HEALY_MDE_Tech_Rep_Specifications_24Sept19.pdf

23303_WFS_1214_420

MDE Technical Representative and Shop Overhaul Services

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to provide the services of a Wartsila Defense Inc. (Wartsila) certified repair facility and technical representative to oversee maintenance of the main diesel engines.

1.2 Government-furnished property (GFP).

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 420-WAGB 801-1, Rev -, Booklet of General Drawings Coast Guard Drawing 420-WAGB 259-001, Rev G, Diagram Combustion Air & Exhaust Gas

System

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 5016, 20-APR-16, S9233-Dh-MMC-010 - Main Diesel

Engine (MDE) (Volume 1) Coast Guard Technical Publication (TP) 5017, 01-JAN-97, S9233-Dh-MMC-020 - Main Diesel

Engine (MDE) (Volume 2) Coast Guard Technical Publication (TP) 5018, 01-JAN-97, S9233-Dh-MMC-030 - Main Diesel

Engine (MDE) (Volume 3) Coast Guard Technical Publication (TP) 5019, 01-JAN-97, S9233-Dh-MMC-040 - Main Diesel

Engine (MDE) (Volume 4) Coast Guard Technical Publication (TP) 5020, 14-JUN-06, S9233-Dh-MMC-050 - Main Diesel

Engine (MDE) (Volume 5, Part 1) Coast Guard Technical Publication (TP) 5020, 14-JUN-06, S9233-Dh-MMC-050 - Main Diesel

Engine (MDE) (Volume 5, Part 2) Coast Guard Technical Publication (TP) 5022, 02-JUN-06, S6265-A4-MMC-010 - Main

Generators, Synchronous Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None.

3. REQUIREMENTS

3.1 General.

3.1.1 The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.1.4 (Inspection report particulars):

3.1.1.1 CIR. The Contractor shall submit a CIR for the inspections listed in the following paragraph:

• 3.6.3 (Disassembly and inspection of turning gear)

• 3.7 (Cam shaft inspection)

3.1.2 Technical Representative. The Contractor shall provide the services of a Wartsila certified Technical Representative (Tech Rep), who is familiar with - the Sulzer 12ZAV40S Diesel Engine, that were manufactured by Wartsila, to accomplish the following tasks – on site:

• Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

• Assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

• Tech Rep shall be present for all disassembly, inspection, reassembly, and testing of the Diesel Engine components.

3.1.2.1 The Contractor shall provide a Tech Rep that is a certified Mechanical Superintendent of Wartsila.

3.1.2.2 The Contractor shall submit the name of the Tech Rep to the COR at the award of the contract.

3.1.2.3 The Contractor shall be required to have this Tech Rep present during the period of performance during normal work hours. Work hours will be Monday through Friday, 0700-1600. Work outside of the normal work hours shall be communicated to the COR.

3.1.3 Protective measures. The Contractor shall take protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3, as applicable, in addition to all other requirements that may be specified in individual work items, to prevent contamination and surface damage of non-affected shipboard equipment, components, and spaces.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000.

3.1.5 Work in this specification item will be performed under the direction of the Mechanical Superintendent and will follow procedures in the manufacturer's technical manual.

3.2 General Information and Scope

3.2.1 The HEALY is equipped with four (4) Sulzer 12ZAV40S main diesel engines (MDEs). Each MDE is attached to a propulsion generator.

3.2.2 The work to be accomplished on each main diesel engine is listed in Table 3.2. The contractor is to supply all parts to complete this work.

TABLE 3.2

MDE NO. 1 (ENGINE SERIAL NUMBER 2025/740386)

Description of Work Amplifying Info Paragraph (below)/Component

Group Number Main Bearing Inspection/Renewal Bearing 1,2 and 7 only 1201-1/A1

Big End Bearings Bearings A4, B4 3302-1/A1

Cam Bearing Inspection Bearings A3, B4 4201-1/A1 Cam Inspection All Camshafts 4101-1/A1, 4201-1/A1 Crank Counterweight Inspection All Counterweights 3101-3/A1 Crankweb Deflection All Cranks 3101-1/A1 Renew Intake Bellows to Turbo (contractor to provide bellows) A and B Bank *See paragraph 3.5 below Remove and realign intake to turbos A and B Bank *See paragraph 3.5.1 below

Remove and Renew Turning Gear Motor Part Number:

KS32701 *See paragraph 3.6.2 below, 3212-1A1

Disassemble/Inspect Turning Gear Box Part Number:

KS32100 *See paragraph 3.6.3 below, 3212-1A1

Pressure Test Nozzles All Nozzles 2722-1/A1 Valve Lash Adjustment All Valves 4401-1/A1

MDE NO. 2 (ENGINE SERIAL NUMBER 2026/740387)

Description of Work Amplifying Info Tech Pub Reference

Main Bearing Inspection/Renewal Bearings 1,2 and 7 1201-1/A1 Big End Bearings Bearings A1, B1 3302-1/A1

Cam Bearing Inspection Bearings B2,B3,A5 4201-1/A1 Cam Inspection All Camshafts 4101-1/A1, 4201-1/A1 Crank Counterweight Inspection All Counterweights 3101-3/A1 Crankweb Deflection All Cranks 3101-1/A1 Renew Intake Bellows to Turbo (contractor to provide bellows) A and B Bank *See paragraph 3.5 below Remove and realign intake to turbos A and B Bank *See paragraph 3.5.1 below

Remove and Renew Turning Gear Motor Part Number:

KS32701 *See paragraph 3.6.2 below, 3212-1A1

Disassemble/Inspect Turning Gear Box Part Number:

KS32100 *See paragraph 3.6.3 below, 3212-1A1

MDE NO. 3 (ENGINE SERIAL NUMBER 2027/740388)

Main Bearing Inspection/Renewal Bearings 1,2 and 7 only 1201-1/A1

Big End Bearings Bearings A1, B1 3302-1/A1

Cam Bearing Inspection Bearings B1,A3,B4,B5 4201-1/A1

Cam Inspection All Camshafts 4101-1/A1, 4201-1/A1 Crank Counterweight Inspection All Counterweights 3101-3/A1 Crankweb Deflection All Cranks 3101-1/A1 Renew Intake Bellows to Turbo (contractor to provide bellows) A and B Bank *See paragraph 3.5 below Remove and realign intake to turbos A and B Bank *See paragraph 3.5.1 below

Remove and Renew Turning Gear Motor Part Number:

KS32701 *See paragraph 3.6.2 below, 3212-1A1

Disassemble/Inspect Turning Gear Box Part Number:

KS32100 *See paragraph 3.6.3 below, 3212-1A1

MDE NO. 4 (ENGINE SERIAL NUMBER 2028/740389)

Main Bearing Inspection/Renewal Bearings 1,2 and 7 only 1201-1/A1

Big End Bearings Bearings A1, B1 3302-1/A1

Cam Bearing Inspection Bearings A3,A5,B4 4201-1/A1 Cam Inspection All Camshafts 4101-1/A1, 4201-1/A1 Crank Counterweight Inspection All Counterweights 3101-3/A1 Crankweb Deflection All Cranks 3101-1/A1 Renew Intake Bellows to Turbo (contractor to provide bellows) A and B Bank *See paragraph 3.5 below

Remove and realign intake to turbos A and B Bank *See paragraph 3.5.1 below

Remove and Renew Turning Gear Motor Part Number:

KS32701 *See paragraph 3.6.2 below, 3212-1A1

Disassemble/Inspect Turning Gear Box Part Number:

KS32100 *See paragraph 3.6.3 below, 3212-1A1

Pressure Test Nozzles All Nozzles 2722-1/A1

Valve Lash Adjustment All Valves 4401-1/A1

3.2.3 Labor to accomplish engine work will be provided by the Coast Guard Naval Engineering Department Seattle, HEALY Port Engineers, and/or Ship’s force. Contractor will provide all labor for ducting and bellows.

3.2.4 All engine work is to be conducted in accordance with Coast Guard Technical Publication (TP) 5018, 01-NOV-03, S9233-Dh-MMC-030 - Main Diesel Engine (MDE) (Volume 3).

3.2.5 Any parts that are being reused shall be installed in the same location from which they were removed.

NOTE

Other contractors and Coast Guard personnel will be conducting maintenance and upgrades to the Machinery Plant Control and Monitoring System (MPCMS) and Engine Exhaust Bellows within the generator rooms.

Coordination with these contractors and the COR will be paramount for a successful completion of all work items.

3.2.6 The contractor shall submit a comprehensive report containing the results of all inspections and work accomplished. Include all measurements taken compared with allowable clearance readings and a written assessment of the bearing and component wear. Include high resolution color photos of each bearing removed and any item presenting unusual wear. One electronic format (CD or DVD) and two color hard copies of the report shall be delivered to the COR within three weeks of completion of sea trials.

3.3 Engine Parts, Gaskets, O-Rings, Etc.

3.3.1 Only class certified or OEM components, whether new or reconditioned, will be accepted.

3.4 General Conditions

3.4.1 Specialized tools listed in the manufacturer's technical instructions, which are required to remove the bearing shells for inspection, are available aboard the vessel.

3.5 Renew Bellows : Constructed Occupational Safety and Health Administration (OSHA) approved scaffolding to work around ducting/bellows on both sides of each engine.

3.5.1 Fabricate and install new bellows on all engines (four engines, 8 bellows). Note existing bellows were modified to compensate for misalignment, fabricate new bellows IAW original design.

3.5.3 Provide all labor, parts, and realign intake ducting on either side of bellows on all for engines (8 total).

3.6 Turning Gear Assembly

3.6.1 Contractor shall provide all required parts and labor.

3.6.2 Contractor shall remove and renew turning gear motors (4 total) with new units.

3.6.3 Contractor shall disassemble and inspect turning gear boxes (4 total) and provide a condition found report (CFR).

3.6.4 Contractor shall reassemble, install, and op-test turning gear boxes.

3.7 Camshaft Inspection

3.7.1 Contractor shall conduct visual inspection of camshafts running surfaces including, but not limited to lobes and drive gear teeth and provide CFR.

3.7.2 Contractor shall conduct cam gear backlash and axial thrust clearance and provide CFR.

3.8 Acceptance Testing

3.8.1 Test Performance. All acceptance tests shall be performed in the presence of the Coast Guard Inspector. Provide a written report to the Coast Guard Inspector of all test results within one week of test completion.

3.8.2 Operational Test. Upon completion of maintenance work the contractor shall submit a testing schedule to the COR, for approval, within five (5) days. The engine shall be tested in accordance with OEM technical publications. The Tech Rep shall provide an operational test guidance detailing the steps necessary to safely and adequately test the MDE’s proving the completion of repairs.

3.8.2.1 Dock Side Testing. Shall occur per the agreed to testing schedule over four (4) days. Start the applicable MDE in accordance with Cutter's Operating Procedures and test run the engine. Check all piping system joints for tightness and correct, as required. During the operational test, record all engine and generator parameters on a log sheet. If any unusual readings are experienced, immediately secure the engine and troubleshoot to determine the cause. Any unusual operating conditions caused by work on this item shall be corrected by the Contractor. Machinery will be operated by the Coast Guard.

3.8.3 Restore all systems and clear tags in accordance with the SFLC Standard Specification 0000 - General Requirements.

3.8.4 Conduct a joint safety inspection with the COR. Ensure that all interferences are restored before commencing engine testing. Any interference that needs to be left un-restored before engine testing begins shall only be done with the approval of the COR.

3.8.5 Ensure a member of the ship’s force, as designated by the COR, is standing by the emergency shutdown while conducting any engine light-off and shut downs.

3.8.6 Post Engine Installation and Adjustments. All systems shall be operated by the Coast Guard, and all testing, and adjusting shall be performed by the Coast Guard in accordance with applicable technical publications and technical representative operational guidance.

NOTE

The ship's electrical load may not be able to supply the required electrical loads. In this case, the engine will be operated up to the electrical load available.

3.8.8 Final Acceptance – The Coast Guard will accept the engine repairs as complete when these specifications are complete and when the one (1) hour load test is satisfactorily completed with the engine operating within the OEM parameters and when the signature analysis shows no discrepancies. If full load cannot be obtained due to insufficient electrical load requirements, the engine will be accepted based on testing with the available electrical load.

4. NOTES

This section is not applicable to this work item.

MDE Technical Representative and Shop Overhaul Services