DY FY22 SSDG major Overhaul SOW.docx

Statement of Work NOAA Ship Oscar Dyson

1.1 Ship’s Service Diesel Genset Engine Overhauls.

1.1.1 Scope

a. Provide all labor, material, services, tools, supervision, manuals, and technical expertise needed to accomplish Major overhauls on two (2) 3508B SSDG Engines #3 & #4 on the NOAA Ship Oscar Dyson in accordance with this specification.

1.1.2 References

a. NOAA Ship Oscar Dyson manual DY-233-01, “Engine 3508(028)”

1.1.3 Government Furnished Material

a. None.

1.1.4 Requirements

a. The engines are under American Bureau of Shipping (ABS) Survey and will require attendance of an ABS surveyor at stages of the overhaul and during the testing phase. The contractor shall schedule and coordinate inspections through the ABS as required. ABS inspectors may be present for part of the inspection, or the entire inspection, depending on the individual surveyor’s discretion. See ABS Rules for Survey After Construction, Part 7, Chapter 6: Machinery Surveys.

b. Provide all labor, materials, equipment, services, disposal services, and miscellaneous related items necessary to accomplish this specification. All work shall be performed by a Caterpillar-certified dealer or service facility that is authorized by the original equipment manufacturer (OEM) to work on 3500 series marine diesel engines. The lead technician must be 3500 series certified master technician. All parts and material shall Caterpillar, Caterpillar remanufactured, or equal components. Parts shall meet the most current Caterpillar Technical Updates. All parts shall be 100% compatible and approved by the OEM. Parts shall not void any applicable warranties.

1. Provide protective covering for the primary passageway to the engine room.

2. The Contractor shall be responsible for shipping and/or transporting all equipment and tools to and from the worksite. Ship’s crew will assist with loading by using the shipboard crane to load any palleted items from the pier to the main deck and back from the main deck to the pier. The Contractor shall load and transport all materials, equipment, tools, and miscellaneous related items from the ship’s main deck to the engine room and then back from the engine room to the ship’s main deck after the completion of the top end overhauls.

3. The contractor shall properly dispose of all project refuse including lube oil and engine coolant.

c. Before beginning the overhaul repair work, conduct an operational test of the engines in the presence of the Government Point of Contact (GPOC) to prove correct operation prior to repairs.

d. Perform the following work items for the specified engine and overhaul. Reference each engine’s Technical Manual.

1. Aftercooler Core: Clean, inspect, pressure test. Reassemble, provide and install new gaskets/ joint material.

2. Provide and install new air inlet manifold gaskets and seals.

3. Inspect camshaft. Roll the engine inspect for damage to the journal and lobes. Provide CFR.

4. Provide and install new camshaft bearings.

5. Inspect Camshaft followers. Provide CFR, note condition and wear.

6. Provide and install new Camshaft thrust Washer. Provide CFR.

7. Provide and install remanufactured connecting rod exchange. Inspect removed assemblies provide CFR, note condition and wear.

8. Provide and install new connecting rod bearings.

9. Inspect crankshaft. Inspect for deflection, damage to journals, or bearing material that has seized to the journals. Check journal taper and profile of crankshaft journals. Note wear/condition/ abnormalities on CFR.

10. Provide and install new crankshaft seals.

11. Inspect vibration damper.

12. Provide and install new crankshaft thrust washer.

13. Provide and install remanufactured Cylinder head assemblies. Inspect removed assemblies provide CFR, note condition and wear.

14. Provide and install remanufactured cylinder liners.

15. Check driven equipment:

a) Ensure proper alignment provide CFR, note condition and wear. Provide readings for radial, axial, and angular misalignment, and inspect for soft foot conditions.

b) Inspect coupling provide CFR, note condition and wear.

c) Provide and install new coupling spider

16. Inspect cylinder block provide CFR, note condition and wear.

17. Inspect Engine Control Module provide CFR, note condition and wear.

18. Inspect Engine Mounts provide CFR, note condition and wear.

19. Inspect Engine Wiring Harness provide CFR, note condition and wear.

20. Inspect Exhaust bellows shields provide CFR, note condition and wear.

21. Inspect Exhaust bellows provide CFR, note condition and wear. Provide and install new gaskets and hardware.

22. Inspect Exhaust manifold seals provide CFR, note condition and wear. Provide and install new gaskets and hardware.

23. Inspect Flywheel provide CFR, note condition and wear.

24. Inspect Fuel pressure regulating valve provide CFR, note condition and wear.

25. Provide and install exchange Fuel priming Pump provide CFR, note condition and wear.

26. Provide and install exchange Fuel transfer pump, provide CFR, note condition and wear.

27. Provide and install new inlet manifold gaskets and seals.

28. External inspection of oil pump, provide CFR, note condition and wear.

29. Inspect and clean oil suction screen.

30. Inspect and clean oil sump.

31. Provide and install replacement oil cooler core.

32. Provide and install CAT remanufactured pistons.

33. Provide and install new piston rings.

34. Inspect pre-lube pump provide CFR, note condition and wear.

35. Inspect pushrods provide CFR, note condition and wear.

36. Inspect Rocker arms provide CFR, note condition and wear.

37. Inspect spacer plates provide CFR, note condition and wear.

38. Inspect and provide rebuild Scavenge oil pump provide CFR, note condition and wear.

39. Provide and install software updates

40. Provide and install CAT ET software updates for all four engines.

41. Provide and install new thermostats for the jacket water and after cooler loops.

42. Provide and install new Thermostatic control elements for the jacket water and after cooler loops.

43. Provide and install remanufactured turbochargers provide CFR, note condition and wear.

44. Provide and install new fuel injectors.

45. Provide and install remanufactured jacket water pump.

46. Provide and install remanufactured aftercooler pump.

47. Provide and install new cylinder and exhaust thermocouples, oil and water systems pressure and temperature sensors.

48. Provide and install new turbo charger insulation blankets.

49. Provide and install new replacement emissions certification film, install after touch up painting.

50. Provide and install new levers and lever linkage (tie rod, pins, bolts, keys, etc.) for the lube oil bypass filter on each engine.

e. Provide and install 175 gallons of Caterpiller “extended Life” coolant-premixed, Per engine (350 gallons total)

f. Provide and install 165 gallons SAE 15W-40 Engine oil per engine (330 gallons total)

g. Provide and install new elastic element for each engine coupling.

1. Turn over original coupling to GPOC, Provide report of condition and wear.

h. Following definitions per reference d. explain the terminology for the services that are performed during an overhaul.

1. Exchange – dealer will exchange the engine’s worn parts for parts that conform to original functional specifications.

2. Inspect – Inspect the components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability of Salvage of Used Parts”. The guidelines were developed in order to help Caterpillar dealers and customers to avoid unnecessary expenditures. New parts are not required if the existing parts can still be used, reconditioned, or repaired.

3. Install New – The service life of the part is exhausted. The part cannot be reconditioned. The replacement part must be a new part.

4. Rebuild – The component is reconditioned in order to comply with reusability guidelines.

5. Replace – The service life of the part is exhausted. The part must be replaced with a part that meets functional specifications. The replacement part may be a new part, a rebuilt part, or a used part.

i. In addition to replacing the major worn components of the engine, the overhaul shall also include inspection of all the parts that are visible during the disassembly, replacement of the seals and gaskets that are removed, and cleaning of the internal passages of the engine and the engine block. Visually inspect all cam shaft lobe surfaces for signs of corrosion, wear, and pitting.

j. Should any of the components listed above or any other parts found during overhaul which are not listed, fail to meet Caterpillar tolerances for wear, submit a condition found report (CFR) to the GPOC. Additional Work, any authorization to proceed with such work will come from the Contracting Officer.

k. At the halfway point of each engine overhaul, contact ABS to conduct an inspection of each engine for credit towards the Continuous Machinery Survey. Engines will not be closed until approval is granted by ABS via the GPOC. The Contractor shall provide ABS and the GPOC with a minimum of 24 hour notice when engine components will be open and ready for inspection by the ABS surveyor.

l. Electrical

1. Inspect all electrical connections/devices, wire standoffs and chafing protection installed on the subject engines and provide a CFR with findings. A contract modification will need to be issued for any additional parts or labor required to correct deficiencies noted. The electrical system, including all components of the shutdown circuitry, must be restored to full operation upon completion of the overhaul.

m. Inspection / Test / Warranty

1. Upon completion of repairs, conduct a satisfactory operational test of the engines in presence of the COR to prove correct operation, and that engines are free of any water, oil and air leaks. The Contractor is required to repair or correct all discrepancies.

2. Test the overhauled diesel generator engines under ship’s electrical load. Test shall be conducted with the GPOC and, if requested by ABS, with the ABS Surveyor in attendance.

3. Take and record a set of cylinder operating temperatures during the above operational tests.

4. Following completion of all work, and in addition to any condition found reports required by other sections of this Statement of Work/ Specification, provide a detailed service report of all maintenance actions and engine component conditions, including but not limited to, all critical clearances and adjustments listed in the OEM references and all parts rebuilt, renewed or exchanged. Prior to disembarking the ship, submit two (2) copies of the detailed service report to the GPOC.

n. Provide paint and restore all new or disturbed surfaces to Caterpillar’s yellow standard paint configuration. Clean all engine surfaces and adjacent areas (including handrails, deck plates, and bilge) of all oil and debris resulting from this work.

o. Provide documentation that maintenance and replacement parts meet the requirements of 40 CFR 1042 and MARPOL Annex VI.

p. Restore or replace all damaged insulation and sound dampening materials.

q. Any new parts required in this specification which are not used shall be credited against the work item or provided to the ship for spares.

r. Provide final report of all work.

1.1.5 Quality assurance

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

1.1.6 Period of Performance

a. 28 October – 7 December 2022

1.1.7 Place of Performance

a. NOAA Ship Oscar Dyson, dockside at NOAA Marine Operation Center, Pacific; 2002 SE Marine Science DR, Newport, OR.

1.1.8 Notes

a. Engine Information

1. Ship Service Diesel Generator #1 (SSGD 1)

b. #3 SSDG

MAKE: CATERPILLAR

MODEL: 3508B

SERIAL #: 3DM00336

ARRANGEMENT #: 173-6953

c. #4 SSDG

MAKE: CATERPILLAR

MODEL: 3508B

SERIAL #: 3DM00339

ARRANGEMENT #: 173-6953