RV Sullivan Engine Repair Services

Project Description: The Broward County Natural Resources Division is seeking a Vendor to provide repair services to the County’s research dive vessel (R/V Thomas L. Sullivan). The Vendor shall furnish all necessary labor, materials, equipment, storage space, transportation, training, supervision, and other services to perform preventative and corrective maintenance services to the vessel. Vessel familiarity is strongly recommended; submission of a quote will be construed that the Vendor is acquainted sufficiently with the work to be performed. All questions or clarification inquiries must be submitted to the Purchasing Agent or Contract Administrator through the B-Pro system prior to the due date. A pre-bid meeting will be held at the boat’s location at Nova Southeastern University Oceanographic Center marina (8000 North Ocean Dr., Dania Beach, FL) on January 24, 2025 @ 10:00 am.
Vessel Specifications and Recent Repair/Work History: The County maintains and operates a 2003 36’ Newton dive model research vessel that is powered by a single Caterpillar 3126 turbo diesel engine. In April 2024 the engine was completely removed from the vessel to allow for installation of 2 new fuel tanks. During this time, a partial overhaul of the engine was completed. The vessel was returned to service in June 2024 and had been operating without incident until the engine experienced a mechanical issue in late October 2024, upon which the engine was immediately shut down. When the breakdown occurred, the engine had accumulated 158 hours of running time since the partial overhaul and has 5,443 hours in total. The engine had also previously been removed for an overhaul back in 2015. For reference, the items that were addressed during the partial overhaul in 2024 are outlined in Appendix 1 (please see below).
Initial diagnostic work has been completed and confirmed the problem is centered around failure of the turbocharger, although the underlying cause is still unclear as it was a brand-new unit that had been installed in May 2024. Inspection of the turbocharger revealed there had been excessive play between the compressor wheel and compressor housing, which resulted in contact between the two components and partial destruction of the compressor wheel and gouging/scaping on the inside of the housing. Metal shavings and debris from the compressor wheel was found inside of the air cooler/aftercooler and cleaned out, and the injectors were removed to facilitate an inspection of the cylinder heads with a borescope. Cylinders 1 and 5 were noted to contain a heavy amount of oil; approximately 1 quart. The air cleaner and exhaust components were removed, and coolant and engine oil were drained. Metal shavings were found in the oil, but there was no indication of damage to the cylinders. Following the initial inspection, the fuel injectors were re-installed but not torqued, and the turbocharger, aftercooler, air cleaner, and exhaust components were left disconnected from the engine.
There are two tachometers connected to the engine, one at each helm station (main deck and flybridge). Not long after the vessel returned to service following the partial engine overhaul and successful sea trials, the tachometers began displaying inaccurate and, at times, erratic RPM readings, although no engine performance issues were noted. In September 2024 one tachometer was replaced with a new unit (flybridge helm console), but a second new tachometer that was purchased for the downstairs helm station appeared to malfunction after installation, so the old unit was re-connected.
Work to be Performed (Summarized): The engine components that have already been removed for inspection need to be either replaced or repaired and then re-assembled according to manufacturer specifications (including but not limited to the turbocharger, aftercooler, valve cover, exhaust, fuel injectors, and new gaskets). New tachometer installation at the downstairs helm station, calibration with the engine rpms, and synchronization with the upstairs tachometer shall also be included along with the engine repair. Once the engine is repaired and re-assembled, the Vendor must ensure that all connections are secure and engine performance is satisfactory, confirmed through a sea trial(s). Further diagnostic/investigative work will be needed to determine the cause of the turbocharger failure, to confirm no additional damage has been done to the engine as the result of ingestion of metal debris into the combustion chamber, to ensure the engine is able to run smoothly and reliably while maintaining proper compression after the repairs have been made, and to make every reasonable effort to identify and correct any issues that might lead to a re-occurrence of the problem. Broward County requests recommendations from the vendor, as they deem appropriate, for any additional investigations of components not listed here that may have been affected by the turbocharger failure, as well as any appropriate servicing items related to repairing the engine after the breakdown (e.g., oil treatment/flushing, oil changes, oil filters, etc.).
Appendix 1. Worklist items from the partial overhaul conducted in April 2024: De-rigged and removed engine, re-installed and re-aligned; inspected and replaced engine mounts as needed; removed and rebuilt heat exchangers, refilled with coolant after reassembly; removed and rebuilt aftercoolers; removed and rebuilt transmission oil cooler; replaced 1 bent pushrod; removed and rebuilt fuel pump; removed and rebuilt fuel injectors (replaced one injector), set valves, injectors, and rack; removed and rebuilt turbocharger (replaced with new); removed oil pan and replaced gasket, cleaned surfaces and applied gasket sealant (in addition to new gasket); changed oil and replaced oil filters; replaced primary Racor fuel filter cartridge and cleaned filter assembly; replaced secondary fuel filter; replaced coolant hoses and clamps; replaced raw water impeller and belts; cleaned, primed, and painted corroded/rusted parts and exterior of entire engine with Caterpillar yellow paint.