner joints with engine at stand still

12) Test run with crew to prove the repair for a minimum of one hour

13) Shutdown engine and open crankcase to check new liner to sleeve and sleeve to block joints for leaks

DELIVERABLES

Contractor to supply both hard copies and electronic copies of as found conditions and the required repairs on the six (6) cylinders. Include the dimensions for the sleeves inserted into the block and the amount bored to receive the sleeves.

Contractor to supply photos of the engine as found and the work accomplished on each cylinder.

ADDITIONAL WORK AND SUPPLEMENTAL ITEMS

ADDITIONAL UNDISCOVERED WORK OR PARTS

Contractor to submit a written Condition Found report (CFR) to the COTR for any additional work outside the contract. Approval for additional work must be approved by either the COTR ($5000 or less) or the Contracting Officer (over $5000) Contractor to provide cost breakdowns as they relate to labor, material, subcontractors and travel costs, if applicable. Supplementary costs must be approved by COTR by written CFR, RFQ, Quotation and Delivery Order process.

Item No 7 – Supplementary Labor – 90 hours @ $_____/Hr = $______________

Item No 8 – Supplementary Material = $10,000