No._3_SSDG_Engine_Overhaul_Specification_Rev_1__Nov_9.pdf

NOAA SHIP NANCY FOSTER

(R-352)

Service Order 9 November 2016

MED/TBL

NO. 3 SHIP SERVICE DIESEL GENERATOR MAJOR OVERHAUL (CASREP NF 2016-17)

l.0 ABSTRACT

1.1 This item describes major overhauls for the No. 3 ship service diesel generator engine on the NOAA Ship NANCY FOSTER. Period of performance will be 3 January to 14 February 2017, at FLETC, North Charleston, SC.

2.0 REFERENCES:

2.1 NOAA Standard Specification AMC-000-3C, "General Requirements for

Small Contract Ship Repairs"

2.2 Technical Manual NF233-04, SS & Emergency Diesel Generators

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location: Engine Room

3.2 Engine Description:

Quantity: One (1) each.

Model: Cummins VTA 28G1 Engine Numbers: 25167103

Generator Description:

Quantity: One (1) Rating: 395 KW MFR: Cummins

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Material: None.

5.0 NOTES:

5.2 The Contractor shall comply with all requirements of the vessel’s equipment tag out program prior starting work.

5.3 Prior to the start of work, the Contractor shall contact the Chief

Engineer to coordinate the implementation of the Tag-Out Program for the entire performance period of this item. The Prime Contractor shall be responsible for compliance by both prime and subcontractor personnel.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 All work shall be performed by an authorized repair facility of the engine manufacturer or under the direct on-site supervision of a factory-trained mechanic currently certified by the engine manufacturer, and shall be performed in such a manner that the manufacturer's warranty on parts and labor is not voided.

7.0 STATEMENT OF WORK REQUIRED

7.1 Provide all labor, material, equipment, tools, staging, shop facilities, rigging, transportation, required to accomplish work in this item. Except as otherwise specified, the contractor shall provide all labor, material, services, tools, supervision, Service Order 9 November 2016 manuals, and technical expertise needed to accomplish the work required by this specification within the specified time limits.

Unless otherwise specified, the contractor shall provide a copy of the applicable manuals, amendments, and service manuals at the job site. All repairs shall be made according to the manufacturer’s engine specifications, clearances, tolerances, and procedures.

7.2 A crane will be available with prior notice to load and unload parts to/from the pier to the main deck only.

7.3 All work shall be performed by an factory authorized repair facility of the engine manufacturer or under the direct on-site supervision of a factory authorized technician. All such work shall be performed in accordance with References 2.1 through 2.2 and all applicable Cummins service, maintenance, and overhaul technical manuals (including all current and applicable amendments and service bulletins).

7.3.1 The contractor will not be allowed to store engine parts or interferences on board the ship. The contractor shall provide temporary storage (shipping container or other portable storage type unit) for these items. This storage unit may be placed on the pier adjacent to the vessel.

Coordinate exact location with the port engineer. The stowage shall provide protection from the weather.

7.4 All engine and generator mounted components that are required for removal as interferences to accomplish work in this specification are to be removed and/or reinstalled by the contractor with new gaskets, seals, sealants, etc.

7.5 The Government will drain the engines of lube oil and jacket water prior to commencement of work. Lube oil will be drained to the waste oil tank.

7.6 The Contractor shall disassemble the generator engine and components in their entirety for cleaning, inspection, and overhaul.

7.7 Thoroughly clean and conduct a thorough visual inspection of all disassembled parts for cracks, scoring, chipping, pitting, signs of overheating, excessive wear, signs of distress, and other defects which could affect serviceability of the engine.

7.8 After inspections and measurements, submit a typed report of all inspection findings and a record of all measurements and readings taken, to the Contracting Officer's Representative (COR). Include in the report recommendations for any additional repairs, inspections, tests, and part renewals not already covered by this specification that are needed to insure continued reliable service of the engine. Do not proceed with any additional (not covered by scope of previously required work) repairs, inspections, tests, part renewal, or reassembly until authorized by the Contracting Officer.

7.9 After submittal of report, provide for an inspection of all engine components by NOAA and ABS Personnel. Provide 48 hours notice for

Service Order 9 November 2016 the inspection.

7.10 Renew all of the following "mandatory-renewal" parts and components in the proper quantities for the engine specified. If "rebuilt" is provided for any replacement component, an OEM certified rebuilt component in lieu of a new component shall be provided. In addition to the general components listed below, the Contractor shall furnish compounds and sealants as required in performance of the overhaul.

a. All Seals, "O"-rings, and gaskets of all removed and dissembled components and parts.

b. All Bearings and bushings. To include but not limited to crankshaft bearings, connecting rod bearings, and accessory drives bearings, and camshaft bearings.

c. Cylinder Kits, to include liners, pistons, connecting rods, piston rings, piston pins, retainers, and associated parts.

d. Cylinder Head Assemblies, to include all valves, seats, guides, springs, retainers, rocker arms, push rods, etc. to provide a complete operational head assembly.

*Utilize upgraded copper seats for water passages upon installation of heads onto the engine.

*Also to include new cylinder head bolts.

e. Lube oil, Mobil Delvac 15W40 motor oil, approximately 24 gallons each engine.

f. Hoses and belts

g. Thermostats and water temperature regulators

h. Coolant. Shellzone Dex-Cool Extended Life Coolant/Antifreeze mixed to 50% coolant and 50% water mixture for total engine cooling system capacity of approximately 35 gallons each engine.

i. Fuel, Water, and Lube Oil Filter elements. Use Fleetguard

Part No. WF2073 to provide initial cooling system pre-charge of 16 units DCA4 upon startup.

j. Crank Shaft Seals

k. Air starters

l. Fuel injectors

m. Fuel pumps to include shutoff solenoid valve and coil. Valve has ¼” NPT pipe connections and 24VDC solenoid.

n. Fresh water pumps, to include new tensioner device assemblies. Turn over existing tensioner devices to ship’s force.

o. Sea water pumps - Note that these engines have been modified

Service Order 9 November 2016 from the original pump to new pumps. The new pumps are Jabsco Model number 18370-0000. Turn over existing pumps to ship’s force.

p. Lube oil pumps

q. Turbochargers - to include new clamps.

r. Governor Actuator and fuel rack linkages. Existing actuators are Woodward model number 8409999990.

s. Piston Cooling Oil spray nozzles and screws.

t. Gear Drive components, to include all gears, bearings, stub shafts, and retaining bolts. Also to include but not limited to accessory drive assemblies for raw water pump and for governor actuator/fuel pump drive assembly.

u. Camshafts, cam followers, washers, and associated bushings/bearings.

v. Lube oil pressure switches.

w. Jacket water temperature switch.

x. Oil Pump assembly

y. L/B and R/B camshaft, bearings, sleeves and installation components.

z. Any component not listed that is required for the level of overhaul. This does not include components identified during inspections in paragraph 7.7 slated for re-use.

7.11 Completely disassemble, clean, visually inspect and test as indicated in the OEM shop manual for V28 engines. Reassemble with new seals/gaskets, and calibrate the following components, parts, and subassemblies:

a. Cylinder block. Inspect dimensionally and inspect for wear, fatigue, cracks.

b. Manifolds, to include oil filter manifold, water filter manifolds, exhaust manifolds, intake manifolds. Accomplish dye penetrant test on the exhaust manifold welds as applicable.

c. Lube Oil Coolers. Accomplish hydrostatic test to 125% operational pressure.

d. After Coolers. Accomplish hydrostatic test to 125% operational pressure.

e. Dampeners.

f. Oil Pump assembly

Service Order 9 November 2016

g. Other components to the extent required to perform the required inspections, tests, and repairs, and to the extent required to renew parts and components.

7.12 Conduct the following inspections of the crankshaft journals.

a. Magnetic Particle Inspection to include both Head Shot and

Coil Shot Methods, and then demagnification when complete.

b. Measure for straightness per (01-15) of V28 Shop Manual.

7.13 After all reports have been accepted and all additional work has been completed, reassemble and reinstall all components that were previously disassembled or removed in accordance with the manufacturer’s instructions. Perform all tests and measurements required for freedom of movement, backlash, clearances, etc.

7.14 Accomplish tune up of engine to factory specifications (adjusting valves and injectors).

7.15 Tests. Conduct the following tests of the engine after all components have been reassembled.

a. Test all alarm and shutdown systems prior to starting the engine. To include but not limited to high jacket water temperature, low lube oil pressure, and over speed.

b. Monitor engine operations as the ship's engineers start the engine. Check all joints for leaks.

c. Provide the services of a marine controls contractor to calibrate the control system for proper load sharing and performance. The controls contractor is to accomplish an initial calibration pier side after the overhaul and then a final calibration during sea trials. A possible marine controls contractor is Intelligent Systems Automation, POC:

David Montgomery, PH: 843-747-8446.

d. Accomplish pier side operational testing with ship’s personnel to simulate the following operational conditions:

Operate No. 3 SSDG for 4 hours under the following load conditions; hour 1 at 25% load, hour 2 at 50% load, hour 3 at 75% load, and the last hour at 90% load. Ship force will provide the necessary loading from ship’s systems to achieve the designated load conditions. Please note some may not be possible due to the vessel status and will be tested at sea as part of paragraph 7.15.f.

e. Monitor and record the following readings every 20 minutes during testing: oil PSI, oil temperature, fuel oil psi, fresh water psi, fresh water temperature, exhaust gas temperature, crankcase pressure, KW, Amps, Volts, frequency and generator bearing temp. Observe engine for visible leaks of liquids or gases.

• Any deficiency will be noted

Service Order 9 November 2016

• All deficiencies will be corrected by the Contractor.

Timing for correction will be determined by severity and vessel schedule.

f. Provide personnel to ride the ship for a 10 hour sea trial during which each engine will be loaded as much as possible and the generator controls will be adjusted for proper load sharing. Paragraph 7.14.e loading will be tested. The Sea Trial will occur after 6 March 2017. Exact date will be provided after work is completed. Vessel is in a restricted repair period and the exact date for the sea trial cannot be given.

END OF SPECIFICATION