10,000 Hour (Top End) Overhaul of Caterpillar D398 Ship Service Diesel Generators

COMBINED SYNOPSIS/SOLICITATION 10,000 Hour (Top End) Overhaul of Caterpillar D398 Ship Service Diesel Generators (I) This is a combined synopsis/solicitation for commercial items prepared in accordance with the format in FAR Subpart 12.6, as supplemented with additional information included in this notice and in accordance with the simplified acquisition procedures authorized in FAR Part 13. This announcement constitutes the only solicitation; proposals are being requested and a written solicitation will not be issued. (II) This solicitation is issued as a request for quotation (RFQ). Submit written quotes on RFQ Number NMAN7200-11-02641SRG. (III) The solicitation document and incorporated provisions and clauses are those in effect through Federal Acquisition Circular 2005-50. (IV) The procurement is unrestricted and open to all sources. The associated NAICS code is 811219. The business size standard is $19.0M. (V) This combined solicitation/synopsis is for purchase of the following commercial services: CLIN 0001 - Provide 10,000 hour (top end) overhaul of the #2 and #3 Caterpillar D398 ship service diesel generators on the NOAA ship McArthur II. The planned place of performance will be Pascagoula, Mississippi, but may change with little or no warning depending upon ship requirements schedule changing and the vendor will need to be flexible with location for service. (VI) Description of requirements is as follows: See attached statement of work which applies to requirement. (VII) Period of performance shall be May 26, 2011 - June 3, 2011: (VIII) FAR 52.212-1, Instructions to Offerors -- Commercial Items (June 2008), applies to this acquisition. (IX) FAR 52.212-2, Evaluation - Commercial Items (Jan 1999), applies to this acquisition. Offers will be evaluated based on price and the factors set forth in paragraph (a), and award will be made to the firm offering the best value to the Government. Paragraph (a) is hereby completed as follows: Evaluation will be based on 1) Past Performance - quote shall included two references including the phone number, full address and email (if available) and contractor's past performance will be based on responsiveness, quality, and customer services, 2) Ability to meet all requirements for accomplishment of the 10,000 hour overhaul, and 2) Price. The Government intends to award a firm-fixed price purchase order on an all or none basis. (X) The offeror must submit a completed copy of the provision at FAR 52.212-3, Offeror Representations and Certifications - Commercial Items (Mar 2011), with its quote. The offeror shall complete the annual representations and certifications electronically at http://orca.bpn.gov . (XI) The clause at FAR 52.212-4, Contract Terms and Conditions - Commercial Items (June 2010) applies to this acquisition. (XII) The clause at FAR 52.212-5, Contract Terms and Conditions Required to Implement Statutes or Executive Orders - Commercial Items (Mar 2011) applies to this acquisition. The following clauses under subparagraph (b) apply: (4) 52.204-10, Reporting Executive Compensation and First-Tier Subcontract Awards (Jul 2010) (Pub. L. 109-282) (31 U.S.C. 6101 note). (20) 52.219-28, Post Award Small Business Program Rerepresentation (Apr 2009) (15 U.S.C. 632(a)(2)). (21) 52.222-3, Convict Labor (June 2003) (E.O. 11755). (22) 52.222-19, Child Labor-Cooperation with Authorities and Remedies (July 2010) (E.O. 13126). (23) 52.222-21, Prohibition of Segregated Facilities (Feb 1999). (24) 52.222-26, Equal Opportunity (Mar 2007) (E.O. 11246). (26) 52.222-36, Affirmative Action for Workers with Disabilities (Oct 2010) (29 U.S.C. 793). (31) 52.223-15, Energy Efficiency in Energy-Consuming Products (Dec 2007) (42 U.S.C. 8259b). (33) 52.223-18, Contractor Policy to Ban Text Messaging While Driving (Sep 2010) (E.O. 13513). (35)(i) 52.225-3, Buy American Act-Free Trade Agreements-Israeli Trade Act (June 2009) (41 U.S.C. 10a-10d, 19 U.S.C. 3301 note, 19 U.S.C. 2112 note, 19 U.S.C. 3805 note, Pub. L. 108-77, 108-78, 108-286, 108-302, 109-53, 109-169, 109-283, and 110-138). (42) 52.232-33, Payment by Electronic Funds Transfer-Central Contractor Registration (Oct 2003) (31 U.S.C. 3332). (XIII) The following clauses are also applicable to this acquisition: 52.252-1 Solicitation Provisions Incorporated by Reference (Feb 1998) 52.252-2 Clauses Incorporated By Reference (Feb 1998), This contract incorporates one or more clauses by reference, with the same force and effect as if they were given in full text. Upon request, the Contracting Officer will make their full text available. Also, the full text of a clause may be accessed electronically at this address: https://www.acquisition.gov/far/index.html (End of Clause) The following additional FAR terms and conditions apply: 52.214-34, Submission of Offers in the English Language (Apr 1991) 52.214-35, Submission of Offer in U.S. Currency (Apr 1991) 52.217-8, Option to Extend Services (Nov 1999) 52.223-1, Biobased Product Certification. (Dec 2007) 52.223-2, Affirmative Procurement of Biobased Products Under Service and Construction Contracts. (Dec 2007) 52.223-3, Hazardous Material Identification and Material Safety Data (Jan 1997) 52.223-4, Recovered Material Certification (May 2008) 52.223-5, Pollution Prevention and Right-to-Know Information (Aug 2003) 52.223-10, Waste Reduction Program (Aug 2000) 52.223-11, Ozone-Depleting Substances (May 2001) 52.223-13, Certification of Toxic Chemical Release Reporting (Aug 2003) 52.223-14, Toxic Chemical Release Reporting (Aug 2003) 52.228-5, Insurance - Work on a Government Installation (Jan 1997) 52.237-2, Protection of Government Buildings, Equipment, and Vegetation (Apr 1984) Department of Commerce Clauses: 1352.201-70, Contracting Officer's Authority (Apr. 2010). The Contracting Officer is the only person authorized to make or approve any changes in any of the requirements of this contract, and, notwithstanding any provisions contained elsewhere in this contract, the said authority remains solely in the Contracting Officer. In the event the contractor makes any changes at the direction of any person other than the Contracting Officer, the change will be considered to have been made without authority and no adjustment will be made in the contract terms and conditions, including price. (XIV) Defense Priorities and Allocations System (DPAS) and assigned rating do not apply. (XV) Quotes are required to be received in the contracting office no later than 4:30 P.M. Mountain Standard Time on April 11, 2011. All quotes must be faxed or emailed to the attention of Suzanne Romberg-Garrett, Doris Turner, and Chris Flint either through email [email protected], [email protected], and [email protected]. The fax number is (303) 497-7719. (XVI) Any questions or inquiries regarding this solicitation should be directed to the following three persons: Suzanne Romberg-Garrett, Doris Turner, and Chris Flint either through email [email protected], [email protected], and [email protected] or faxed at 303-497-7719 no later than 4:00 p.m. MST, April 7, 2011. STATEMENT OF WORK CATERPILLAR D398 10,000 HOUR OVERHAUL 1. SCOPE. This specification contains requirements for the10,000 hour overhaul of the number 2 and number 3 Caterpillar D398 diesel engines on NOAA Ship McArthur II. The serial numbers of the engines are as follows: Engine #2:35Z00949; Engine #3:35Z00952. 2. REFERENCES. 2.1 Technical manual T9312-AG-MM0-010/11083 Engine Generator Set Model D398B 2.2 Caterpillar Maintenance Management Schedule for Marine Engines (SEBU6102) 2.3 Caterpillar Operations and Maintenance Manual (SEBU5698) 2.4 Caterpillar Service Manual (SEBR0511) 2.5 Generator alignment procedure (attached). 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. 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. Contractor shall submit evidence of being a Caterpillar Authorized Marine Dealer (A.M.D.) prior to start of work. 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 2.5. 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 pre-chambers (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 Remove turbo aftercooler cores (housings and elements). These components will be taken to a local radiator shop to be cleaned. Upon their return, contractor shall pressure test and reinstall the cores. 3.2.5 Clean and check all valve mechanism assemblies in accordance with Reference 2.4. 3.2.6 Test and adjust the fuel nozzles in accordance with Reference 2.4 prior to installation. 3.2.7 Check and adjust the fuel timing, reset all tappets and check valve rotators in accordance with Reference 2.4. 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 2.5. 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 Additional Repairs. 3.4.1 #3 diesel engine is to have the rear main oil seal and oil pan gasket replaced. The engine is to be separated from the generator and the generator shifted sufficiently for access. The pan is to be unbolted from the engine to allow replacement of the gasket. 3.4.2 After removing the pan, thoroughly clean gasket surfaces and internal areas of the pan. Inspect the sump for cleanliness or signs of damage/distortion on the mating surfaces. The CME will verify cleanliness prior to reinstalling the pan. Approval to reinstall the pan must be obtained from the CME in writing. 3.4.3 While the generator is pulled back from the engine, the rear main oil seal is to be replaced on the #3 engine. 3.4.4 Provide a new gasket and reinstall the oil pan. After lowering the engine back onto the foundations, the generator is to be reconnected and alignment verified. 3.4.5 In addition to the salt water pump repairs required by paragraph 3.2.3, the salt water pumps for main diesel engines 1 and 4 are also to be rebuilt according to the requirements of 3.2.3. As part of the rebuild of the engine pumps (total of four pumps) the contractor is to provide one pump with a new bronze pump casing. The specific pump to have the casing replaced will be determined after the pumps have been disassembled for inspection. 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. 3.7 Testing. 3.7.1 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 full load and operate for one hour. Provide technicians to observe operation, verify joints are leak-free, make adjustments, and record teat data. 3.7.2 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. 3.7.3 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 g. turbo outlet air pressure 3.7.4 Submit a report of all test data collected. Report shall include manufacturer's recommended limits for each parameter measured. 3.8 Final Adjustments and Tune-up. 3.8.1 After satisfactory completion of operational testing, reset valves and accomplish final adjustments and tune-ups as required to provide smooth, efficient, and reliable operation. 3.9 Notes. 3.9.1 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 office. Government will pay for ABS fees associated with the inspections under a separate purchase order. 3.9.2 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. 3.9.2 Reference 2.1 will be available for review during scheduled pre-bid inspection and during the performance period of the contract. References 2.2 through 2.4 shall be contractor furnished. Reference 2.5 follows this specification as an attachment. END OF SPECIFICATION Reference 2.5 GENERATOR ALIGNMENT PROCEDURE The Contractor shall take the following readings before disassembly: a. generator fan angular deflection, b. generator shaft runout (TIR), c. crankshaft end play, d. crankshaft deflection. Above readings shall be taken again upon reassembly, after the generator to engine alignment relationships have been re-established. Record all results on condition reports and report the results to the attending NOAA Port Engineer, or assigned representative. Before performing the parallel and angular alignment checks, ensure that the natural clearance between the base and its foundation is properly gapped with shims at all mounting locations and check that all base-to-foundation bolts are tightened to their final torque. If deflection of the base is noted, loosen base-to-foundation bolts at affected locations, shim as necessary to eliminate deflection, and re-tighten base-to-foundation bolts to their final torque. Inability to attain repeatability of readings may be due to cocking of the flywheel by the turning tool. An end-supporting turning tool has proven to be superior to free-gear types for taking these particular reading. If an end-supported tool is not available, good results are attainable with a free-gear type if tooth engagement is reduced to the bare minimum necessary to turn the flywheel. The deflection dial indicator must not have a leash attached since it may change readings. PARALLEL ALIGNMENT (SHAFT RUNOUT) Ensure that the generator shaft surface, which is to be measured with the dial indicator, is clean. Solvent and or light sanding with emery cloth should remove any dirt or rust accumulation. Place the base of a dial indicator on the uppermost generator adaptor frame rib and position the indicator finger, which requires extensions, on the generator shaft. Preliminary readings can be taken on the coupling; final readings will be taken on the shaft only. Zero the dial indicator at the 12 o'clock position. It is essential to ensure that the dial indicator base does not move during the run-out check. Any movement will result in erroneous readings. Rotate the shaft one revolution starting at the 12 o'clock position, checking and recording the dial indicator readings every 90 degrees. To validate the readings, at the completion of the revolution, the dial indicator must return to 0 at the original 12 o'clock starting position. In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft. Desired reading is 0.000 inch. Total indicator readings shall not exceed .005 inches. Adjust drive flex plate pack (discs) to flywheel installation as necessary to bring parallel alignment into tolerance. Adjustment is accomplished by changing the diesel engine flywheel to generator drive flex plate pack relationship. If total indicator readings exceed 0.005 inches, adjustment is accomplished by removing the drive flex plate pack to flywheel bolts and turning the engine flywheel with the turning gear. The generator can be prevented from rotating with the engine by installing a capscrew in the generator coupling and then holding the generator with a 36" long pinch bar or angle iron placed on the capscrew and generator web. The engine to flywheel relationship is changed one or more bolt holes at a time. Reinstall the drive flex plate pack to flywheel bolts and take runout readings. Adjust as necessary to bring TIR readings into tolerance. GENERATOR ANGULAR ALIGNMENT Place a deflection dial indicator at the 12 o'clock position between the forward face of the fan and the drive flex plate at a point as far away as possible from the centerline of the shaft. The contact points for the deflection dial indicator fingers should be lightly punch marked. Starting at the 12 o'clock position, rotate the shaft one revolution checking and recording readings every 90 degrees. To validate readings, at the completion of the revolution, the deflection dial indicator must return to zero at the 12 o'clock starting position. In order to ensure accuracy, repeatability of the readings must be obtained for two consecutive revolutions of the shaft. Desired generator angular alignment readings are as follows: 12 O'CLOCK: 0.000 (starting point) 3 O'CLOCK: 0.000 TO +0.004 6 O'CLOCK: 0.000 TO +0.008 9 O'CLOCK: 0.000 TO +0.004 12 O'CLOCK: 0.000 (original starting point) Adjust as necessary to bring angularity readings into compliance with paragraph 3 above. If adjustment is effected, a final set of angularity readings must be obtained after all bolts securing the generator to the engine and the generator to base are tightened to their final torque. CRANKSHAFT DEFLECTION Measure between faces of connecting rod throws of the crankshaft next to the center main bearing #4 and within .250 in. of the counterweight in accordance with Caterpillar Instructions. Record readings. CRANKSHAFT END PLAY Measure crankshaft end play in accordance with Caterpillar instructions. Record readings. OBSERVANCE OF LEGAL HOLIDAYS AND SITE CLOSURE INFORMATION The Contractor hereby agrees to observe the following Federal holidays, plus any other day off work designated by Federal Statute, by Executive Order, or by Presidential proclamation: New Year's Day Labor Day Martin Luther King's Birthday Columbus Day President's Day Veteran's Day Memorial Day Thanksgiving Day Independence Day Christmas Day When any holiday falls on a Saturday, the preceding Friday is observed; when any holiday falls on a Sunday, the following Monday is observed. All personnel assigned to this contract shall limit their observation of holidays to those set forth above. In each instance, the Contractor agrees to continue to provide sufficient personnel to perform requirements of any critical tasks already in operation or scheduled, and shall be guided by the instructions issued by the Contracting Officer or the MIC. In the event of a site dismissal or closure due to weather, emergency or other circumstances, the contractor is instructed to contact the MIC or Alternate MIC for guidance. The Certification and Accreditation (C&A) requirements of Clause 1352.239-72 do not apply, and a Security Accreditation Package is not required.