Work_Package_A.docx

Work Package A – Engine & Propulsion System A.1 Purpose The Contractor shall provide all labor, supervision, materials, equipment, tools, transportation, testing, and commissioning necessary for the removal, rebuild, and reinstallation of two (2) Caterpillar 3208 marine diesel engines and two (2) associated Arneson Surface Drives. Work shall include restoring the vessel’s propulsion system to safe, reliable, and like-new operating condition in accordance with original equipment manufacturer (OEM) standards and recommendations.

A total of three (3) Caterpillar 3208 marine diesel engines are required to be inspected under this contract. The Contractor shall assess the condition of all three (3) engines and provide recommendations to the NPS regarding the most suitable two (2) engines for complete rebuild, installation, and final operational use upon project completion.

A.1.1 Engine Inspection The Contractor shall inspect and evaluate one (1) uninstalled, crated, NPS-owned Caterpillar 3208 marine diesel engine previously removed from the vessel due to mechanical failure. The purpose of this inspection is to provide the National Park Service (NPS) with a professional recommendation regarding whether this engine should be rebuilt and installed in place of the currently installed starboard engine in order to maintain the vessel’s original OEM propulsion configuration.

A.2 Scope of Work A.2.1 Engine Removal & Disassembly

· Disconnect and remove both Caterpillar 3208 engines from the vessel.

· Disassemble each engine to bare block, including:

· External accessories (alternator, starter, pumps, heat exchangers)

· Induction/exhaust systems (turbochargers, manifolds)

· Fuel system (injection pump, injectors, lines)

· Lubrication and cooling systems

· Top and bottom end components (valvetrain, pistons, crankshaft, camshaft)

· Sensors, senders, and wiring harnesses A.2.2 Cleaning & Inspection

· Chemically clean and degrease all components.

· Perform non-destructive testing (NDT) including magnaflux and pressure testing.

· Conduct dimensional inspections per OEM specifications.

· Document all findings and submit corrective action and parts replacement plan.

**All corrective action and parts replacements shall be submitted for written acceptance and formal incorporation into the contract in the form of a modification between the contracting officer and company owner or legally authorized company official before the corrective actions and parts replacement are authorized** A.2.3 Machining & Component Restoration

· Machine block, heads, crankshaft, and rods as required.

· Rebuild or replace turbochargers, heat exchangers, oil coolers, and fuel injection components.

· Bench test and calibrate injection pumps and injectors with certification.

A.2.4 Reassembly

· Reassemble engines using new OEM or equivalent components:

· Full gasket and seal kits

· Pistons, rings, bearings, valves, and timing components

· Sensors, filters, hoses, belts, and mounts

· Assemble to OEM torque specs using calibrated tools.

· Prime oil system and preserve engines for transport if not test-run.

A.3 Arneson Surface Drive Overhaul A.3.1 Removal & Inspection

· Remove two (2) Arneson outdrives and propellers.

· Inspect drive shafts, couplings, bearings, seals, hydraulic systems, and housings.

· Document condition and provide repair recommendations.

**Contractor staff shall provide recommendations in writing to the Contracting Officer for acceptance through modification prior to repair and inclusion of repair into the contract** A.3.2 Repair & Reconditioning

· Recondition or replace propellers to OEM pitch and balance.

· Replace worn or damaged outdrive components as necessary.

· Service hydraulic and lubrication systems with approved fluids.

A.3.3 Reinstallation

· Reinstall outdrives and propellers per manufacturer specifications.

· Align and torque all mechanical, hydraulic, and electrical connections.

A.4 On-Vessel Integration A.4.1 Mounting & Alignment

· Prepare engine beds and install new or re-conditioned mounts.

· Align engines to marine gears and shafts within manufacturer tolerances.

A.4.2 System Reconnection

· Reconnect and test:

· Fuel systems (A1-15 hose, filters, valves)

· Cooling systems (raw/jacket water, strainers, seacocks)

· Lubrication systems (coolers, filters, sensors)

· Exhaust systems (manifolds, risers, mufflers, insulation)

· Electrical systems (alternators, starters, gauges, alarms)

· Control systems (throttle, shift, governor linkages) A.4.3 Winterization & Safety

· Install winterization valves and engine compartment heaters.

· Verify ABYC-compliant clearances and safety features.

A.5 Testing & Commissioning A.5.1 Dockside Testing

· Perform pre-start checks, leak tests, and system verifications.

· Run engines at idle and mid-range to confirm stability and performance.

A.5.2 Sea Trials

· Conduct minimum 2-hour sea trials under load.

· Verify:

· Rated Revolutions Per Minute (RPM) at wide open throttle (WOT)

· Fuel pressure, boost, exhaust gas temperature (EGT), coolant/oil temps

· Exhaust backpressure and vibration levels

· Adjust valve lash and re-torque fasteners post-trial.

A.5.3 Final Reporting

· Submit commissioning report with all measured values and deviations.

· Provide oil/filter change and inspection documentation.

A.6 Acceptance Criteria

· Engines start reliably, idle smoothly, and reach rated WOT RPM.

· No leaks, abnormal smoke, or excessive vibration.

· All systems function per OEM and ABYC standards.

· Sea trial performance meets or exceeds baseline metrics.

· NPS sign-off on punch list items upon successful demonstration.

A.7 Warranty

· Minimum 12 months or 1,000 operating hours (whichever occurs first) on all workmanship and installed parts.

· Warranty includes labor for replacement/removal/reinstallation of defective components identified within 12 months or 1,000 operating hours at no additional cost(s) to the Government.