RFQ_ATTACHMENT_1.pdf

CATERPILLAR D398 20,000 HOUR ENGINE OVERHAUL and SHIPS

SERVICE DIESEL GENERATOR (ELECTRICAL END) OVERHAUL AND

CLEANING

1.0 SCOPE. This specification contains requirements for

the 20,000 hour overhaul of two, Caterpillar D398 engines on NOAA Ship Gordon Gunter. Serial Numbers: Engine #2:

35Z01560; Engine #4: 35Z01566.

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-300-1, "Overhaul of

Electrical Rotating Machinery"

2.6 Generator alignment procedure (attached).

2.7 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. NOTE: The 21-day performance period shall be strictly adhered to. 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 or under the direct on-site supervision of a factory-trained mechanic currently certified by the engine manufacturer. Submit evidence of being a Caterpillar Authorized Marine Dealer (A.M.D.) 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:

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. 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 groups, couplings, clamps

(remanufactured)

b. Camshaft kit (shaft, lifters)(remanufactured)

c. Camshaft bearings

d. Front gear bushings

e. Governor linkage

f. Actuator (remanufactured)

h. Thermostats and water temperature regulators

i. Cylinder head assemblies with valves

(remanufactured)

j. Cylinder packs (remanufactured)

k. Dampers

l. Fuel nozzles

m. Fuel pump assemblies

n. Fuel transfer pump (remanufactured)

o. Oil relief valve and spring

p. Fuel injection pump group yoke screw and lock nuts

q. Main bearings, (complete, including thrusts)

r. Rod bearings, complete

s. Front and rear cover seals and gaskets*

t. Front and rear hydromechanical seals - directional

u. Jacket water pumps (remanufactured)

v. Jacket water heater hoses

y. Jacket water thermostats

w. Sea water pumps (rebuild kit and new impeller)

x. Lube oil coolers, non-removable core

(remanufactured)

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

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

aa. 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. Deliver the cores to a local radiator shop for cleaning. 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 SHIPS SERVICE DIESEL GENERATOR (ELECTRICAL END)

OVERHAUL AND CLEANING

3.3.1 Disconnect the four (4) ship’s service generators

(electrical end) from their respective diesel engine prime movers, Caterpillar D398s. Before disassembly, take and record generator shaft runout readings and deflection readings of the generator fan to flex plate. Prior to uncoupling the generator from the diesel engine prime mover, install blocks and other supports needed to support the generator-end of the diesel crankshaft and coupling. Upon reassembly, readings are once again to be taken and the generator adjusted in accordance with manufacturer’s specifications. Provide the ship’s Chief Engineer and the COR at least 24 hours prior notification so they may witness those readings.

(a) Insert a matting to protect the iron laminations and windings between the main rotor and stationary fields.

(b) Remove bolts that fasten generator frame to engine.

(c) Mark flex plates to fly wheel and remove flex plates being sure they are marked for the same location, and together.

(d) Do not shift any rotating flex plates.

(e) Remove generator mounting bolts and slide generators aft enough to remove flex plates, mark location on shaft.

(f) Remove rotating fan and inner air shield.

(g) Remove exciter covers.

(h) Remove rotating exciter.

(i) Remove stationary exciter.

(j) Open rotating exciter connections from rectifier assembly.

3.3.2 Remove the generators from the ship to a suitable

electrical shop. Disassemble and inspect the generators; provide a Condition Report with results of inspections to COR. Perform a

"Standard Overhaul" of the generators in accordance with

Reference 2.5 and the following:

(a) All work shall be accomplished in accordance with manufacturer's recommended procedures.

(b) All replacement parts shall be genuine Kato factory built or approved parts.

3.3.3 Renew the generators’ bearings (1 each per generator)

same as existing and rework the housings as necessary to ensure the correct fit. The existing bearing part no. is 012-21202-00.

3.3.4 Reassemble generators after all work is completed;

reinstall, reconnect and test. Mechanically align generators with their respective engines following the Generator Alignment

Procedure in section 3.5.4 below.

3.3.5 After generator electrical sets are reinstalled, conduct final testing of the generators as follows:

a. Measure and record insulation resistance with a 500 volt megger.

b. Perform a D.C. high potential leakage test as follows.

Apply D.C. voltage to the winding starting at 25% E, where

E is rated voltage. Hold this voltage until leakage current is stabilized and record values. Raise the voltage in steps of 25% E to allow the leakage current to stabilize at each step and record the values. The maximum voltage of the test will not exceed 0.66 (2E + 1000) which is 66% of new machined test value. If a runaway leakage current condition is noted at any of the voltage steps the test will be stopped immediately and the COR notified immediately. Upon completion of the test, plot the data as a curve.

c. Perform a no-load running test. Check for noise, end play, vibration, magnetic center, bearing temperature rise and no-load current.

d. Perform a reactive load bank test at 100% load until temperatures stabilize. Provide a copy of the proposed load test procedure to the COR for acceptance prior to performing the work. Provide the COR a copy of the load test results in a condition report.

e. Provide the COR a copy of the load test results in a condition report.

3.3.6 Attach a metal tag to each generator stating the

following:

(a) Type of varnish and insulation used.

(b) Record of megger readings taken before and after overhaul.

(c) Contractor's name and date of generator overhaul.

3.4 Quality Assurance

3.4.1 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 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 manufacturer's recommended upper or lower limits, testing shall be stopped and the cause determined and corrected before continuing.

3.4.2 Record the following information near the end of full

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

3.4.3 Submit a report of all test data collected. Report

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

3.4.4 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.

3.4.5 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.

3.5 Notes.

3.5.1 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

(Mobile, AL) office. Government will pay ABS fees associated with the survey under a separate purchase order.

3.5.2 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.

3.5.3 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 Gordon Gunter. 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.

3.5.4 Generator technical data:

Manufacturer: Kato

Model No.: A211630000/5R4274

Type: 21163

Catalog Number: 6P6-2400

Bearing Number: 012-21202-00

KVA/KW: 600

RPM: 1800

Voltage: 600

Amps: 907

3.5.5 GENERATOR ALIGNMENT PROCEDURE

Take the following readings before disassembly:

a. generator fan angular deflection,

b. generator shaft runout (TIR),

c. crankshaft end play,

d. crankshaft deflection.

Take the above readings again upon reassembly, after the generator to engine alignment relationships have been re-established.

Record all results on condition reports and report the results to the attending NOAA Port Engineer, or assigned representative.

Before performing the parallel and angular alignment checks, ensure that the natural clearance between the base and its foundation is properly gapped with shims at all mounting locations and check that all base-to-foundation bolts are tightened to their final torque. If deflection of the base is noted, loosen base-to-foundation bolts at affected locations, shim as necessary to eliminate deflection, and re-tighten base-to-foundation bolts to their final torque.

Inability to attain repeatability of readings may be due to cocking of the flywheel by the turning tool. An end-supporting turning tool has proven to be superior to free-gear types for taking these particular reading. If an end-supported tool is not available, good results are attainable with a free-gear type if tooth engagement is reduced to the bare minimum necessary to turn the flywheel.

The deflection dial indicator must not have a leash attached since it may change readings.

PARALLEL ALIGNMENT (SHAFT RUNOUT)

Ensure that the generator shaft surface, which is to be measured with the dial indicator, is clean. Solvent and or light sanding with emery cloth should remove any dirt or rust accumulation.

Place the base of a dial indicator on the uppermost generator adaptor frame rib and position the indicator finger, which requires extensions, on the generator shaft.

Preliminary readings can be taken on the coupling; final readings will be taken on the shaft only. Zero the dial indicator at the 12 o'clock position. It is essential to ensure that the dial indicator base does not move during the run-out check. Any movement will result in erroneous readings.

Rotate the shaft one revolution starting at the 12 o'clock position, checking and recording the dial indicator readings every 90 degrees. To validate the readings, at the completion of the revolution, the dial indicator must return to 0 at the original 12 o'clock starting position.

In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft.

Desired reading is 0.000 inch. Total indicator readings shall not exceed .005 inches. Adjust drive flex plate pack

(discs) to flywheel installation as necessary to bring parallel alignment into tolerance.

Adjustment is accomplished by changing the diesel engine flywheel to generator drive flex plate pack relationship.

If total indicator readings exceed 0.005 inches, adjustment is accomplished by removing the drive flex plate pack to flywheel bolts and turning the engine flywheel with the turning gear. The generator can be prevented from rotating with the engine by installing a capscrew in the generator coupling and then holding the generator with a 36" long pinch bar or angle iron placed on the capscrew and generator web. The engine to flywheel relationship is changed one or more bolt holes at a time. Reinstall the drive flex plate pack to flywheel bolts and take runout readings. Adjust as necessary to bring TIR readings into tolerance.

GENERATOR ANGULAR ALIGNMENT

Place a deflection dial indicator at the 12 o'clock position between the forward face of the fan and the drive flex plate at a point as far away as possible from the centerline of the shaft. The contact points for the deflection dial indicator fingers should be lightly punch marked.

Starting at the 12 o'clock position, rotate the shaft one revolution checking and recording readings every 90 degrees. To validate readings, at the completion of the revolution, the deflection dial indicator must return to zero at the 12 o'clock starting position. In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft.

Desired generator angular alignment readings are as follows:

12 O'CLOCK: 0.000 (starting point)

3 O'CLOCK: 0.000 TO +0.004

6 O'CLOCK: 0.000 TO +0.008

9 O'CLOCK: 0.000 TO +0.004

12 O'CLOCK: 0.000 (original starting point)

Adjust as necessary to bring angularity readings into compliance with paragraph 3 above. If adjustment is effected, a final set of angularity readings must be obtained after all bolts securing the generator to the engine and the generator to base are tightened to their final torque.

END OF SPECIFICATION