SOW_1_00_10K_OH_2A_MPDE__rev7_1.doc

USNS SALVOR

(T-ARS-52)

Statement of Work

MACHINERY, PROPULSION

ONE 10K HR OVERHAUL OF CATERPILLAR D399 MAIN PROPULSION DIESEL ENGINE

1. ABSTRACT

1.1. This specification contains the general requirements and procedures to be used in accomplishing a 10,000 hour overhaul of Caterpillar D399 diesel engines. The contractor shall provide the necessary transportation of all necessary materials to the vessel's location.

2. REFERENCES/ENCLOSURES

2.1. References:

2.1.1 Technical Manual T6270-AB-MMC-010, Caterpillar Engine, Generator Set

2.1.2 Caterpillar Maintenance Management Schedule for Marine Engines (SEBU6102)

2.1.3 Caterpillar Operation and Maintenance Manual (SEBU5698)

2.1.4 Caterpillar Service Manual (SEBR0511)

2.1.5 MCS 10_06P thru 09 ME 2A thru 1B, In Tech Marine DWG# 839172 thru 76.

2.1.6 MCS Engine Electrical Shut-Off, In Tech Dwg# 8391414.

3. ITEM LOCATION/DESCRIPTION

3.1. Location/Quantity

3.1.2 Location:

Main Machinery Rm (#2A ME)

3.1.3 Quantity:

One(1) Main Propulsion Diesel Engine.

3.2. Item Description/Manufacturer’s Data:

3.2.1. Description: Diesel Engine 10K Overhaul

3.2.2. Manufacturer’s Data: Caterpillar Model D399TA

4. GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES: NONE

5. NOTES

5.1. The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs including but not limited to GTRs 1-7.

5.2. The contractor and all subcontractors, regardless of tier are advised to review other work items under this contract to determine their affect on the work required under this work item.

5.3. The contractor shall comply with all requirements of equipment tag out program as established by COMSCINST 3540.6, as amended, section 15.2.2, Engineering Operations and Maintenance Manual. The Chief Engineer is to administer the program. Prior to the start of work, the contractor shall contact the MSC Port Engineer and / or the Chief Engineer to coordinate the implementation of the Tag Out Program for the entire performance period of this item. The prime contractor shall be responsible for compliance by both prime and subcontractor personnel.

5.4 The performance period begins on or about 15 Oct 2015 and shall be completed no later than 4 Nov. 2015.

6. QUALITY ASSURANCE REQUIREMENTS

6.1. None additional.

7. STATEMENT OF WORK

7.1. Arrangements/Outfitting:

7.1.1. Provide all material and special equipment. Make all engine removals and restorations. Remove and replace all interferences, stage and unstage, make all disassemblies and subsequent reassemblies. (Material, unless specifically stated as Government Material (GFM) shall be supplied by the contractor).

7.2. Structural: None

7.3. Mechanical/Fluids:

7.3.1 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 item within the specified time requirements.

7.3.2 All work shall be performed by a qualified Caterpillar Technician and repair facility and under the direct on-site supervision of a factory-trained mechanic currently certified by the engine manufacturer, and shall be performed in such a manner that the manufacturer's warranty on parts and labor is not voided. All parts and labor supplied by the Contractor shall be fully warranted.

7.3.3 Provide and install "mandatory-renewal" parts and components during the overhaul as required by this specification, the Detail Specification, and other procurement documents. Renewal of other parts and components determined to be needed shall be provided and installed by the Contractor. Additional parts and components which are needed will be negotiated by the attending MSC Port Engineer as an additional cost to the purchase order or contract.

7.3.4 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 and rebuilt components and parts, the Contractor shall perform visual and dimensional inspections to verify that the components and parts are acceptable for use.

7.3.5 Where rebuilt 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. 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.

7.3.6 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.

7.3.7 Disassemble the engine(s), 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.

7.3.8 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.

7.3.9 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 attending MSC Port Engineer and Chief Engineer. 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 attending MSC Port Engineer or representative.

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

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

7.3.12 The Contractor shall clean up all debris incidentals to the performance of the required work on a daily basis. Upon completion of all work, clean all work sites to their as-found condition.

7.3.13 At the halfway point of the engine/generator overhaul, the contractor representative will contact ABS to conduct an inspection for credit towards the unit's Continuous Machinery Survey. The unit will not be closed until approval is granted by the ABS. The contractor shall provide the attending MSC Port Engineer and Chief Engineer with a minimum of 24 hours notice as to when the unit will be open and ready for inspection by the ABS surveyor. Unless otherwise specified in the invoking specification the cost of the ABS inspection will be to the MSFSC account.

7.3.14 The contractor shall provide detailed reports of all maintenance actions and engine component conditions upon completion of the overhaul, including but not limited to, all critical clearances and adjustments listed in references, all parts rebuilt, renewed or exchanged in addition to the Contractor Condition Reports.

7.3.15 Any new parts required by this overhaul that are not used will be credited against the work item or provided to the ship for spares as directed by the attending MSC Port Engineer and Chief Engineer.

7.3.16 The contractor shall perform the 10,000 hour top-end overhaul as specified in references 2.1.1 through 2.1.5.and enclosure 2.2.1.

7.3.17 Install new or Caterpillar re-manufactured parts and components, as follows:

7.3.17.1 Cylinder heads, complete with valves, springs, guides and pre-chambers (8 each).

7.3.17.2 Impeller P/N 4L6220

7.3.17.3 Rebuild Kit P/N 1W7066

7.3.17.4 Elbow Assembly P/N 5L1549

7.3.17.5 New Seals and New Gaskets

7.3.17.6 Turbo charger cartridges with gaskets and seals, Two (2).

7.3.17.7 New Thermostats with seals and gaskets.

7.3.17.8 Re-manufactured Jacket water pump with new seals and gaskets.

7.3.17.9 All New Fuel Nozzles.

7.3.17.10 12- Turbo Seal Kits

7.3.17.1.1 6- Air Cooler Repair Kits

7.3.18 Properly clean, in place, air and water sides of the after-cooler core. Renew all seals and gaskets. Replace aluminum adapters.

7.3.19 Clean and check all valve mechanism assemblies in accordance with 2.1.4.

7.3.20 Test and adjust the new fuel nozzles in accordance with reference 2.1.4 prior to installation.

7.3.21 Check and adjust the fuel timing in accordance with reference 2.1.4.

7.3.22 All items are to be presented to the ABS surveyor at the time of the Continuous Machinery Survey inspection.

7.3.23 During reinstallation of all parts, new gaskets, grommets, O-rings, and joints are to be used throughout and all items shall be torqued to reference 2.1.3 specifications. Reset all tappets and check valve rotators in accordance with references.

7.3.24 Accomplish the requirements of enclosure 2.2.1 to verify that the engine to generator alignment is within specification. If realignment or adjustments are required, a change order will be issued.

7.4 Electrical:

7.4.1 Using References 2.1.5 & 2.1.6, the contractor shall inspect all electrical connections, test low lube oil pressure and high jacket water temperature safety shutdown devices, exhaust pyrometer leads and readouts, wire standoffs and chafing protections installed on the engine and generator unit and provide a condition report stating general condition and any abnormal findings. A Change Order will be issued for any additional work.

7.5 Electronics:

7.5.1 The contractor shall make known to all personal working on the Caterpillar Engine and generator unit, that electrical and electronic controls and devices are present and may require necessary precautions, isolations etc. that must be protected from damage during the overhaul period. All testing

7.6 Preparation of Drawings/Documentation:

7.6.1 The contractor shall take a set of written cylinder operating temperatures, fluid operating temperatures and pressures during the testing of 7.7.1.

7.7 Inspection/Test:

7.7.1 The contractor shall notify the Chief Engineer and the attending Port Engineer when the overhauled engine and generator unit is ready to be tested under ship's propulsion load for an approximate period of two hours or as directed by the Port Engineer. Using references 2.1.5 & 2.1.6 test all shut downs and alarms. The Chief Engineer or his representative will be responsible for actually engaging the unit on the vessels main bus. The ABS surveyor shall be informed by the contractor in order to attend the final testing so credit can be given for the Continuous Machinery Survey on the unit.

7.8 Painting:

7.8.1 Mechanically clean, prime and paint all new and disturbed surfaces to match surrounding areas.

7.9 Marking: None

7.10 Manufacturer’s Representative

7.10.1 OEM CATERPILLAR rep. must be factory trained by In-Tech Marine Svc. in shut down re-locations and PLC logic. Which were incorporated new Local Diesel Control Panels (LDCP) with new ESO Modifications and Main Console control Up-grade.

CATERPILLAR technician must test new electronic Emergency shut-downs.

7.11 SMART DEMONSTRATION:

7.11.1 In addition to the above requirements and after completeion of the overhaul the contractor will demonstrate all shut down devises in the presence of the SMART team Propulsion rep.

7.11.2 The demonstration will include all Main Propulsion Engines, four (4).

And all three (3) Main Diesel Generators.

8.0

GENERAL REQUIREMENTS

8.1 The contractor shall provide all labor, material and equipment to accomplish this specification item.

8.2The contractor shall remove and reinstall all interferences necessary to accomplish this specification item.

8.3Inspection and acceptance of all work shall be by the designated MSC Representative. The MSC Port Engineer is the single point of contact authorized to address technical questions.

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