Specification - Gordon Gunter Overhaul.docx

NOAA Ship GORDON GUNTER May 2022

NOAA SHIP GORDON GUNTER SSDG 10,000 HOUR OVERHAUL

1. SCOPE. This specification contains requirements for the 10,000 hour overhaul of two Caterpillar D398 diesel engines on NOAA Ship Gordon Gunter. The serial numbers of the engines are as follows: Engine #2: 35Z01560; Engine #4: 35Z01566.

2. REFERENCES.

2.1 Caterpillar Maintenance Management Schedule for Marine Engines (SEBU6102)

2.2 Caterpillar Operations and Maintenance Manual (SEBU5698)

2.3 Caterpillar Service Manual (SEBR0511)

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. NOTE: The 8-day performance period shall be strictly adhered to.

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.

3.1.3 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.

3.1.4 All parts and labor provided by the contractor shall be fully warranted. Work shall be performed in such a manner that the manufacturer’s warranty on parts and labor is not voided.

3.1.5 Provide and install “mandatory renewal” parts and components as required by this specification and other procurement documents. 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.

3.1.6 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 or rebuilt components or parts, perform visual and dimensional inspections to verify that the components or parts are acceptable for use.

3.1.7 Where rebuilt components or parts are provided (as authorized or specified), existing components and parts shall be replaced on an exchange basis with components and parts which have been manufactured at the engine manufacturer’s factory, and the existing components shall become the property of the contractor in their as-found condition. When factory re- manufactured 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 parts and 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.

3.1.8 Interferences shall be removed and reinstalled, as required, at no additional cost to the Government. Contractor is responsible for removing piping to/from the engine, engine heat exchangers, air motors, etc.

3.1.9 Disassemble the engines, 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.

3.1.10 Thoroughly clean and conduct a thorough visual inspection 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 of the engine. 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.

3.1.11 After inspections and tests have been completed and prior to reassembling the components, submit a report of all inspection findings and test results to the COTR. Report shall include a record of all measurements and readings taken, as well as recommendations for additional repairs, parts renewals, inspections, or tests needed to ensure continued reliable operation of the engine. Do not proceed with any additional work until authorized by the Contracting Officer.

3.1.12 After the report has been accepted and all additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed. Reinstallation of all components throughout shall be with new gaskets, seals, grommets, and o-rings.

3.1.13 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 worksites to their as-found condition.

3.1.14 At the midpoint of the engine overhaul, the contractor shall contact the local office of the American Bureau of Shipping (ABS) and request a surveyor attend the ship and conduct an inspection for credit toward the engines’ Continuous Machinery Survey. The contractor shall provide the COTR a minimum of 24 hours notice as to when the units will be open and ready for inspection by the ABS surveyor. The engines shall not be closed until approval is granted by ABS via the COTR. NOAA will pay for the ABS services directly under a separate purchase agreement.

3.2 Mechanical/Fluid.

3.2.1 The contractor shall perform the 10,000 hour top-end overhaul on both engines as specified in References 2.1 through 2.3.

3.2.2 Renew the following parts and components on each engine. Where “remanufactured” is added in parenthesis after a component, a remanufactured or “unit exchange” component may be provided in lieu of a new component. Quantities listed are per engine.

a. Cylinder head assemblies, complete with valves, springs, guides and prechambers (remanufactured), 6 ea.

b. Fuel nozzle injectors with o-rings, 12 ea.

c. Jacket water pump (remanufactured), 1 ea.

d. Turbocharger cartridges with seals and gaskets (remanufactured).

e. Jacket water thermostats with seals and gaskets.

3.2.3 Rebuild the existing salt water pump on each engine using the following parts:

a. Impeller, P/N 4L6220

b. Rebuild kit, P/N 1W7066

c. Elbow assembly, P/N 5L1549

d. New seals and gaskets

3.2.4 Clean aftercooler cores; send aftercooler cores out for industrial cleaning, reseal and re-gasket.

3.2.5 Clean and check all valve mechanism assemblies in accordance with Reference 2.2

3.2.6 Test and adjust the fuel nozzles in accordance with Reference 2.2 prior to installation.

3.2.7 Check and adjust the fuel timing, reset all tappets and check valve rotators in accordance with Reference 2.2.

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

3.2.9 During reinstallation of all parts, new gaskets, grommets, o-rings, and joints are to be used throughout and all items shall be torque to specifications listed in Reference 2.3.

3.2.10 Check engine-to-generator alignment in accordance with the Reference 2.2. If realignment or adjustments are required, such work will be negotiated by the Contracting Officer as an additional cost.

3.3 Electrical.

3.3.1 Test low lube oil pressure and high jacket water temperature safety shutdown devices. Inspect all electrical connections, exhaust pyrometer leads and readouts, wire standoffs and chafing protections installed on the engines and generators. Provide a condition report detailing general conditions found, as well as any abnormal findings, along with recommended corrective action, if any. Such corrective action will be negotiated by the Contracting Officer as an additional cost.

3.4 Electronics.

3.4.1 The contractor shall make known to all personnel working on the engines and generators that electrical and electronic devices and controls are present. These components must be protected from damage during the overhaul period and may require special precautions, isolation, etc.

3.5 Painting.

3.6.1 The contractor shall restore all disturbed surfaces to standard Caterpillar paint scheme. Surfaces to be painted shall be free of dirt and grease prior to paint application.

3.6 Testing.

3.6.1 The Contractor shall notify the ship’s Chief Engineer, COTR, and ABS surveyor 24 hours prior to the engine/generator units being ready for testing under the ship’s electrical load. Test operate the engines after overhaul using the ship’s dockside hotel load for a period not less than two hours. Test all alarm and shutdown systems prior to starting. Ship’s force will line up and start engines and engage the generators on the ship’s main bus. Operate engines at no-load until normal no- load operating temperatures are reached, then increase load incrementally up to available load and operate for two hours. Provide technicians to observe operation, verify joints are leak-free, make adjustments, and record test data.

3.6.2 Temperatures and pressures shall be monitored and compared 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.

3.6.3 Record the following information near the end of the full-load test; provide test instruments as required:

a. cylinder exhaust temperatures

b. lube oil temperatures

c. water temperatures

d. fuel oil pressure

e. lube oil pressure

f. electrical load on generator prime mover

3.6.4 Submit a report of all test data collected. Report shall include manufacturer’s recommended limits for each parameter measured.

3.7 Final Adjustments and Tune-up.

3.7.1 After satisfactory completion of operational testing, reset valves and accomplish final adjustments and tune-ups as required to provide smooth, efficient, and reliable operation.

3.8 Notes.

3.8.1 Contractor is responsible for providing all PPE, personal cleaning agents, and personal cleaning stations.

3.8.2 Unless precluded by task related PPE (such as welding), all Contractor personnel are required to wear face coverings that cover the nose and mouth while on the ship at all times. Face coverings are required for all interior and exterior areas of the vessel.

3.8.3 To the maximum extent practicable, and not to interfere with production work, Contractor shall practice social distancing while on NOAA property.

3.8.4 Contractor personnel shall clean hands immediately after boarding the vessel and prior to proceeding to the work area. Hands shall be cleaned each time the vessel is boarded.

3.8.5 American Bureau of Shipping (ABS) inspection of 10,000 hour overhauls is required for credit toward the ship’s Continuous Machinery Survey. Contractor shall inform ABS of progress and arrange for inspections as required by the local (Mobile, AL) office. Government will pay for ABS fees associated with the inspections under a separate purchase order. ABS Mobile contact: Senior Surveyor Neal Powell. Tel: (251) 661-3500; cell: (251) 370-7751; e-mail: npowell@eagle.org

3.8.6 Ship’s force is available to provide shipboard crane service during normal working hours (M-F 0830-1530) to lift parts between the pier and the ship’s aft deck. 24 hours advance notice is required. Actual rigging of parts and moving parts to/from the aft deck and generator room shall be the responsibility of the contractor.

3.8.7 Reference 2.1 will be available for review during scheduled pre-bid inspection and during the performance period of the contract. References 2.1 through 2.3 shall be contractor furnished.

3.8.8 The Government anticipates award of a firm fixed-price order for the 10,000 hour overhaul of the two D398 SSDG’s on board NOAA Ship Gordon Gunter. 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.

END OF SPECIFICATION