Specification - PISCES FY23 Engine Overhauls.pdf

NOAA Ship PISCES 3512 SSDG Overhauls

June 2022

NOAA SHIP PISCES FY23 ENGINE OVERHAULS

1. SCOPE

1.1.Complete a top end overhaul on the two Caterpillar 3512B engines in accordance with this specification. Serial Numbers for the two CAT 3512B engines on NOAA Ship PISCES are as follows:

Engine #1: 8EM00549 – 3512 Top End Overhaul Engine #2: 8EM00550 – 3512 Top End Overhaul

2. REFERENCES

2.1.NOAA Standard Specification AMC-000-1F, "General Requirements for Ship Repair Contract Work on NOAA Ships"

2.2. Technical Manual FRV40-226-029-010 “Diesel Engine Caterpillar 3512B”

2.3. Technical Manual FRV40-226-028-010 “Diesel Engine Caterpillar 3508B”

2.4. Technical Manual FRV40-226-041-010 “Kato Generator, 3 Phase Synchronous”

3. GOVERNMENT FURNISHED MATERIAL

3.1. None

4. REQUIREMENTS

4.1.General: The following requirements apply to all work.

4.1.1. Except as otherwise specified, the contractor shall provide all labor, material, services, tools, consumables, supervision, manuals, and technical expertise required to accomplish the work detailed in this specification.

4.1.2. All work shall be accomplished by an authorized repair facility of Caterpillar Tractor Company. All work shall be performed in accordance with Caterpillar service, maintenance, and overhaul technical manuals, including all current and applicable amendments and service bulletins, and References 2.1 through 2.4, in such a manner that the manufacturer’s warranty on parts and labor is not voided.

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 Caterpillar engine specifications, clearances, tolerances, and procedures.

4.1.3. Provide and install “mandatory-renewal” parts and components as required by this specification. Additional components requiring renewal may be provided by the Government (if available) or contractor and installed by the contractor.

Procurement and installation of additional parts and components will be the subject of additional work negotiated by the Contracting Officer.

4.1.4. Except where re-manufactured components are authorized or specified, only new, original Caterpillar non-surplus components and parts shall be used. Prior to installing all parts, perform visual and dimensional inspections to verify components and parts are acceptable for use.

4.1.5. Where re-manufactured components are provided, existing components shall be replaced on an exchange basis with components which have been re-manufactured at Caterpillar Tractor Company’s factory or a Caterpillar- authorized repair facility;

all remanufactured components shall meet Caterpillar’s remanufactured 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.

a. The existing components become the property of the contractor in their as-found condition.

b. When factory re-manufactured or new components are not available, existing components shall be disassembled, cleaned, inspected, repaired (including renewal of all parts needed), reassembled, and calibrated by a Caterpillar authorized repair facility using Caterpillar parts.

4.1.6. Disassemble the engine components, and parts to the extent required to perform the required inspections, repairs, and parts renewal.

4.1.7. Thoroughly clean, then conduct visual inspections of all disassembled parts retained for re-use. Inspect for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability. 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.

4.1.8. Remove and reinstall all interferences as required, at no additional cost to the

Government. Contractor is responsible for removing and reinstalling electrical cabling and piping to or from the engine, engine heat exchangers, air motors, etc.

Contractor shall provide proper termination and support for all removed interferences.

4.1.9. After inspections have been completed and prior to reassembling components, submit a report of all inspection findings and test results to the COR. Include a record of all measurements and readings taken as well as recommendations for additional repairs, inspections or testing. Contractor shall not proceed with any additional work until authorized by the Contracting Officer

4.1.10. After the report has been accepted and all additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed using all new gaskets, seals, grommets, and O-rings.

4.1.11. At the end of each work day, accomplish a clean-up of all debris incidental to the performance of the required work. Upon completion of all work, clean all work sites to their as-found condition.

4.1.12. Co-ordinate mechanical and electrical tag-outs with ship’s force engineering department prior to commencement of overhauls.

4.1.13. Contractor shall drain and dispose of all liquids (fuel, lube oil, and jacket water) in the engines prior to beginning work. Upon completion of work, Contractor shall restore engine coolant and lube oil levels to the recommended levels using contractor provided lubricating oil and coolant. Replacement coolant shall be an OEM approved pre-mixed engine coolant.

4.2.Accomplish the following work for the Top End Overhauls on all four engines:

4.2.1. Coordinate draining all fuel, lube oil, and jacket water from all four generators with Ship’s Force. Contractor shall provide a pump truck to remove and dispose the coolant and lube oil from the ship’s waste oil tank. For bidding purposes, estimate 1000 gallons of waste to be removed and disposed. Contactor shall coordinate scheduling tank discharge with ship’s force.

4.2.2. Remove all interferences and obstructions including piping, wiring, and grating as needed to conduct work.

4.2.3. Accomplish the work of a “Second Top End Overhaul” on SSDG 1 and SSDG 2 in accordance with Table 61 on Pages 132-133 of References 2.2. Where work directed in Paragraphs 4.2.4 and 4.2.5 includes work not specified in Table 61, Contractor shall follow work directed in this specification (sub-paragraphs italicized to aid in identification).

4.2.4. Contractor shall renew all of the "mandatory-renewal" parts and components as specified in Table 61 of References 2.2. Where "re-manufactured" is added in parenthesis after a component, a re-manufactured component may be provided in lieu of a new component.

4.2.4.1. Seals, "o"-rings, and gaskets of all removed and disassembled components and parts

4.2.4.2. Turbochargers (re-manufactured)

4.2.4.3. Thermostats and water temperature regulators

4.2.4.4. Cylinder head assemblies (re-manufactured)

4.2.4.5. Fuel injectors (re-manufactured)

4.2.4.6. Fresh water pumps (re-manufactured)

4.2.4.7. Aftercooler cores (remove, clean, pressure test)

4.2.4.8. Filter elements

4.2.4.9. Crankcase breathers

4.2.5. In addition to the overhaul work of Table 61, contractor shall replace the following with new for each engine:

4.2.5.1. All thermostats and water temperature regulators

4.2.5.2. Fresh water pumps (re-manufactured)

4.2.5.3. Exhaust pyrometers for cylinders and each bank

4.2.5.4. Injector wiring harness for each cylinder

4.2.5.5. Replace all fuel oil, lube oil, and engine coolant hoses. Replacement hoses shall be pressure tested and tagged with the test pressure, date of pressure test, and facility completing the pressure test. Affix the hose tag to the hose using stainless steel wire. Install chaffing gear where needed. For bidding purposes, hose quantities are provided below. Submit a CFR for additional hose replacement.

4.2.5.5.1. Fresh Water Hoses (QTY 4, 1-inch diameter hose, 5 feet long, rated for a minimum of 500 PSI)

4.2.5.5.2. Fuel Oil Hoses (QTY 4, QTY 4, 1-inch diameter hose, 5 feet long, rated for a minimum of 500 PSI)

4.2.5.5.3. Lube Oil Hoses (QTY 4, QTY 4, 1-inch diameter hose, 5 feet long, rated for a minimum of 500 PSI)

4.2.6. Clean, inspect, test, and reassemble the following components, parts and subassemblies of Table 61 of References 2.2:

4.2.6.1. Wiring harnesses (ensure all wiring has chaffing gear where needed)

4.2.6.2. Fuel pressure regulating valve

4.2.6.3. Aluminum spacer plates

4.2.6.4. Cam shaft inspection

4.2.6.5. Oil suction screen and oil pump

4.2.6.6. Exhaust manifold bellows and gaskets

4.2.6.7. Cylinder Bank Inspection (QTY 2 per engine)

4.2.6.8. Fuel Priming Pump

4.2.6.9. Fuel Transfer Pump

4.2.6.10. Scavenge Oil Pump

4.2.6.11. Rocker arms

4.2.6.12. Check Engine Control Module (ECM) software; enter and review system;

advise if updates are needed.

4.3.Upon completion of repairs, work with Ship’s Force to refill all both engines with lube oil and engine coolant. Contractor shall provide 500 gallons of OEM approved lubricating oil and 500 gallons of pre-mixed engine coolant. Turn over any remaining lube oil and engine coolant to the ship. Submit a CFR for additional fluids required.

Contractor shall provide all pre-mixed extended life engine coolant and shall assist Ship’s Force with refilling the engines to the proper coolant levels. Contractor shall provide 24 hours’ notice prior to refilling engines with coolant.

4.4.Inspect SSDG 3 and SSDG 4 and submit a CFR for any repairs beyond those specified below. Inspection shall include checking for leaks and operational performance testing.

4.4.1. Replace the turbochargers in both engines

4.4.2. Procure and flash one (QTY 1) ECM as a spare for SSDG 3 (one 3508 ECM) and turnover to Ship’s Force.

4.5.Conduct the following tests on all four SSDGs after all components have been reassembled.

4.5.1. Test all shutdown systems prior to starting the engine. Conduct a preliminary tune-up of the engine.

4.5.2. Monitor engine operations as the ship's engineers start the engine. Check all joints for leaks.

4.5.3. Perform operational tests of each engine using ship’s hotel load for two hours.

Ship’s force will add equipment to the bus for testing purposes. Make adjustments, correct leaks, and continuously monitor performance of the engine. If at any time a temperature or pressure exceeds or falls below Caterpillar’s recommended upper or lower limits, the test shall be stopped and the cause determined. After the cause has been corrected, the test shall be restarted from the beginning.

4.5.4. Near the end of the test period, take and record the following information. Provide test instruments as required:

4.5.4.1. Cylinder exhaust temperatures

4.5.4.2. Lube oil temperatures

4.5.4.3. Coolant temperatures

4.5.4.4. Fuel oil pressure

4.5.4.5. Lube oil pressure

4.5.4.6. Water pressures

4.5.4.7. Turbo outlet air pressure

4.5.4.8. Electrical Load on generator prime movers

4.5.4.9. Other operating parameters as permitted by installed instrumentation.

4.5.5. Prepare and submit to COR a report of all data taken during the test period.Include Caterpillar’s re

4.5.6. After satisfactory completion of the operational test, make final adjustments as required to provide smooth, efficient, and reliable operation of the engine.

4.6. Paint all new, disturbed, and re-manufactured parts with OEM paint.

4.7. Complete an alignment inspection on each of the four engines and generator assemblies, to include foot deflection. Submit results to COR along with any additional recommendation repairs

5. QUALITY ASSURANCE

5.1.COR inspection / witness of post-overhaul testing, along with submittal of documentation called out in specification.

6. NOTES

6.1.Work will be accomplished while PISCES is dockside at the following address:

NOAA Gulf Marine Support Facility 151 Watts Ave Pascagoula, MS 39567

6.2.Ship’s force is available to provide crane service during normal working hours to lift parts between the pier and aft deck; 24 hour notice required. Rigging of parts and moving of parts from aft deck into engine room shall be the responsibility of the Contractor.

6.3.The following is engine and generator information:

Diesel Generator Sets No. 1 and No. 2 600 Volt, 1360 kW, 1700 kVA MFG: Kato- Caterpillar Model: 3512B DITA SCAC

Engine No. 1 Serial No: 8EM00549 Engine No. 2 Serial No: 8EM00550

Kato Generator Serial No 1: 17824-01 Kato Generator Serial No 2: 17824-02 Kato Generator Model No: AA27756000

Diesel Generator Sets No. 3 and No. 4 600 Volt, 910 kW, 1137.5 kVA MFG: Kato- Caterpillar Model: 3508B DITA SCAC

Engine No. 3 Serial No: 3DM00508 Engine No. 4 Serial No: 3DM00509

Kato Generator Serial No. 3: 17825-02 Kato Generator Serial No. 4: 17825-01 Kato Generator Model No: AA27757000

-END OF SPECIFICATION-