Engine_Overhaul.pdf

NOAA SHIP RONALD H. BROWN

(R-104)

30 Octd 2018

MED/JAL

DIESEL ENGINE OVERHAULS

l.0 ABSTRACT

1.1 This item describes the MAJOR overhaul of the #2 diesel engine and TOP END Overhaul of the #1 diesel engine.

2.0 REFERENCES

2.1 NOAA Specification “Overhaul of Caterpillar 3500 Series Diesel

Engines Rev. 12/2017”.

2.2 KATO Standard AC Generator Instruction Manual.

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location: Generator Room

3.2 Description:

3.2.1 No. 2 Diesel Generator:

CAT 3516, S/N 25Z04095

KATO Generator, 1500 KW

3.2.2 No. 1 Diesel Generator:

CAT 3516, S/N 25Z04096

KATO Generator, 1500 KW

4.0GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Material: Engine Lube Oil and Jacket Water

4.2 Government Furnished Services: The Government will be providing the services for ABS surveys and inspections.

4.3 Cat Parts:

4.3.1 Two (2) EA Bracket Ass. P/N 7N-5345

4.3.2 Two (2) EA Lever Ass. P/N 7N-5378

4.3.3 Two (2) EA Suppport Ass. P/N 7N-5976

4.3.4 Two (2) EA Lever Gov. P/N 1N-4674

4.3.5 One (1) EA Set Screw P/N 4W-4803

4.3.6 One (1) EA Nut P/N 9S-8752

4.3.7 One (1) EA Gasket P/N 8N-1996

5.0 NOTES:

5.1 The Contractor shall comply with all requirements of the vessel’s equipment tag out program prior starting work.

5.2 Prior to the start of work, the Contractor shall contact 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.

30 Octd 2018

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0 STATEMENT OF WORK REQUIRED

7.1 Accomplish a “Top End” overhaul of the #1 Propulsion Diesel Generator in accordance with Reference 2.1 with the following exceptions and changes.

7.1.1 The Government will drain the engine of lube oil and jacket water prior to commencement of the overhaul. Lube oil will be drained to the waste oil tank.

7.1.2 The Government will provide and install new lube oil, jacket water, and jacket water treatment.

7.2 In addition to the top end overhaul for the #1 Propulsino Deisel Generator accomplish the additional repairs to the fuel rack.

7.2.1 Renew the fuel rack parts listed in paragraph 4.3. The

contractor shall remove and reinstall all other engine components required to gain access to renew these parts on the front of the engine. This includes but is not limited to the engine jacket water expansion tank and the governor actuator. All gaskets, sealants, etc. required to remove and restore interference engine components shall be provided new by the contractor.

7.3 Accomplish a “Major” overhaul of the #2 Propulsion Diesel Generator in accordance with Reference 2.1 with the following exceptions and changes.

7.3.1 The Government will drain the engine of lube oil and jacket water prior to commencement of the overhaul. Lube oil will be drained to the waste oil tank.

7.3.2 The Government will provide and install new lube oil, jacket water, and jacket water treatment.

7.4 Remove the governor from each engine and send to an authorized Woodward Governor repair facility for overhaul. The governor is a Woodward EGB-10P, S/N 22543860/61.

7.4.1 Overhaul is to include complete disassembly, inspection, and bench testing, painting and calibration after repairs. The following parts are to be renewed:

7.4.1.1 All o-rings, seals, gaskets

7.4.1.2 All bearings, bushings.

7.4.1.3 Drive Shaft

7.4.1.4 Oil cup

7.4.1.5 Integral cooler (overhaul kit)

7.4.1.6 PV Plunger and bushing

7.4.1.7 Dial (EGB13 overhaul kit)

30 Octd 2018

7.4.1.8 Provide condition report with estimate for

additional parts required upon disassembly.

7.4.1.9 Reassemble and bench test in accordance with

manufacturer’s requirements.

7.4.1.10 Reinstall on engine. Make all adjustments for

normal engine operation.

7.4.1.11 Provide the services of an authorized Woodward

Technician during dock trials to set and calibrate the overhauled governor and the 2301A Governor controller located in the switchboard.

7.5 Note that Reference 2.1 paragraph 5.8 requires the electrical generator end bearings to be renewed. In order for the bearing to be renewed, the contractor is to temporarily rig/move the generator away from the engine and temporary removal of the exciter/PMG assembly. Reference 2.2 is provided for guidance.

7.6 Note that Reference 2.1 Paragraph 3.4.4 contains a requirement for an underway sea trial. For estimating purposes assume this will be 10 hour sea trial departing and returning to Charleston, SC.

END OF SPECIFICATION