MTU 20V4000M93L QL4 20200221.pdf

REVISION No. 1 CHANGE No.

MTU 20V4000M93L QL4 OVERHAUL AND ANALYSIS

P-233-2044

ORIGINATED BY Richard Biagiotti DATE 02/2020

ORIGINATOR’S COMMAND SFLC PBPL

DEPARTMENT / DIVISION SFLC-PBPL-AMS1

INTERNAL REVIEWER Patrick Mulrooney DATE 02/2020

SWORB APPROVAL_______________________ __DATE________

1.0 SCOPE

1.1. This specification describes the requirements for the overhaul of non-ready for issue MTU

20V4000M93L marine diesel engine. The engines to be overhauled have reached the time interval, in accordance with (IAW) MTU Maintenance Schedule MA50075, in which

12,000 hour maintenance tasks are required, or may have experienced a catastrophic failure

1.2. The specification describes the requirements for commissioning services of a newly installed overhauled MTU 20V4000M93L engine.

1.3. The specification describes the requirements for technical support for the MTU

20V4000M93L engine system.

1.4. This specification describes the requirements for wear analysis of the MTU 20V4000M93L engine to determine appropriateness of maintenance as applicable to a 1DS (continuous operation, variable, low load) engine.

1.5. This sets forth the requirements for the following equipment which will be issued to the contractor as Government Furnished Equipment (GFE);

a. ENGINE, DIESEL P/N 20V4000M93L, NSN 2815-12-392-7931, 26,900 lbs

b. CONTAINER, METAL ASSEMBLY, P/N 101PPI1001, NSN 8150-01-F18-5402, 6,640 lbs

c. FACTORY WOODED SKID, P/N None, 2,250 lbs

2.0 APPLICABLE DOCUMENTS

2.1. APPLICABLE DOCUMENTS – The following documents form a part of this specification to the extent specified herein.

2.2. GOVERNMENT DOCUMENTS-

a. SFLC Specification- D-000-0100, Bar Coding for Coast Guard Material.

2.3. COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the most current version listed by number and date from the referenced industry organization. Commercial documents may also be listed in the Department of Defense Index of Specifications and

Standards (DODISS).

a. MTU 20V4000M93L Functional Description MA13029

b. MTU 20V4000M93L Operating Instructions MA15071

c. MTU 20V4000M93L Maintenance and Overhaul Manual MA22019, Removal

Spaces and Weights MS68001, Maintenance Schedule MA50075, Instruction for

General Overhaul MA25014, and Instructions for Overhaul of Sub-Assemblies

MA20011

d. MTU 20V4000M93L Spare Parts Manual MA30188

e. MTU Fluids and Lubricants Specification A001061

f. MTU Preservation and Re-preservation Specifications A001070

g. MTU FRC-B MSC-5 System Documentation S000150

h. MTU 20V4000M93L Automation System Operations Manual EA530020

i. MTU 20V4000M93L Automation System Parts Manual EA535015

j. ANSI/NCSL Z540 3 2006.08.03, Requirements for the Calibration of Measuring and

Test Equipment.

k. ANSI/ASQC Q90003-1994, Inspection System.

2.4. SPECIFICATION ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence, unless otherwise specified herein. The Contractor shall notify the Contracting Officer in writing prior to continuing work of any perceived conflicts contained herein.

2.5. DEPARTUARE FROM SPECIFICATION – Departure from this specification shall not be allowed unless approved by the Contracting Officer.

a. If the Contractor finds it necessary to suggest implementing change or depart from applicable specifications they shall request permission.

b. Request for change shall clearly describe the changes proposed, the reason for change, advantages of the proposed changes, price increase or decrease (if any) resulting from the change.

3.0 REQUIREMENTS

3.1. GENERAL – The contractor shall overhaul the engine and components listed in MTU

Maintenance Schedule MA50075. All 12,000 operating hour tasks shall be accomplished.

a. The contractor must possess a current MTU distributor agreement authorizing the service of their products. Any changes and/or modifications to the distributor agreement shall be forwarded immediately to the Contracting Officer. The Coast

Guard reserves the right to request from the contractor proof of their distributor agreement at any time.

b. Contractor must have access to service bulletins applicable to the 20V4000M93L engine.

c. The contractor shall provide, when requested by the Contracting Officer, detailed evidence of their experience overhauling, repairing, and testing of the MTU 4000 03 marine diesel engine and components listed in this specification.

d. The Contractor shall have access to MTU’s secure MTU IT Business portal and the

MTU Central Data Base.

e. All tools and test equipment shall be calibrated in accordance with section 4.3

f. The contractor shall ensure all work performed under this contract is by technicians possessing the training, qualifications, and certifications (specified in the referenced manuals) to the level appropriate for the specific task they are performing. Any work performed by un-certified/qualified, or under certified/qualified technicians will be subject to contractual remedies.

g. The overhaul and component inspections shall be completed using current OEM parts, components, processes, and practices.

h. Testing shall be conducted in accordance with MTU factory acceptance run-in and final acceptance protocol.

i. The contractor shall notify the Contracting Officer prior to all testing. The Coast

Guard reserves the right to witness all testing.

j. The overhauled engine shall be dynamometer tested to full load, 4,216KW, IAW

MTU run-in/final acceptance test procedures. When run-in and full load dynamometer testing cannot be conducted on-site, the engine shall be load tested to a minimum 2,700KW on-site with full load test completed at a remote facility when authorized by the Contracting Officer.

k. Upon completion of overhaul the contractor shall provide the Contracting Officer an electronic copy of the final acceptance engine test certificate (Birth Certificate).

l. Upon receipt of components, regardless of condition, the contractor shall store material inside in a secure area away from adverse weather.

m. The contractor shall be capable of overhauling a minimum of 20 engines per year.

n. The contractor shall conduct wear analysis on engines as required.

o. The contractor is solely responsible to facilitate and coordinate subcontractors’ performance requirements.

p. The contractor shall submit reports within the time line set forth in the delivery schedule.

q. The contractor shall provide the following Key Personnel. A Primary Project

Manager (PM) and Alternate Project Manager (APM) who shall be the single point of contact for the Contracting Officer and the Contracting Officers Representative.

The name, position, title, experience of these persons shall be stated in writing to the

Contracting Officer prior to contract award. The PM and APM shall be abreast of all support the contractor is currently providing the USCG under this contract, and shall be able to address inquiries from the Contracting Officer and the Contracting

Officers Representative regarding that support. The PM shall be able to read, write, speak and understand English fluently.

r. American Bureau of Shipping (ABS) certification not to this applicable to this specification.

3.2. OVERHAUL/REPAIR ENGINE – When directed by the Contracting Officer, using the applicable MTU Technical Publications and Standards, the contractor shall provide all labor, equipment, special tools, materials, and parts to receive, inspect, overhaul, test, preserve, paint, package, and provide warranty for the engine and components listed in

MTU Maintenance Schedule MA50075. All 12,000-hour maintenance tasks shall be accomplished. The contractor shall incorporate, at no cost to the Coast Guard, all applicable MTU engine service bulletin modifications. The contractor shall complete these requirements in accordance with the referenced delivery order.

a. The contractor shall receive a non-ready for issue engine, NSN 2815-12-392-7931, document the as-received condition and submit appendix A.

b. The contractor shall disassemble engine, inspect, and submit condition found report appendix B. Include cost for any additional work.

c. The contractor shall maintain critical dimensions documentation, as specified in

Instruction for General Overhaul MA25014, and made available to Contracting

Officer or Contracting Officer Representative (COR) upon request.

d. The contractor shall conduct a dynamometer test in accordance with the factory run-in and acceptance test procedure on overhauled engine per appendix C and submit report.

e. The contractor shall preserve the engine IAW MTU Preservation and Re-preservation Specifications A001070. Freeze protection is required IAW, chapter

5.3.2, Storage with unfilled medium circuits. Use internal preservation corrosion inhibitor Glysacorr P133 antifreeze at 50% volume or equivalent. Submit to the

Contracting Officer MTU Check Sheet for Preservation upon preservation completion.

f. The contractor shall paint the overhauled engine with Valspar LIC 50 general purpose polyurethane enamel RAL9010 white following all manufactures surface preparations, mixing ratios, and dry times. Paint shall be sprayed on all surfaces 3-5 mils thick.

g. The contractor shall package the overhauled in IAW Preservation and Re-preservation Specifications A001070, chapter 8.2, Climate-compatible long term storage. Mark overhauled engine IAW section 5.4 of this specification.

h. The contractor shall submit a cumulative tracking report on the 15th of each month with status of all open delivery/task orders appendix

3.3. ENGINE ANALYSIS – 30 days after contract award the contractor shall submit for

Contracting Officer approval their in-depth analysis plan describing the nondestructive testing methodology to ascertain engine wear and appropriateness of the current maintenance schedule. At a minimum the plan shall include the following; indications of operator induced wear (for example low load conditions), indications of maintainer induced wear (for example improper valve lash adjustment), observed wear relative to anticipated wear, and internal corrosive wear. Include in the plan which components to be analyzed, the quantity to be analyzed (for example all injectors, all cylinder liners), the level of testing (for example laboratory testing, comparative, measurements, etc.) to be completed, and how maintenance periodicity appropriateness to be determined. Include in plan estimated duration of the analysis. The analysis shall be conducted on an engine inducted for overhaul.

3.3.1- When directed by the Contracting Officer conduct wear analysis.

3.3.2- Upon completion of analysis the contractor shall deliver to the Contracting Officer, an electronic copy of Report of Engine Wear Analysis. At a minimum the report shall all include; all findings, operator recommendations, maintainer recommendations, and recommend new maintenance schedule based upon analysis findings.

3.4. COMMISSION ENGINE- When directed by the Contracting Officer the contractor shall provide a technical representative for two days to provide start-up commissioning services on the overhauled 20V4000M93L engine(s) aboard a154’ WPC in accordance with MTU specifications. This shall be accomplished at a location designated by the Coast Guard.

The contractor shall submit a Commissioning Report, appendix E. When commissioning services cannot be completed because of an existing shipboard discrepancy, the contractor shall submit a condition found report and a cost estimate to correct discrepancies using rates section 3.5 of this specification.

3.5. TECHNICAL SUPPORT- When directed by the Contacting Officer the contractor shall provide technical support for the 20V4000M93L propulsion system to include; the Engine

Control System (ECS), Machinery Control and Monitoring System (MCMS), and Remote

Control System (RCS) at the location determined by the Coast Guard. This support includes, but is not limited to; phone support, on-site technical assistance to equipment diagnostics, troubleshooting, and repairing equipment faults. All requests for technical support will authorized by the Contracting Officer under a separate task order.

3.6. ROOT CAUSE FAILURE ANALYSIS- In the event of a catastrophic failure of a

20V4000M93L engine the Contracting Officer, on a separate task order,(may) will send the failed engine to the Contractor’s facility to determine the root failure. A report of findings shall be submitted to the Contracting Office thirty (45) days of receipt of the failed engine.

3.7. WARRANTY- The engines are being overhauled as system stock and will be placed into inventory and not for immediate installation. The Contractor shall provide a warranty for a period of one (1) year of operation, following up to two (2) years in storage. Storage commences upon receipt of the component at the designated Coast Guard facility. The warranty commences the date the engine is installed on a 154’ WPC. The warranty shall cover all parts and workmanship defects. The contractor shall contact the 154’ WPC cutter within twenty –four (24) hours after receiving notification by the Coast Guard of a warranty claim.

3.8. TRAVEL- The contractor shall be required to travel to support this statement of work section 3.5 Technical Support. Costs for transportation, lodging, meals, and incidental expenses incurred shall be reimbursed using the current Federal Travel Regulations and not to exceed the maximum per diem and lodging rates for the time/location of performance. See Federal Acquisition Regulation (FAR) 31.205-46 (a)(2).

4.0 QUALITY ASSURANCE

4.1. GENERAL - The Contractor shall maintain an inspection system which shall ensure each item offered to the Coast Guard for acceptance conforms to contract requirements. The system shall be documented and in compliance with ANSI/ASQS Q90003.

4.2. RECORDS - The Contractor shall maintain records of all measurements, inspections, and tests. The records shall indicate the nature and number of observations made, type of deficiencies found and the corrective action taken. Records shall be furnished upon request of Contractors Officers Representative (COR).

4.3. CONTRACTORS CALIBRATION SYSTEM - The Contractor as well as any

Subcontractors shall be required to maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with ANSI/NCSL Z540-3. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to ensure adherence to calibration schedules. Calibration standards shall be traceable to the National

Institute of Standards and Technology (NIST). Documentation in support of this requirement shall be readily available for Contractors Officers Representative (COR) review.

4.4. RESPONSIBILITY FOR INSPECTION - The Contractor shall be responsible for all inspections/test requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all inspection requirements. All testing and inspection shall be at the Contractors facility or other facilities acceptable to the Coast

Guard. The Coast Guard reserves the right to verify or have performed any of the inspection/tests set forth in this specification where such inspections are deemed necessary to ensure that supplies or services conform to the prescribed requirements.

4.5. REQUIRED TESTS - Each component provided under this contract shall be operationally tested when required by MTU procedures.

4.6. TEST REPORT - The Contractor shall submit the final test reports in accordance with this specification.

a. One copy of the test reports shall be packed with each component delivered under this contract.

b. One electronic copy of the test reports shall be provided to the Contracting Officers

Representative (COR).

4.7. PACKING INSPECTION - The Contracting Officer shall be notified after preservation seven (7) days prior to the packaging, and marking of the completed units. The Coast

Guard reserves the right to perform an on-site inspection if deemed necessary.

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. PRESERVATION (Internal) – In accordance with section 3.2(e) of this specification.

5.2. PRESERVATION (External) - In accordance with section 3.2(e) of this specification.

5.3. PACKAGING– Each engine shall be packaged in accordance with MTU Preservation and

Re-preservation Specifications A001070, section 8.2, in climate-compatible long term storage packaging in either a re-usable skid mounted wooden box or steel shipping container (NSN 8150-01-F18-5402). Each container shall be internally braced to and cushioned to prevent movement of the assembly. The container and internal bracing shall be capable of protecting the assembly while in storage and from rough handling during multiple shipments.

a. The Contractor shall place in a plastic envelope in each container, copies of all test and inspection results, caution tags, and coolant flush instructions to be completed prior to light off.

5.4. MARKING – Each preserved, packed, and packaged item shall be stenciled in the upper left-hand side of the two longest sides, (two opposite sides if square) of each box.

a. Machine made stencils shall be used for all marking.

b. All marking shall be in black print on a contrasting back ground (white paint) and at least 2” high.

c. The marking shall be in the format as follows:

NATIONAL STOCK NUMBER 2815-12-379-7231

ITEM NAME ENGINE, DIESEL

PART NUMBER 20V4000M93L

SERIAL NUMBER “As per Enclosed Item”

CONTRACT NUMBER See Contract

DELIVERY ORDER NUMBER As submitted on the Order

SHIPPING WEIGHT As Determined by Contractor

QUANTITY & UNIT OF ISSUE 1- EA

PRESERVED FOR LONG TERM

STORAGE ON Date preserved

CONDITION CODE CONDITION A

OTHER DATA AS COAST GUARD SFLC MATERIAL

DIRECTED REUSABLE CONTAINER,

DO NOT DAMAGE.

DO NOT DESTROY.

d. The following marking shall be placed on all four sides and the top of each box, in stenciled black print at least 2” high.

Reusable Container- Do Not Damage

Remove Bolts Prior To Removing Cover

Use Forklift To Unload Do Not Lift By Cover

5.5. BAR CODING – Bar code labels shall be supplied on all crates.

a. All bar coded labels shall be in accordance with SFLC specification D-000-0100.

b. The actual labels shall be Type “V”, Grade “A”, Style”2”, Composition “b” with plastic laminate.

c. Each label shall contain encoded data for the Stock Number, Delivery Order Number and Contract Number.

6.0 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1. GOVERNMENT DOCUMENTS

a. USCG Surface Forces Logistics Center

707 Ordnance Road

Baltimore, MD 21226

Attn: Technical Information Management Branch

410-762-6471

6.2. COMMERCIAL DOCUMENTS

a. Rolls-Royce Solutions Americas

39525 Mackenzie Drive Novi, MI 48377

248-560-8000 https://www.mtu-solutions.com/eu/en.regionselect.html_

b. International Organization for Standardization

American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

212-642-4900 https://www.mtu-solutions.com/eu/en.regionselect.html_