MTU 20V4000M93L QL4 with_analysis 20191211.pdf

REVISION No. 0 CHANGE No.

MTU 20V4000M93L QL4 OVERHAUL AND ANALYSIS

P-233-2044

ORIGINATED BY Richard Biagiotti DATE 09/2019

ORIGINATOR’S COMMAND SFLC PBPL

DEPARTMENT / DIVISION SFLC-PBPL-AMS1

INTERNAL REVIEWER Patrick Mulrooney DATE 10/2019

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 acquired 12,000 running hours. As required by MTU Maintenance Schedule MA/50075/02E require extended maintenance.

1.2. The specification describes the requirements for commissioning services of a newly installed 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:

ENGINE, DIESEL P/N 20V4000M93L, NSN 2815-12-379-7231

CONTAINER ASSEMBLY, P/N 101PPI1001, NSN 8150-01-F18-5402

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, Rev G, 2/06, 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 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 MA13029/01E

b. MTU 20V4000M93L Operating Instructions MA15071/05E

c. MTU 20V4000M93L Maintenance and Overhaul Manual MA22019/01E, MS68001/02E, MA50075/02E, MA25014/03E, and MA20011/02E

d. MTU 20V4000M93L Spare Parts Manual MA30188/02DE and MA3018/02DE

e. MTU Fluids and Lubricants Specification A001061/36E

f. MTU Preservation and Re-preservation Specifications A001070/00E

g. MTU FRC-B MSC-5 System Documentation S000150/00E

h. MTU 20V4000M93L Automation System Operations Manual EA530020/00E

i. MTU 20V4000M93L Automation System Parts Manual EA535015/02DE

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

Test Equipment.

k. ANSI/ASQC Q90003-1994, Dated 18 July 94, 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 within 1 (one) week in writing 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

Technical Documentation MA50075/02E. All 12,000 operating hour tasks shall be accomplished.

a. The contractor must possess a current MTU dealership agreement authorizing the service of their products.

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 the MTU

20V4000M93L series diesel engine and components listed in this specification.

d. The Contractor shall have access to MTU’s secure File Transfer Protocol (FTP) in order to access project software and calibration files.

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. The contractor is responsible for ensuring their technicians’ qualifications are up to date and are available to the Coast Guard upon request. 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 procedures using MTU control protocol.

i. The Coast Guard reserves the right to witness all testing

j. The dynamometer testing shall be conducted on-site at the contractor’s facility in accordance with MTU procedures to 4,300KW.

k. Upon completion of overhaul the contractor shall provide the Coast Guard an electronic copy of engines configuration data, service bulletins, and technical publications, and birth certificate.

l. The contractor shall provide a quarterly cross reference describing all part number changes to any parts for the 20V4000M93L series engine and electronic control system.

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

n. The contractor shall be capable of simultaneously overhauling engines with a 22 engine per year throughput.

o. The contractor shall conduct a wear analysis on four engines.

p. The contractor is responsible to facilitate the requirements of any sub-contractors

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

r. The contractor shall provide a primary Project Manager (PM) who shall be the single point of contact for the Contracting Officer and the Contracting Officers

Representative. The contractor shall also provide an alternate PM when the primary

PM is unavailable.

3.2. OVERHAUL 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, and package the engine and all components listed in MTU Technical

Documentation MA50075/02E. 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 directed upgrades, enhancements, and campaigns.

The contractor shall complete these requirements in accordance with the attached Delivery

Schedule.

a. The contractor shall receive a non-ready for issue engine, NSN 2815-12-379-7231, and document the as-received condition. Submit appendix A.

b. The contractor shall dissemble engine and submit condition found report. Appendix

B.

c. The contractor shall submit critical dimensions report. Appendix C.

d. The contractor shall conduct an eight hour dynamometer test the overhauled engine and submit report. Appendix D.

e. The contractor shall preserve the engine IAW MTU Initial Factory Preservation

Standard MTV 5073 and packaged in climate-compatible packaging.

f. The contractor shall paint the overhauled engine IAW section 5.2 of this specification.

g. The contractor shall package and mark overhauled engine IAW section 5.3 and 5.4 of this specification.

h. The contractor shall submit a cumulative tracking report. Appendix E.

3.3. ENGINE ANALYSIS – 30 days after contract award the contractor shall submit for approval an in-depth analysis proposal describing the 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, internal corrosive wear. Include in the proposal 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.

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

3.3.2- The contractor shall deliver to the Contracting Officer, in one hard copy and one electronic copy of Report of Engine Wear Analysis. Report shall all include all findings, operator recommendations, maintainer recommendations, and new MTU approved maintenance schedule.

3.4. COMMISSION ENGINE- When directed by the Contracting Officer the contractor shall provide a technical representative seven days after notification to commission the overhauled 20V4000M93L engine(s) aboard a 154’ WPC in accordance with MTU specifications. This shall be accomplished at cutters homeport. The contractor shall submit a Commissioning Report. Appendix F. 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 labor rates IAW 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.

3.5.1 Remote Technical Support- The contractor shall provide remote technical support and diagnostics as requested. When request for technical support is made, the contractor shall provide a live technical representative within one hour to assist the person making the request. This support shall be available 24 hours a day, 7 days a week. This support may consist of phone consultation, fax, or email inquiries.

3.5.2 On-site Technical Support- The contractor shall provide on-site technical support at the location of the cutter. This could be at the cutters home port or at a remote port. This support includes, but is not limited to, on-site technical assistance to CG personnel during their performance of preventive or corrective maintenance, on-site technical assistance to

CG personnel performing equipment diagnostics, troubleshooting, and repairing equipment faults. A request for on-site support will through the Contracting Officer.

3.5.3 Deployment with the cutter- On-site technical support may require the technical representatives(s) to deploy with the cutter. The contractor is responsible for ensuring their employees track their work hours while deployed. The contractor shall bill for the hourly labor rate in for all hours worked while deployed with the cutter. The contractor shall provide an “inactive deployed” labor rate for when their technicians are deployed, but not working on a task. The contractor shall use this labor rate when their technicians are finished the applicable tasks but due to the request of the Coast Guard they must remain deployed on the cutter.

3.6. FAILURE ANALYSIS- In the event of a catastrophic failure and at the discretion of the

Contracting Officer; on a separate task order the failed engine or failed component will be sent to the Contractor’s facility to determine the cause of the casualty. All parts & labor shall be priced separately and shall be negotiated under each task order. A condition found report shall be submitted to the Contracting Officer within thirty (30) days of receipt of the failed parts.

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 six (6) months of operation, following up to one (1) year 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 24 (twenty –four) 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 sections 3.4 Commissioning of engine(s) and 3.5 Technical support (3.4). 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 arrival of the Coast Guard representative.

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 Coast Guard 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 copy of the test reports shall be provided to the Coast Guard representative when present upon final test acceptance.

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) – Each engine shall be internally preserved in accordance with

MTU Preservation and Re-preservation Specifications. Preservation shall provide adequate protection to the assembly during long term storage of at least one year. All openings shall be plugged or blanked.

5.2. PRESERVATION (External) - Each assembly shall be cleaned externally. Each assembly shall be painted to preserve the painted surfaces and to present a new appearance. Paint and color shall be in accordance with the OEM’s original specifications. Electronic control system components shall not be painted.

a. All surfaces shall be cleaned of grease and oil

b. All loose scale and paint shall be removed

c. MTU original OEM white paint shall be sprayed on all surfaces 3-5 mils thick, allow a minimum of seven (7) hours drying for primed surfaces.

d. When all paint is dry, the masking shall be removed including from the component data plate.

e. Coat all unpainted metal surfaces with a light amount of grease, except for hot surfaces.

f. Plug or cap any fittings/flanges or openings.

g. Each component shall be wrapped in water vapor resistant paper when appropriate.

5.3. PACKING – Each engine shall be packaged in accordance with MTU Preservation and Re-preservation Specifications, climate-compatible packaging in 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 for that component.

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: TIMB

410-762-6471

6.2. COMMERCIAL DOCUMENTS

a. MTU North America, INC

13400 Outer Drive West

Detroit, Michigan 48239, USA

313-592-7000 http://www.mtu-online.com

b. International Organization for Standardization

American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

212-642-4900 http://www.mtu-online.com/