SOW OEM Service Rebuild BUZ (1)_Redacted.pdf

STATEMENT OF WORK

JML #: 42754750

DD2276 #: N4523A25RC00Y81

Ship/Activity:

Title: Universal High Pack Complete Overhaul

Place of Performance: Contractor’s Location

Period of Performance: 01/06/2025 to 04/28/2025

1. INTRODUCTION:

Contractor will provide all tooling, equipment, replacement parts called out in the scope of work, as well as freight transportation to and from contractor’s location necessary to complete an overhaul for One American Compressor

Universal High Packs. During FY 2018 the shipyard requested a complete machine overhaul on One American Compressor which is part of the OEM manufactures preventive maintenance cycle. This service contract is requested in order to overhaul/refurbish the existing machine asset to extend the useful life of this equipment instead of replacing the original asset at a cost savings to the Federal Government of approximately for a new compressor.

Currently, we are in FY 2025, the compressor is functional but due for complete overhaul per OEM suggested preventive maintenance cycle.

2 SCOPE:

The Contractor shall perform a complete factory overhaul on an American Compressor Universal HIGHPACK five stage air cooled oil lubricated reciprocating compressor per the following OEM manufacturer’s process/procedure in accordance with OEM manufacturer’s specifications. All replacement parts used during the compressor’s overhaul service must be manufactured per OEM technical specifications to include but not limited to correct machining dimensions; surface finishes, geometric tolerances, and selected manufacturing materials. Only direct OEM replacements parts from Contractor shall be used during the compressor’s overhaul service. The compressor overhaul service must be provided by the OEM manufacturer to guarantee that the compressor will function within the original manufacturer’s designed specification/tolerances and overall performance. The Contractor will also include a 6 month/500 hour warranty covering defects in materials and/or workmanship for the compressor.

1) Full disassembly and inspection. Report findings to customer’s representative.

2) Disassemble all inter stage coolers and moisture separators. Flush all internal surfaces using a circulating solvent pump system to remove all debris from extended internal cooling fins.

3) Caustic hot dip all castings and components. Magnaflux castings for cracks.

4) Polish and deburr crankshaft main journal and critical O.D. bearing fit surfaces.

5) Replace crankshaft radial and thrust bearing assemblies, locking plates, circlips, and thrust washer.

6) Replace and resize all connecting rod babbit bearing shells.

7) Replace all wrist pins and needle bearings.

8) Measure and hone 1st through 5th stage cylinders.

9) Measure 1st through 5th piston assemblies, polish all ring lands, and pin bores.

10) Replace all piston rings. Fit all end gaps.

11) Replace gear oil pump assembly.

12) Assemble bare compressor frame/cylinders, perform operational test run, and break-in of bare pump for approximately. 16 hours, no load condition, to seat piston rings. This preliminary break in procedure is performed on a test stand and not installed on main frame at this time.

13) Disassemble motor, inspect and replace motor bearings, drive V-belts and fan V-belts.

14) Disassemble purification rack, clean and install new seals and cartridges.

15) Inspect control panel components, clean and test.

16) Install bare compressor, cylinder heads, and rigid piping on main frame. Align all cooler flanges and mounts.

Remove any piping and cooler strain. Install, align, and pre-tension drive belts.

17) Sequence valve installation, interconnecting tubing, and cooler hook ups to purge all interstages.

18) Perform operational test run of assembled compressor package. Raise operating pressures incremental to finalize break-in of piston rings. This requires approximately 6 hours additional run.

19) Confirm all control functions and shut downs are operating correctly.

20) Perform re-torque of all fasteners, anchors, and crush gaskets.

21) Final alignment and tension of drive belts and fan belts.

22) Final inspect of piping and cooler mounting strain.

23) Primer and paint 100% industrial enamel.

The Contractor shall provide the overhauled fully functional compressor with the following new parts installed.

1ea: P/N:SM-VLVST, Valve assembly set, 10 valves

1ea: P/N:SM-PRST, Piston ring set

1ea: P/N:SM-PINST, Piston pin & bearing set, 5 pins & 5 bearings

1ea: P/N:SM-CKST:Crankshaft Assembly

1ea: P/N:SM-CBST, Crankshaft bearing set

1ea: P/N:sm-OP: Oil pump assembly

1ea: P/N:SM-CGSK, Cylinder gasket set

1ea: P/N:SM-VGSK, Valve gasket set

1ea: P/N:SM-MBST, Motor bearing set

1ea: P/N:SM-FBST, Fan hub bearing and seal set

1ea: P/N: PACK 8, V-belt set for compressor

1ea: P/N: PACK 46, V-belt set for cooling fan

5ea: P/N: PACK 27, Remote control valve set

1ea: P/N: COND 4, Condensate separator element

1ea: P/N: PACK 2, Oil filter

1ea: P/N: AIR 3, Air filter cartridge

1ea: P/N: AIR 6, Air filter restriction indicator

1ea: P/N:0602-SM-PGSK, Purification O-ring and back up ring kit

4ea: P/N: PURE 1, Purification molecular sieve cartridge

2ea: P/N: PURE 2, Purification combination cartridge

2ea: P/N: PURE 3, Purification coalescing filter element

5ea: P/N: OIL Compressor lubricant (gallons)

3 GOVERNMENT-FURNISHED PROPERTY:

3.1 Original acquisition value of material: The Contractor shall sign and return the

DD 1149, Requisition and Invoice/Shipping Document with the equipment. The Government representative will sign and return it to the Contracting Officer/GFP property manager.

3.2 Location of GFP: Currently located at but machine will be delivered to for ship out to vendor location via vendor provided Freight Company. Machine will be Overhauled at contractor’s location and returned back to upon completion.

3.3 Manufacturer, model # and type include serial number(s):

AMERICAN COMPRESSOR, MODEL: 55H75/D, S/N: 180127-UE 1

3.4 Government provided or contractor pickup: Contractor pickup. Contractor is responsible for the costs to return the item to PSNS & IMF.

6. QUALITY CONTROL:

The contractor shall ensure it has an adequate quality control management system to overhaul the equipment, ensure that it is operating correctly and warranty the work.

7. GOVERNMENT REPRESENTATIVE:

All technical clarifications will be coordinated through the Government Representative. Any changes to the contract in terms of scope, time or money must be through the Contracting Officer via a modification.