23001_JLW_87WPB_REVISED_12APR11.docx

23001_JLW_0211_87WPB

Main Diesel Engine Assembly, Port and Stbd, Perform W5 Maintenance

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform a W-5 Overhaul of the port and stbd main diesel engines.

1.2 Government-furnished property.

($/UNIT)

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel, Electronic Systems Support Unit (ESU) or local Electronic Support Detachment (ESD).

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Jan 2009, General Requirements Coast Guard Technical Publication (TP) 4573, Coolant Heating System, 17 March 2003

OTHER REFERENCES

MTU 8V 396 TE.4 Maintenance Manual M020046/21E MTU 8V 396 TE94 Parts Catalog M033971/00DE, Order #771903 MTU V396 TE.4 Tolerances & Wear Limits List M070026/00E MTU Tool List M004021/20DE MTU Exhaust Turbocharger ZR140 M040052/10E MTU Solenoid Actuator, Description, Assembly Instructions M040082/10E MTU Service Information 396-99/0562B Electric Governor Actuator with Oil Drain MTU Fluids and Lubricants Specification A001061/32E MTU Engine management System Typ ECS 396/S Version E & F with ETB 4E/ETB 4F Document numbers; E 531 406/01 E, E 531 405/ 01E & E 531 403/02E MTU Customer Connecting System CCS for ECS 396, E 531 416/00E MTU Customer Connecting System CCS for ECS 396, E 531 415/00EMTU Electrical Start Device SUE-ES for ECS 396, E 531 482/00E MTU Engine Control System Illustrated Parts Catalog E 535 145/01ED MTU Junction Box CCS-ECS 396E Illustrated Parts Catalog E 535 151/01ED MTU Local Operating Panel for ECS E 531 301/01E MTU Local Operating Panel LOP-ECS Illustrated Parts Catalog E 535 297/02ED MTU Electrical Start Equipment SUE-ES Illustrated Parts Catalog E 535 187/00ED MTU Monitoring & Control Unit Documentation E 535 164/00ED Installation of MTU Electronic Systems E 530 606/06E ANSI/NCSL Z540 3 2006.08.03, Requirements for the Calibration of Measuring and Test Equipment.

ANSI/ASQC Q90003-1994, dtd 18 July 94, Inspection System.

3. REQUIREMENTS

3.1 General. The Contractor shall:

3.1.1 Technical Representative Services. For disassembly and repair work, provide an on-site technical representative certified by MTU to the M2 Level and have a minimum of five years MTU experience in marine use over the last ten years. The Technical Representative must have successfully completed a W5 maintenance procedure on an MTU 8V396TE94 engine within the last three years. The technical representative shall advise on manufacturer's information, dimensions, and clearances associated with the system, conduct proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, and reassembly of the marine propulsion diesel engine.

3.1.1.1 For dock and sea trials, provide an on-site qualified technical representative certified by MTU to the E3 Level.

3.1.1.2 Provide & legally possess a certified, current, and authorized MTU software key (Dongle).

3.1.2 Interferences. Be aware that interferences in way of work may include, but are not limited to the following:

· Piping

· Valves

· Electrical Wiring

· Insulation

3.1.3 Labor. Provide all necessary labor to perform disassembly, reassembly, and any other required repairs associated with this contract.

3.1.4 Training. Allow Coast Guard personnel to observe all diagnostic and repair tasks; advise ship’s force on proper operation and maintenance of the equipment in the normal course of performing disassembly, reassembly, and repairs. Coast Guard personnel may be allowed to perform minor tasks, at the discretion of the Contractor, if those tasks will assist in training and in no way compromise schedule. Coast Guard personnel shall NOT be utilized to complete contract obligations; the Contractor shall supply adequate labor to complete the contract within the performance period without Coast Guard supplied labor.

3.1.5 Reports. All reports shall be forwarded to the Port Engineer (COTR), KO, and copied to 87 PDM Section Chief.

3.2 Maintenance, overhaul and repair work. The Contractor shall perform the following on each:

3.2.1 W5 Maintenance. Perform an in place MTU 8V396TE94 Maintenance Operation W5, in accordance with the references listed beneath Section 2 above. Submit Condition Found Reports (CFRs)for all inspections.

3.2.2 Non-Government-furnished part and component renewal. Renew all gaskets, seals, o-rings and fasteners disturbed during the performance of disassembly and reassembly. Renew all other components required by the MTU 8V396TE94 Maintenance Operation W5. Furnish all required components not identified as Government-furnished Property (GFP). The contractor shall use only MTU certified components; The use of aftermarket non-certified components is not permitted.

3.2.3 Government-furnished part and component renewal. Renew the following components using Government-furnished property.

· “A” Bank Turbocharger

· “B” Bank Turbocharger

· Cylinder Heads

· Jacket Water Pump

· Sea Water Pump

· Starter Motor

3.2.4 Clean and Inspect Components. Remove, clean, inspect, and reinstall the following components. Submit CFR for all inspections.

· Sequential Turbo Charging Actuator

· Sequential Turbo Charger Mechanism

· Lube Oil Cooler

· Intercooler Plate Cooler

· Charge Air Manifold

3.2.4.1 Clean and inspect the Cylinder Liners in place, without removal. Renew components using Government-furnished property if a Change Request is released by the KO.

3.2.4.2 If during the course of conducting the W5 maintenance the contractor discovers any damaged parts or parts worn beyond specification , the contractor shall submit a Condition Found Report (CFR) to the COTR & Contracting Officer for approval. The CFR shall include the price of any parts that cannot be furnished by the Government as well as the estimated labor cost to correct the discrepancy.

3.3 Quality Assurance. The Contractor shall maintain an inspection system, which shall ensure each item offered to the Government for acceptance conforms to contract requirements. The system shall be documented and in compliance with ANSI/ASQS Q90003.

3.3.1 Records. The Contractor shall maintain records of all 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.

3.3.2 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 Government review.

3.3.3 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. Testing and inspection shall be at the Contractors facility or other facilities acceptable to the Government. The Government 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.

3.3.4 Reports. All reports shall be forwarded to the Port Engineer (COTR), KO, and copied to 87 PDM Section Chief.

3.4 Dock and sea trials. Under the supervision of the COTR, the Contractor shall commission the engine and conduct dock and sea trials utilizing the Diagnostic System (DIASYS) to ensure proper operation of the marine propulsion diesel engines, in accordance with Std Spec 0000_STD. The contractor shall demonstrate for the CG Inspector or COTR that all engine parameters are within the correct range and the engine is operating properly. Submit CFR detailing all sea trial test results.

4. NOTES

4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all tests.