SSDG_Engine_Overhaul.pdf

NOAA Ship Henry B. Bigelow SSDG Engine Overhaul (3508)

December 2015

1. Work Description – Includes labor, material and equipment to perform the 2nd top end overhaul on SSDG No. 3 diesel engine.

2. References

(a) Tech Manual HB-233 01 (FRV40-225-028-010), “Diesel Engine Caterpillar 3508B”

3. Government Furnished Equipment

3.1 None

4. Requirements

4.1 General – The following requirements apply to all work:

4.1.1 Except as otherwise specified, the contractor shall provide all labor, material, services, tools, supervision, and technical expertise needed to accomplish the work required by this specification.

4.1.2 All work shall be performed by an authorized repair facility of the engine manufacturer for the model of engine specified, and shall be performed in such a manner that the manufacturer’s warranty on parts and labor is not voided.

4.1.3 Provide and install “mandatory-renewal” parts and components during the overhaul as required by this specification, Detail Specification, and other procurement documents. Renewal of other parts and components determined to be needed may be provided by the government and shall be installed by the contractor. Additional needed parts and components which are not provided by the government will be negotiated by the Contracting Officer as an additional cost to the purchase order or contract.

4.1.4 Except where remanufactured 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 and remanufactured components and parts, perform visual and dimensional inspections to verify that the components and parts are acceptable for use.

4.1.5 Where remanufactured components are provided (as authorized or specified), existing components shall be replaced on an exchange basis with components which have been remanufactured at the engine manufacturer’s 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 by the manufacturer's factory or a manufacturer-authorized repair facility. Remanufactured components

December 2015 shall meet the manufacturer's remanufactured 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.

4.1.6 All work shall be in accordance with the manufacturer's service, maintenance, and overhaul technical manuals, including all current and applicable amendments and service bulletins. 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.

4.1.7 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.

4.1.8 Thoroughly clean and conduct a thorough visual inspection of all disassembled parts for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability of the engine.

4.1.9 After inspections and tests have been completed and prior to reassembling the components, submit a typed report of all inspection findings and test results, including a record of all measurements and readings taken, to the Contracting Officer's Representative (COR) or other NOAA representative named in the procurement document. Include in the report recommendations for all additional repairs, inspections, tests, and part renewals needed to insure continued reliable service of the engine. Do not proceed with any additional (not covered by scope of previously required work) repairs, inspections, tests, part renewal, or reassembly until authorized by the Contracting Officer or purchasing agent who issued the procurement document.

4.1.10 After the report has been accepted and all additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed.

4.1.11 Remove and reinstall interferences as required to accomplish the required work.

4.1.12 Daily 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.

4.1.13 Coordinate mechanical and electrical tagouts through ships force engineering department.

4.2 Top End Overhaul – The following requirements apply:

4.2.1 Perform the 2nd top end overhaul of the Caterpillar 3508 B SSDG diesel engine No. 3 per the requirements of Caterpillar as defined in Reference (a) and as follows:

4.2.2 Drain and properly dispose of all liquids in the engines.

December 2015

4.2.3 Renew all of 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, O-rings, and gaskets of all removed and disassembled components and parts

b. Turbocharger cartridges (remanufactured)

c. Thermostats, water and oil temperature regulators

d. Cylinder head assemblies (remanufactured)

e. Fuel injectors (remanufactured)

f. Fresh water pumps (remanufactured)

g. Sea water pump (remanufactured)

h. Air starter (remanufactured)

i. Aftercooler cores (remove, clean, pressure test)

j. Lube oil coolers (clean, pressure test)

k. Filter elements

l. Lube oil

m. Magnetic speed pickups

n. Hoses (pressure test and ensure all hoses have chaffing gear where needed)

o. Renew the gasket on each side of the first exhaust expansion joint from the engine.

These gaskets are not Caterpillar parts.

p. ABS approved fuel and oil line spray tape

4.2.4 Clean, inspect, test, and reassemble the following components, parts and subassemblies:

a. Wiring harness (ensure all wiring has chaffing gear where needed)

b. Rocker arms

c. Fuel pressure regulating valve

December 2015

d. Push rods e Spacer plates

f. Cam shaft inspection

4.2.5 Refill the coolant (ship will provide non-chromate corrosion inhibitor) and lube oil systems. The coolant system shall be refilled with fresh water and the same type of non-chromate corrosion inhibitor (ship will provide) as existing and the lube oil crankcase shall be filled with the same type lube oil as existing.

4.2.6 Tests - Conduct the following tests of the engine after all components have been reassembled.

a. Test all alarm and shutdown systems prior to starting the engine. Conduct a preliminary tune-up of the engine.

b. Monitor engine operations as the ship's engineers start the engine. Check all joints for leaks.

4.2.7 Perform operational tests of the engine as follows:

a. Operate engines at no-load for one hour and until normal no-load operating temperatures are reached.

b. Increase the load on the engine to 25-percent of its normal operating full load and operate for one-half hour.

c. Increase the load on the engine to 50-percent of its normal operating full load and operate for one-half hour.

d. Increase the load on the engine to 75-percent of its normal operating full load and operate for one hour.

e. Increase the load on the engine to 100-percent of its normal operating full load and operate for two hours.

4.2.8 For electrical generators prime movers, the ship will install house loads onto the generators for the load tests. Loads tests up to 50-percent capacity shall be performed pier side.

All load tests over 50-percent capacity shall be performed during an underway testing. Test loads shall be based on the full load capacity of the generator.

4.2.9 During and following each operational test period, make adjustments, correct leaks, and monitor performance of the engine.

December 2015

4.2.10 Near the end of each operational test period, take and record the following information:

a. crankcase pressure

b. cylinder exhaust temperatures

c. lube oil temperatures

d. water temperatures

e. fuel oil pressures

f. lube oil pressures

g. water pressures

h. electrical load on generator prime movers

i. exhaust back pressures

j. air box pressure

k. other operating parameters as permitted by installed instrumentation.

4.2.11 Prepare and submit to the COR or other NOAA representative named in the procurement document a report of all data taken in conjunction with the test periods. Include in the report the manufacturer's recommended limits for the applicable parameter.

4.2.12 During the performance of the tests, continually monitor the temperatures and pressures and compare them to the manufacturer's recommended limits. If at any time a temperature or pressure exceeds or falls below the manufacturer's recommended upper or lower limits, the tests shall be stopped and the cause is to be determined. After the cause has been corrected, the tests shall be restarted from the beginning.

4.2.13 Final Adjustments and Tune-up - After satisfactory completion of the operational tests, perform the following:

a. Reset valves, reset injectors, and set governor speed.

b. Conduct final adjustments and tune-ups as required to provide smooth, efficient, and reliable operation of the engine.

c. Paint all new unpainted parts (remanufactured) with OEM paint.

December 2015

5. Quality Assurance

5.1 COR inspection.

6. Notes

6.1 The SSDG diesel engine use Shell Rotella 15w-40. Approximately 350 gallons total.

6.2 The following is the engine and generator information:

Diesel Engine No. 3

MFG: Caterpillar Inc.

Model: 3508 Serial: 3DM00469

SSDG No. 3 MFG: ASIRobicon

MODEL: 500X4-1138

SERIAL: 8006281-2004

600 Volt, 910 kW, 1138 kVA

6.3 There will be engine exhaust pipe support work going on above the engine. The deck above the engine will already be covered. The engine contractor shall provide plastic to cover the engine, while open, during off hours to prevent foreign material from entering the engine.

END OF ITEM