0552_A_TEPF-CCSI-HOSE REPLACEMENT (5 Y.docx

1.0 ABSTRACT

The purpose of this item is to renew critical fuel oil and lube oil, nonmetallic, flexible hoses and expansion joints on the vessel’s diesel engines.

2.0 REFERENCES/ENCLOSURES

2.1 References

2.1.1 46 CFR §56 - Piping Systems and Appurtenances Tech Manual S9233-EN-MMC-010; Main Propulsion Diesel Engine Parts Manual IMO MSC.1, Circ 1321 Guidelines for Measures to Prevent Fires in Engine Rooms and Cargo Pump Rooms

2.2 Enclosures

2.2.1 T-EPF Critical Hose and Expansion Joint List

2.2.2 Hose Identification Tag

3.0 ITEM LOCATION/DESCRIPTION/QUANTITY

3.1 Location

3.1.1 Main Engine Room 1 (5-52-1)

3.1.2 Main Engine Room 2 (5-52-2)

3.2 Description/Quantity

3.2.1 Main Propulsion Diesel Engines – Four per ship

3.2.1.1 Mfg: MTU Friedrichshafen GMBH

3.2.1.2 Model: 20V8000M71L

3.2.2 Vessels

3.2.2.1 USNS YUMA

3.2.2.2 USNS NEWPORT

3.2.2.3 USNS CARSON CITY

3.2.2.4 USNS BRUNSWICK

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material (GFM): None

4.3 Government Furnished Services (GFS): None

4.4 Government Furnished Information (GFI): None

5.0 NOTES

5.1 The contractor and all subcontractors, regardless of tier, must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs including but not limited to GTRs 1 through 7, 22, 23, 24, 28, and 29.

5.2 WIPING OF INTERNAL SURFACES INTERNAL TO CASES AND SUMPS WILL ONLY BE CONDUCTED USING LINT-FREE RAGS APPROVED FOR USE BY THE OMT REP.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 None additional

7.0 STATEMENT OF WORK REQUIRED

7.1 Provide and operate equipment and supply all services and assistance to accomplish the thorough examination, renewal, testing and certification of the nonmetallic flexible fuel oil and lube oil hoses and expansion joints on diesel engines using USCG, ABS, the Manufacturer’s requirements and Reference 2.1.1 – 2.1.4 as guidance.

7.2 With assistance from the Chief Engineer tag out the diesel engines and their fuel oil and lube oil systems ensuring they are depressurized and drained during this work item. Thoroughly drain and dispose of the residual liquids using the local, state and federal regulations. Clean and gas free to ensure the area is safe for hot work. A competent Marine Chemist shall certify that the area and space are safe for hot work daily.

7.3 Provide temporary caps or plugs on open connections to adequately protect the system and ship from contamination, leaks and fire hazards during the accomplishment of this work item. Coordinate removals and reinstallations with the Chief Engineer to ensure the vessel is always aware of engine status until the hose work is completed.

7.3.1 Replacement: replace all fuel oil and lube oil hoses and expansion joints listed in Enclosure 2.2.1 using USCG, ABS, the manufacturers design, installation, maintenance instructions and service bulletins as guidance. The replacement shall include/verify:

a. Material is compatible with the system fluid.

b. The maximum system design pressure does not exceed the rated working pressure.

3.2.2.5 Nonmetallic flexible hose and expansion joint (as required) assemblies shall have end fittings requiring no further adjustment or field attachable fittings. All nonmetallic flexible hose and expansion joint assemblies shall fully conform to ABS Marine Vessel Rules, including the permanent mark requirements. The end fitting threads shall be the same as existing and the fitting material shall meet or exceed the designed specifications. Any nonmetallic flexible hose assemblies and expansion joint assemblies that do not meet these requirements must be rejected. If special equipment is required, such as crimping machines, it must be of the type and design specified by the manufacturer.

NOTE: a hose assembly consists of one hose and two end fittings. End fittings shall be new and same as existing fitting threads.

7.3.2 System Test: Conduct testing of each new fuel oil and lube oil hose assembly and expansion joint assembly using 46 CFR §56.97-30(e) as guidance. The testing includes/verifies:

a. A shop hydrostatic test of all nonmetallic flexible assemblies to a test pressure equivalent to not less than 1.5 times the maximum allowable working pressure.

b. Ensure the test gauge has been calibrated within the last 12 months.

c. The test medium shall be clean fresh water.

d. The hose test layout shall be straight, without kinks or twists.

e. Ensure all air has been bled from the nonmetallic flexible assemblies before pressure testing.

f. Test pressure shall be held for a minimum of ten minutes.

g. Hoses and expansion joints shall not burst, leak or show signs of fitting separation.

h. After hydrostatic testing, the assembly shall be flushed with water between 130 °F and 180 °F for a period between five and ten minutes. Flush shall be straight through and not recirculated.

i. Upon successful completion of hydrostatic testing, attach a noncorrodible metal stamped identification tag to each hose or expansion joint assembly using Enclosure 2.2.2 for guidance. Tags manufactured locally shall contain the following information as a minimum: ship name, hose type/size, system pressure and installation date.

j. Upon completion of pressure tests, dry the assembly and cap or plug the end fittings to prevent damage and to keep out dirt. Use of self-sticking tape alone is not authorized for foreign material exclusion.

k. Upon installation, secure the hose assemblies from vibration with soft nonferrous metal straps

l. An operational test of installed hose and expansion joint assemblies on their diesel engine confirming no leakage during dock trials.

m. Install SOLAS approved spray shields/tape on all new hose joints upon successful completion of testing.

Possible Source for tape:

T-ISS Spray Stop Anti-Splashing Tape (SOLAS approved spray shield tape) https://t-iss.com/shop/solas-tapes/spray-stop-anti-splashing-tape/

7.4 Testing shall be coordinated with the OMT REP, ABS Surveyors and USCG Inspectors to allow for observation if deemed necessary.

7.5 Protect the hoses and coupling threads from damage during the accomplishment of this work item.

7.6 Reports

7.6.1 When inspection, service and testing reveal any deficiency a condition report is to be submitted to the OMT REP with recommended repairs and parts required. Submit one electronic copy in Portable Document Format (PDF).

7.6.2 Submit a report that includes “as released” condition of the flexible hoses. Submit one electronic copy in Portable Document Format (PDF).

7.6.3 All reports and checklists are to be completed and signed by the person who carried out the inspection and maintenance work and countersigned by the company’s representative.

7.7 Painting/Lagging

7.7.1 Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces.

7.7.2 Renew lagging where damaged or disturbed.

7.8 Manufacturer’s Representative: None

7.9 Preparation of Drawings

9. Provide electronic copies of all revised and/or updated technical documentation including drawings, technical manuals, service bulletins, parts lists, certification and test data associated with the work performed or parts supplied to the OMT REP.

8.0 GENERAL REQUIREMENTS:

USNS BRUNSWICK and NEWPORT

3.3 None additional

0552M - 10

ENCLOSURE 2.2.1 T-EPF CRITICAL HOSE AND EXPANSION JOINT LIST

MAIN PROPULSION DIESEL ENGINE (MPDE)

Item

Part Number

NSN/TNICN

Description

Qty1

UOM2

ENCLOSURE 2.2.2 HOSE IDENTIFICATION TAGS

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