1.1.3 DRAFT PWS HPAC Rev 1 .pdf

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High Pressure Air Compressor, 18, 000 hour overhaul
Solicitation number
20260002927
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This is a Performance Work Statement (PWS) for the overhaul and electrical upgrade of two Dresser-Rand high pressure air compressors (HPACs) for a TAO Class ship under a UNREP contract.

The contractor must perform an 18,000-hour maintenance overhaul on two HPACs (Model N20NL-11C, Serial Numbers XM51224 and XM51318) currently located at Alabama Shipyard and transport them to an OEM-approved facility for shop overhaul. The primary work includes: disassembly and inspection of crossheads, connecting rods, and crankshaft; replacement of bearing shells and main bearings; cleaning and inspection of the frame, oil sump, and oil pump; replacement of the crankshaft oil seal; cleaning and inspection of piston rod oil wiper assemblies; overhaul of the freshwater pump; cleaning and hydrostatic testing of the cooling water system; and refurbishment of the manual condensate drain manifold, drain line check valves, and unloading valves. Additionally, the contractor must perform a system upgrade to the electrical and condensate drain system to address obsolete equipment. All work must be performed in accordance with NAVSEA technical manuals and completed in the presence of MSCREP representatives. The contractor must submit "as found" condition reports during disassembly, prepare equipment for operational testing in the OEM workshop, arrange transportation of the overhauled compressors back to LP-26 MSC Norfolk Warehouse, provide technical manuals and drawings for the system upgrades performed, and submit final reports documenting the "as released" condition of the HPACs. An OEM-authorized field service representative must oversee all work to ensure compliance with manufacturer's standards and performance specifications.

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(TAO Class)

UNREP CONTRACT NO. TBD

ITEM NO. PWS CATEGORY "A"

HPAC OVERHAUL & ELECTRICAL

1.0 ABSTRACT

The purpose of this item is to perform the 18,000 hour maintenance on the ship’s high pressure air compressors (HPACs)AND perform the electrical and condensate drain upgrade (due to obsolete equipment installed).

2.0 REFERENCES

2.1 NAVSEA Tech Manual T6220-AS-MMO-010, High Pressure

Air Compressor Model: N20NL-11C

2.2 NAVSEA Tech Manual S6220-DR-OMI-B10 AIR

COMPRESSORS HIGH PRESSURE OIL-FREE MODELS N20NL-11G

AND N20NL-11H WITH PROGRAMMABLE LOGIC CONTROLLER

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Locations

a. MSC to ship to Contractor’s Facility

3.1.2 Quantity: Two (2)

3.2 Item Description/Manufacturer’s Data

3.2.1 Manufacturer: Dresser-Rand

Company Model Number: N20NL- 11C

3.2.2 Serial number for compressor 1

is XM51224.

3.2.3 Serial number for compressor 2

is XM51318.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE: None

5.0 NOTES:

5.1 Do not allow grease or oil to contaminate parts

that contact the air stream. Ensure all lockout/tagout procedures are in accordance with current shipboard instructions.

5.2 Refer to the manufacturer’s technical manual for

detailed, step-by-step procedures for the following maintenance action.

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

7.0 STATEMENT OF WORK REQUIRED

7.1 Two (2) used HPAC Compressors as identified within

Para 3.0, currently located in Alabama Shipyard will be delivered to the OEM approved facility for shop overhaul.

7.2 Drain and dispose of any liquid in accordance with

all federal, state, and local regulations.

7.3 Temporarily remove crossheads and connecting rods

from the compressor.

7.3.1 Remove and replace connecting rod crankpin

bearing shells. When installing new shells, ensure that the oil passages are currently aligned.

7.3.2 Clean all crosshead and connecting rod

parts with an approved solvent, paying particular attention to all oil passages.

7.3.3 Inspect and measure all critical

dimensions of the crosshead, crosshead pin, and retaining ring. Take a gage reading of the connecting rod crankpin bearing. Replace any components exceeding allowable tolerances or are otherwise damaged.

7.4 Remove the crankshaft and main bearings.

7.4.1 Clean the crankshaft, paying particular

attention to the journals surfaces and or passages.

7.4.2 Inspect the crankshaft for nicks, scratches other surface defects or cracks.

Perform a magnetic particle test.

7.4.3 Measure the critical dimensions of the

crankshaft. Submit an “as found” condition report including recommendation to replace the crankshaft if allowable tolerances are exceeded.

7.4.4 Check the main bearing saddles for

irregularities or debris.

7.4.5 Replace all main bearings and take gage

readings to ensure correct clearances.

7.4.6 Reinstall crankshaft.

7.5 Thoroughly clean the frame and oil sump.

7.5.1 Drain lube oil sump.

7.5.2 Remove all dirt or sludge deposits.

7.5.3 Replace O-ring in sump drain plug.

7.5.4 Clean all oil pipes, including those

previously removed from compressor and the lube oil strainer.

7.5.5 Inspect all portions of the frame and

sump for damage or other defects.

7.6 Disassemble and inspect the oil pump. Pay

particular attention to the rotor assembly. Submit an “as found” condition report. Reassemble the oil pump.

7.7 Replace the crankshaft oil seal.

7.8 Clean and inspect the piston rod oil wiper

assemblies.

Note: Before disassembling a wiper ring matchmark the ring segments to permit correct reassembly.

7.8.1 Examine the wiper rings for cracks or

breakage. If one segment needs replacement, change the entire set.

7.8.2 Clean the stuffing boxes before

reinstalling rings. Reinstall rings.

7.9 Temporarily remove and overhaul the freshwater

pump.

7.9.1 Disassemble freshwater pump and submit an

“as found” condition report.

7.9.2 Reassemble and reinstall freshwater pump.

7.10 Clean the cooling water system.

7.10.1 Open and inspect the air coolers and

cooling water heat exchanger. Submit an “as found” condition report.

7.10.2 Clean the cooling water system of dirt

and debris. MSCREP to inspect.

7.10.3 Close the cooler with new gaskets.

7.11 Hydrostatically test the cooling water system.

7.12 Refurbish the manual condensate drain manifold.

7.13 Refurbish the drain line check valves.

7.14 Refurbish the unloading valve and unloading valve

pilot valve.

7.15 Perform system upgrade to the drains (as are

obsolete and not supported) “Electrical and Condensate Drain system related” to allow for compressors to have supportability for future repairs/service requirements.

7.16 Prepare equipment for testing and accomplish

operational test in OEM Workshop in the presence of

MSCREP.

7.17 After completion of all portions of this contract, coordinate arrange for transportation of Government Materials, two (2) Overhauled Condition Code “A” HPAC Compressors as identified within Para 3.0, from Contractors OEM Workshop back to LP-26 MSC

Norfolk Warehouse.

7.18 Reports

7.18.1 When inspection, service and testing

reveal any deficiency a condition report is to be submitted to the MSCREP with recommended repairs and parts required.

Submit one (1) electronic copy in Portable Document Format (PDF).

7.18.2 Submit a report that includes “as

released” condition of the HPACs. Submit one

(1) electronic copy in Portable Document Format (PDF).

7.18.3 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.

7.19 Painting/Lagging

7.19.1 Prepare, prime, paint and restore all

new, soiled, and disturbed surfaces to match surrounding surfaces.

7.20 Manufacturer’s Representative

7.20.1 Provide the services of an OEM authorized

field service representative to accomplish all work and testing on the HPACs identified in paragraph 3.0 ensuring compliance with the manufacturer’s standards and performance specifications.

7.20.2 Possible Source

RESERVED

7.21 Preparation of Drawings: Provide Tech

Manual/Drawings (all relevant data) for the Electrical and Condensate Drain system related upgrades performed.

ITEM NO. PWS CATEGORY "A"

8.0 GENERAL REQUIREMENTS: None additional

2.1 NAVSEA Tech Manual T6220-AS-MMO-010, High Pressure Air Compressor Model: N20NL-11C
2.2 NAVSEA Tech Manual S6220-DR-OMI-B10 AIR COMPRESSORS HIGH PRESSURE OIL-FREE MODELS N20NL-11G AND N20NL-11H WITH PROGRAMMABLE LOGIC CONTROLLER
5.1 Do not allow grease or oil to contaminate parts that contact the air stream. Ensure all lockout/tagout procedures are in accordance with current shipboard instructions.
5.2 Refer to the manufacturer’s technical manual for detailed, step-by-step procedures for the following maintenance action.
7.1 Two (2) used HPAC Compressors as identified within Para 3.0, currently located in Alabama Shipyard will be delivered to the OEM approved facility for shop overhaul.
7.2 Drain and dispose of any liquid in accordance with all federal, state, and local regulations.
7.3.2 Clean all crosshead and connecting rod parts with an approved solvent, paying particular attention to all oil passages.
7.3.3 Inspect and measure all critical dimensions of the crosshead, crosshead pin, and retaining ring. Take a gage reading of the connecting rod crankpin bearing. Replace any components exceeding allowable tolerances or are otherwise damaged.
7.4.1 Clean the crankshaft, paying particular attention to the journals surfaces and or passages.
7.4.2 Inspect the crankshaft for nicks, scratches other surface defects or cracks. Perform a magnetic particle test.
7.4.3 Measure the critical dimensions of the crankshaft. Submit an “as found” condition report including recommendation to replace the crankshaft if allowable tolerances are exceeded.
7.4.4 Check the main bearing saddles for irregularities or debris.
7.4.5 Replace all main bearings and take gage readings to ensure correct clearances.
7.4.6 Reinstall crankshaft.
7.5 Thoroughly clean the frame and oil sump.
7.5.1 Drain lube oil sump.
7.5.2 Remove all dirt or sludge deposits.
7.5.3 Replace O-ring in sump drain plug.
7.5.4 Clean all oil pipes, including those previously removed from compressor and the lube oil strainer.
7.5.5 Inspect all portions of the frame and sump for damage or other defects.
7.6 Disassemble and inspect the oil pump. Pay particular attention to the rotor assembly. Submit an “as found” condition report. Reassemble the oil pump.
7.7 Replace the crankshaft oil seal.
7.8 Clean and inspect the piston rod oil wiper assemblies.
7.8.1 Examine the wiper rings for cracks or breakage. If one segment needs replacement, change the entire set.
7.8.2 Clean the stuffing boxes before reinstalling rings. Reinstall rings.
7.9 Temporarily remove and overhaul the freshwater pump.
7.9.1 Disassemble freshwater pump and submit an “as found” condition report.
7.9.2 Reassemble and reinstall freshwater pump.
7.10 Clean the cooling water system.
7.10.1 Open and inspect the air coolers and cooling water heat exchanger. Submit an “as found” condition report.
7.10.2 Clean the cooling water system of dirt and debris. MSCREP to inspect.
7.10.3 Close the cooler with new gaskets.
7.11 Hydrostatically test the cooling water system.
7.12 Refurbish the manual condensate drain manifold.
7.13 Refurbish the drain line check valves.
7.14 Refurbish the unloading valve and unloading valve pilot valve.
7.15 Perform system upgrade to the drains (as are obsolete and not supported) “Electrical and Condensate Drain system related” to allow for compressors to have supportability for future repairs/service requirements.
7.16 Prepare equipment for testing and accomplish operational test in OEM Workshop in the presence of MSCREP.
7.17 After completion of all portions of this contract, coordinate arrange for transportation of Government Materials, two (2) Overhauled Condition Code “A” HPAC Compressors as identified within Para 3.0, from Contractors OEM Workshop back to LP-26 MS...
7.18.1 When inspection, service and testing reveal any deficiency a condition report is to be submitted to the MSCREP with recommended repairs and parts required. Submit one (1) electronic copy in Portable Document Format (PDF).
7.18.2 Submit a report that includes “as released” condition of the HPACs. Submit one (1) electronic copy in Portable Document Format (PDF).
7.18.3 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.
7.19.1 Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces.
7.20.1 Provide the services of an OEM authorized field service representative to accomplish all work and testing on the HPACs identified in paragraph 3.0 ensuring compliance with the manufacturer’s standards and performance specifications.
7.20.2 Possible Source

7.21 Preparation of Drawings: Provide Tech Manual/Drawings (all relevant data) for the Electrical and Condensate Drain system related upgrades performed.

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