ARCTIC_SOR_004_SSDG_Top_End_Overhaul_JAN_2016.doc

USNS ARCTIC

(T-AOE 8)

ARC FY16 SOR003 26JAN2016

MSC/PM1CM6/JB

SSDG TOP END (20,000 Hr) OVERHAUL

1.0 ABSTRACT:

1.0 This item describes the requirement to accomplish Top End Overhaul #2, 3 and 5 Ship Service Diesel Generator (SSDG) with an authorized CATERPILLAR technical representative, providing oversight and assistance during the rebuild process. The parts for the top end overhaul shall be provided by the authorized CAT dealer.

2.0 REFERENCE:

2.0 NAVSEA Tech Manual S9311-CG-MMA-010, Generator Set, Ship's Service Emergency Diesel Generator.

3.0 ITEM LOCATION/DESCRIPTION

3.0 Location/Quantity

3.0.1 Main Machinery Room #1 (3 &5)

3.0.1.1 Nr 3 SSDG Serial Number 5PG00015

3.0.1.2 Nr 5 SSDG Serial Number 5PG00013

3.0.2 Main Machinery Room#2 (2)

3.0.2.1 Nr 2 SSDG Serial Number 5PG00014

3.1 Item Description/Manufacturer's Data:

3.1.1 Ship’s Service Diesel Generator

Manufacturer: Caterpillar

Model: 3608

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES: None

5.0 NOTES:

5.0 All work specified in this item shall be in accomplished under the guidance and supervision of the Manufacturer’s Representative.

5.1 The Period of Performance for this work shall be from 1 March to 31 May, 2016.

5.2 This work shall be performed at a pier to be determined at the Norfolk Naval Station.

5.3 It is the contractor’s responsibility to provide visit requests (EPIC Forms) and any necessary documents to gain access to the Naval Base.

5.4 The ship will be in a repair period from March 14 to May 18, 2016. The ability for the ship to provide full loading of the generator, for final operational testing, will be on a case by case basis, due to the equipment throughout the vessel being out of commission for maintenance and repairs. The contractor shall acknowledge this stipulation prior to the commencement of work. The period of performance is set to start prior to the availability and conclude after its completion. This notification serves as prior notice and there shall be no delay and disruption claims considered.

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0 STATEMENT OF WORK REQUIRED:

7.0 Arrangements/Outfitting: None Additional

7.1 Structural: None Additional

7.2 Mechanical/Fluids: For Each Ship’s Service Diesel Generator listed in Para 3;

7.2.1 Perform preliminary operation test and inspection to determine any unidentified discrepancies which may require correction, not required by this statement of work. In the event of such a discovery, submit a report of as-found conditions to the port engineer.

7.2.2 Perform a preliminary inspection of shipboard diesel engine special tooling to ensure it is the most updated tooling. If discrepancies exist, submit a condition report to the contracting officer and port engineer.

7.2.3 Temporarily remove and reinstall all interferences required to accomplish work under this item.

7.2.4 The ship’s crew shall perform the teardown of each SSDG. For bidding purposes estimate that the CAT representative shall be required on site for a period of no more than 16 hours, per engine, during the disassembly phase.

7.2.5 The ship’s crew shall perform the reassembly of each SSDG under the guidance and assistance of the CAT representative. For bidding purposes estimate that the reassembly period shall take 7 continuous days, per engine . The ship will work for a period of 12 hours from Monday to Friday and 8 hours a day on weekends.

7.2.6 Provide all labor, special tools, materials and equipment to perform a top end overhaul (20,000 hour) of the 3608 engine described in para 3.0 per manufacturer recommendations, the overhaul of the engine shall include but is not limited to the following:

7.2.6.1 Recondition or provide remanufactured Cylinder heads, and Cylinder liners. Replace cylinder head bolts with new.

7.2.6.2 Replace cylinder head gaskets, head seals, head o-rings, head plugs, piston rings sets, oil pump bushings and seals, oil cooler seals and regulator, connecting rod bearings, exhaust manifold gaskets, and inlet air lines seals.

7.2.6.3 Refurbish oil and water temperature regulators and replace seals.

7.2.6.4 Refurbish or replace air starter motors, lubricator pump, oil pump, FO transfer pump and engine JW pumps with remanufactured parts, if not available then perform the following.

7.2.6.4.1 Temporarily remove the fuel oil transfer pump, oil pump, valve lubricator pump, two JW water pumps and both air starter motors and transport to shop.

7.2.6.4.2 Disassemble pumps and lay out parts for inspection. Submit an “as found” condition report.

7.2.6.4.3 Reassemble pumps with new bearings and seals.

7.2.6.4.4 Transport pumps back to ship and reinstall.

7.2.6.5 Inspect main and thrust bearings.

7.2.6.6 Clean and inspect the oil cooler core and oil suction screen.

7.2.6.7 Provide and replace sixteen (16) each cylinder dual element thermocouples. (per engine) CYLINDER DuAl Element THERMOCOUPLE Part Number: 1K2BKI5HM1240ATA Manufacturer: JMS Southeast Inc.

Phone: 1-800-873-1835

E-mail: sensors@jms-se.com

7.2.6.8 Replace all Lube and Fuel Filters. The contractor shall provide enough lube oil filters to cover three oil changes per engine.

7.2.7 All replacement parts and materials shall be from OEM.

7.2.8 Parts ordered and found not to be required during the course of the overhaul, will be turned over to the USNS Arctic.

7.2.9 Ships Force will drain engine oil as required and provide oil to fill engine for operation. The ship is expected to change oil three times during the operational test portion of the work requirement.

7.2.10 Ships Force will drain and fill the Jacket Water cooling system.

7.2.11 Baseline oil and water samples will be taken by both contractor and ship for testing.

7.3 Electrical:

7.3.1 The contractor shall confirm all tag out/lock outs prior to commencing work.

7.4 Electronics: None Additional

7.5 Preparation of Drawings:

7.5.1 Contractor to provide a final service report after the completion of repairs detailing the initial conditions found, the parts replaced, the results off all inspections, and the initial and final readings of critical parameters. Copies of the report shall be provided to the Chief Engineer, Port Engineer and the ABS surveyor.

7.6 Inspection/Test:

1.1.1 Inspection:

1.1.1.1 Prior to operation, OEM rep shall inspect and certify to the ship that all work is complete and engine is ready for operation.

1.1.2 Operational Test:

1.1.2.1 Operate engine in accordance with manufactures’ recommended break in procedure. Engine break-in and testing may be conducted using ships load.

1.1.2.2 Recertify and return all SSDG’s to a serviceable condition at the conclusion of the overhaul in accordance with OEM recommended procedures.

1.1.2.3 After break-in, perform operational tests at approximately 25, 50, 75, and 100 percent loads in the presence of the Port Engineer/ CHIEF ENGINEER and ABS for a minimum of 2 hours or until engine parameters stabilize. OEM rep shall verify and certify that engine is operating within established parameters.

1.1.2.4 Engine shall be operated for a minimum of 10 contiguous hours at approximately 75% Load, while recording parameters hourly. Manufacturers shall observe operation and make any required adjustments to achieve operation in accordance with manufacturer’s recommendation.

1.1.2.5 Ship shall collect baseline Diesel Analyzer data during load testing. Max firing pressures shall be measured on all cylinders OEM rep shall review for operation within OEM parameters.

1.1.2.6 Post operational test, oil and jacket water samples will be drawn for laboratory analysis, provide analysis reports to port engineer and Chief Engineer.

1.2 Painting: All new and disturbed surfaces shall be thoroughly cleaned and painted with two coats (5-6 mils) of paint to match surroundings.

1.3 Manufacturer Representative:

1.3.1 The equipment addressed in this work item is categorized as critical equipment in accordance with MSC policy on the classification of critical shipboard systems and equipment. Only Original Equipment Manufacturer (OEM) authorized technical field service representatives and OEM parts shall be used to accomplish the requirements of this work item for this critical equipment including oversight and guidance on all aspects of equipment as-found condition inspection, removal, disassembly, reassembly, repairs, modifications, reinstallation and testing as applicable. The technical representative shall attend all operational tests.

1.3.2 An OEM authorized technical field service representative is defined as either a direct employee of the OEM, or an employee of a secondary company which has a current written agreement with the OEM to provide service and repair for that equipment. The OEM authorized technical field service representative shall have full access to the OEM drawings, technical service bulletins, special tools and OEM replacement parts.

2.0 GENERAL REQUIREMENTS: None Additional

Arctic SOR 004-1