RFQ_ATTACHMENT_2.pdf

NOAA Ship PISCES

SSDG 22,500 Hour Overhaul

August 2016

NOAA Ship PISCES SSDG 22,500 hour Engine Overhauls

1. SCOPE This specification contains requirements for 22,500

Hour overhaul of two, Caterpillar 3512 engines (Serial numbers:

Engine #1 8EM00550; Engine #2 8EM00549 Arrangement 1744947) on

NOAA Ship PISCES.

2. References

2.1. NOAA Standard Specification AMC-000-1F, "General

Requirements for Ship Repair Contract Work on NOAA Ships"

2.2. Caterpillar Operation and Maintenance Manual

(SEBU6916-04)

2.3. Caterpillar Parts Manual (SEBP 2446-14)

2.4. TDI Starter Tech Manual

3. 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 2.3 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. 3512 SSDG 22,500 Hour Engine Overhaul

Accomplish the following work for 22,500 hour overhauls:

3.2.1. Engines will be drained of oil and jacket water

by ship’s force prior to start of repairs.

3.2.2. Provide a pump truck to remove coolant from the

ship’s waste tank and dispose of. For bidding purposes, estimate 300 gallons of coolant to be removed/disposed.

3.2.3. Exchange, Inspect, Install New, Rebuild, or

Replace the parts and components in accordance with tables 57 & 58 on pages 129-131 of reference 2.2. All pistons and connecting rods shall be replaced as new.

3.2.4. Touch-up all disturbed surfaces to standard

Caterpillar paint scheme; surfaces to be painted shall be free of dirt and grease.

3.2.5. Fill coolant and lube oil systems. Government

will provide lube oil. Government will fill coolant system with Caterpillar approved (DEAC) Diesel Engine

Antifreeze/Coolant as existing. Coolant to be furnished by Contractor.

3.3. 3508 & 3512 SSDG Air Starter Renewals

3.3.1. Remove four (4) currently installed air starters

and provide to the COR.

3.3.2. Provide and install new turbine air starters.

New starters to be TDI T50-P. See reference 2.4.

3.3.3. Provide two (2) air starter rebuild kits and one

(1) spare TDI T50-P starter to the COR.

3.3.4. All necessary piping and wiring modifications, if

any, shall be performed by the contractor.

3.3.5. Touch-up all disturbed surfaces to standard

3.4. 3508 & 3512 SSDG and EDG Hose Renewals

3.4.1. Renew all fuel hoses. All new hoses shall be made

and installed with all new 316 stainless steel fittings.

3.4.2. Renew all pre-lube pump hoses. All new hoses shall

be made and installed with all new 316 stainless steel fittings.

3.4.3. Touch-up all disturbed surfaces to standard

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:

4.2.1. Cylinder exhaust temperatures

4.2.2. Lube oil temperatures

4.2.3. Coolant temperatures

4.2.4. Fuel oil pressure

4.2.5. Lube oil pressure

4.2.6. Water pressures

4.2.7. Turbo outlet air pressure

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. Accomplish all work at the NOAA Gulf Marine Support

Facility; 151 Watts Ave; Pascagoula, MS.

5.2. 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.

5.3. The Government anticipates award of a firm fixed-price

order for the 22,500 hour overhaul of the two 3512 SSDGs on board NOAA Ship PISCES. 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.

5.4. Figure 1-1 is a photo of the current air starter

configuration.

Figure 1-1

-END OF SPECIFICATION-