Turbo_Overhaul_Spec_R-251-0120_(2).doc

USCG – SFLC

DATE – 06/1992

R-251-120

REVISION H 06/2008

Change 1 11/2009

REVISION NO. I . CHANGE NO. ___1_____.

OVERHAUL SPECIFICATION FOR ALCO TURBOCHARGERS

USED ON 210 AND 270 FT WMEC COAST GUARD VESSELS

R-251-0120 ORIGINATED BY Steve Hardsock . DATE 06/1992 .

ORIGINATOR’S COMMAND Surface Forces Logistics Center .

DEPARTMENT/DIVISION Long Range Enforcer Product Line .

UPDATED BY S.R. Twomey (Revision I) DATE 12//2014 .

OVERHAUL SPECIFICATION FOR ALCO TURBOCHARGERS

USED ON 210 AND 270 FT WMEC COAST GUARD VESSELS

1.0. SCOPE

1.1. This document sets forth the requirements for the receipt, disassembly, inspection, condition/test reports, overhaul, reassembly, testing, preservation, packaging, packing and marking of Globe/Alco Turbochargers used on U.S. Coast Guard 251 Series BF Goodrich/Alco Diesel Engines.

1.2. GOVERNMENT FURNISHED PROPERTY (GFP) - The listed items are managed by the Coast Guard Engineering Logistics Center, Curtis Bay Md.

a. Turbocharger Model 131, P/N 22602171-2, Stock Number: 2950-01-233-3468

b. Turbocharger Model 165, P/N 22602128-2, Stock Number: 2950-01-118-7979

c. Turbocharger Model 720, P/N 22600172-4, Stock Number: 2990-01-363-1644

2.0. APPLICABLE DOCUMENTS

2.1. GENERAL – The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to insure the completeness of this list, document users are cautioned that they must meet all specified requirements of the documents cited in section 3, 4, or 5 of this specification, whether or not they are listed here.

2.2. GOVERNMENT AND COMMERCIAL DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the Department of Defense Single Stock Point of Specification and Standards (DODSSP) and supplements thereto.

2.2.1. Federal

a. TT-P-28H, DATED June 28, 2007, Paint, Aluminum, Heat Resisting.

b. FED-STD-595B CHANGE NOTICE 1, DATED January, 11, 1994, FED-STD-STD 595B DATED December 15, 1989, Colors Used in Government Procurement.

2.2.2. Military

a. ASTM D7478/D7478M, Standard Specification for Heavy Duty Sheathed Wood Crates

b. MIL-STD-2073-1D CHANGE NOTICE 1, DATED May 10, 2002, MIL-STD-2073-1D DATED December 15, 1999, Standard Practice for Military Packaging.

c. MIL-DTL-15090D DATED November 6, 1996, MIL-E-15090C DATED March 30, 1982, Enamel, Equipment Light Gray (Formula No. 111).

d. MIL-PRF-21260E DATED July 31, 1998 Lubricating Oil, Internal Combustion Engine, Preservative Break-In

e. MIL-PRF-16173E(SH) w/INT. AMENDMENT 1 DATED September 7, 2006 Corrosion Preventive Compound, Solvent Cutback, Cold-Application

2.2.3. NAVSEA Technical Publications - T9074-AS-GIB-010/271, DATED February 16, 1999, Requirements for Nondestructive Testing Methods.

2.2.4. Coast Guard Specifications - United States Coast Guard SFLC Specification D-000-0100 Rev G dated 02/2006, Bar Coding for USCG Surface Forces Logistics Center Procured Material.

2.2.5. BF Goodrich/Alco Inc.

a. Maintenance Manual MI-11206C for Turbocharger Model 131 Dated July 1981

b. Maintenance Manual MI-11209A for Turbocharger Model 165 Dated May 1973

c. Maintenance Manual MI-11210B for Turbocharger Model 720 Dated March 1974

2.2.6. American Society for Quality (ASQ) - ASQ Q9001-2008, DATED 2008, Quality Management Systems - Requirements.

2.2.7. National Conference of Standards Laboratories (NCSL) - NCSL Z540.3-2006 DATED 2006, General Requirements for Calibration Laboratories and Measuring and Test Equipment.

2.2.8. Steel Structures Painting Council (SSPC) - SSPC-PAINT 25, DATED May 1, 1997, Editorial Changes November 1, 2004, Zinc Oxide, Alkyd, Linseed Oil Primer for Use Over Hand Cleaned Steel (Without Lead and Chromate Pigments-Red Iron Oxide).

2.2.9. American Society for Testing Materials International (ASTM) – ASTM D7478/D7478M DATED 01 October 2008, Standard Specification for Heavy Duty Sheathed Wood Crates.

2.3. SPECIFICATION ORDER OF PRECEDENCE - In the event of a conflict between this specification and the references cited herein, this specification shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

2.4. DOCUMENT AVAILABILITY – To obtain the referenced documents see section 6.1.

3.0. REQUIREMENTS

3.1. GENERAL – Inspections, repair/overhaul and testing of each turbocharger shall be accomplished in accordance with all applicable documents listed in section 2.0 of this specification.

3.2. GOVERNMENT FURNISHED PROPERTY (GFP) - The Contractor shall provide protective storage for the GFP when not in use, and safe handling when in use.

3.2.1. The storage area shall at a minimum be closed on all sides, dry, and locked when the equipment is not in use.

3.3. ARRIVAL INSPECTION/DISASSEMBLY INSPECTION - Each turbocharger received by the Contractor shall be disassembled and inspected. A detailed report shall be completed and submitted to the Contracting Officer to include the following information:

3.3.1. No further work shall be accomplished until the report is approved by the Contracting Officer.

a. Date of inspection.

b. Inspectors name.

c. Identification of units by serial number, part number, and stock number.

d. Condition of the shipping crate and any cost of repair.

e. List Mandatory parts as priced in the contract as one line and a total price (Appendix A through C).

f. List of contingency parts by part number & CLIN, and their applicable prices (Appendix D through F).

g. Cost of overhaul labor as applicable.

h. Comments if any pertaining to unusual observations during inspection & disassembly.

i. Dimensional inspection of bearing bores, rotor shaft journal areas, seal areas, disc fit and impeller fit areas using clearance table in Appendix G through L as applicable.

j. A list of defective or worn parts recommended for repair/refurbishment vice replacement and the associated cost to accomplish.

k. If not previously condemned, each rotor disk, impeller, inducer, and gas inlet of each turbocharger shall be dye penetrant tested in accordance with NAVSEA T9074-AS-GIB-010/271 and the results provided in the initial report with discrepancies highlighted.

3.4. OVERHAULS – Each turbocharger shall be overhauled in accordance with the documents cited in section 2.0 and appendices G through L as applicable.

3.4.1. Replacement Parts - All replacement parts shall be new and manufactured in accordance with Globe/Alco specifications and standards, the Original Equipment Manufacturer (OEM).

a. Repair of Parts - Defective or worn parts may be repaired/refurbished if the Contractor deems it more economical than replacement. The performance and function of the repaired parts shall be equal to that of a new part. A listing of all parts recommended for repair shall be part of the Arrival Inspection as required in section 3.3 of this specification.

3.4.2. Mandatory Repairs – the following shall be accomplished on each turbocharger inducted for repair/overhaul.

a. Cleaning/repairing of all bolt holes

b. Rotor Balancing

c. Installation of Mandatory Replacement Parts

d. Cleaning and Painting (see section 3.6)

3.5. MANDATORY REPLACEMENT PARTS

3.5.1. Model 131 as per Appendix A.

3.5.2. Model 165 as per Appendix B.

3.5.3. Model 720 as per Appendix C.

3.6. SURFACE CLEANING & PAINTING

3.6.1. Cleaning

a. All scale and paint shall be removed.

b. All surfaces shall be solvent cleaned of all grease and oil.

3.6.2. Painting

a. These items shall be masked or plugged and not painted:

1. Oil inlet and drain openings

2. Hoses, hose connections or openings

3. Identification plate

4. Air inlet and discharge openings and flanges, exhaust inlet and discharge openings and flanges.

5. Water inlet and discharge openings

6. Any other openings that will permit foreign material to enter the turbocharger

b. All external areas not exposed to temperature that normally exceeds 300 degrees F., while turbocharger is in operation, shall be coated as follows:

1. One coat, 2-3 mils thickness with Primer in accordance with SSPC-PAINT 25.

2. Two coats, at least 2 mils thick total, of high gloss Equipment Enamel, MIL-E-15090C, Formula 111, Type I, Class 1, light gray, Color No. 16492 per Federal Standard 595C.

c. All external surfaces normally exposed to temperatures that exceeds 300 degree F. shall be painted with 2 coats, 2 mils total thickness of Heat-Resistant Aluminum Paint, Federal Specification TT-P-28G.

d. When all paint is dry, the masking shall be removed.

3.7. REASSEMBLY REPORT/TEST REPORT - The Contractor shall submit a Reassembly Report/Test Report to the Contracting Officer for approval.

3.7.1. The Reassembly Report/Test Report shall include all inspections and tests specified herein and all other inspections and tests needed to verify conformance to the requirements.

3.7.2. The Reassembly Report/Test Report shall include (unless otherwise noted), but not be limited to:

a. Time and date of test or inspection.

b. A chronological listing of the tests and inspections performed.

c. Step-by-step inspection procedures for the assembly and pass/fail criteria.

d. Assembly dimensions, tolerances, thrust, adjustments, torque specs, and balance records observed, and all deficiencies found and the corrective action taken. Any deficiencies noted shall be highlighted.

e. A complete listing of all measuring test equipment (MTE) used with MTE serial numbers.

f. Dimensional inspection report with tolerances. Any deficiencies noted shall be highlighted.

g. Rotor assembly balance record, with tolerances.

1. The rotor assemblies shall be spun-balanced at the OEM recommended RPM.

2. The rate of unbalance for each model of Turbocharger shall not exceed the following Specified amounts.

a Model 131 - 0.02 in. oz.

b Model 165 - 0.02 in. oz.

c Model 720 – 0.05 in. oz.

h. Date and signatures of test or inspection personnel.

i. Signature of Government witness, if any.

3.8. NOTIFICATIONS & INSPECTIONS - The Contractor shall notify the Contracting Officer a minimum of ten (10) calendar days prior to any inspections or testing required herein.

4.0. QUALITY ASSURANCE

4.1. RESPONSIBILITY FOR INSPECTION - The Contractor is responsible for the performance of all inspection requirements as specified herein. The Contractor may use his own or any other facilities for the performance of the inspections and tests, unless disapproved by the Coast Guard. The Government reserves the right to perform or witness any of the inspections and tests set forth in this specification at any time.

4.2. RESPONSIBILITY FOR COMPLIANCE - All items shall meet the requirements of this specification. The inspections set forth in this specification shall become part of the Contractor's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.3. QUALITY PROGRAM - The Contractor shall maintain a documented Quality Control (QC) Program conforming to ANSI/ASQ Q9003-1994. A copy of this program shall be submitted to the Contracting Officer for approval within 15 calendar days after contract award.

4.4. INSPECTIONS - The inspections required herein are the minimum required and are not intended to replace any controls, examinations, inspections or tests normally employed by the Contractor to assure the quality of the equipment. The following are required and will be monitored by a Government Quality Assurance Representative.

4.4.1. Rotor balancing inspection in accordance with section 3.7.2.g of this specification.

4.4.2. Preservation, packing, and marking in accordance with section 5.0 of this specification.

4.5. CALIBRATION SYSTEM - The Contractor shall maintain a test equipment calibration program conforming to ANSI/NCSL Z540.3-2006. The Contractor shall have a copy of the calibration program readily available during the term of this contract for review by any Coast Guard personnel upon request.

4.6. NONCOMPLIANCE - Shall mean any single failure of any individual part or subsystem during inspection or testing.

4.6.1. The Contractor shall replace the failed part with new, and continue testing.

4.6.2. If, during assembly any noises, rubbing, or grinding are heard or felt indicating potential problems the entire test procedure shall be repeated after replacement of the failed part(s).

4.6.3. Any flaws detected in materials or construction methods which reduces the usefulness of the turbochargers to the Coast Guard shall be resolved before completing any further work.

4.6.4. Any unusual noises or other non-compliances, as determined by the Coast Guard Inspector, will require re-testing and shall be cause for failure.

4.7. TEST AND INSPECTION REPORTS - One copy of any inspection or test report approved for use from submittal shall be sent to the Contracting Officer for approval. A copy shall also be given to the Coast Guard Quality Assurance Representative upon his arrival at the Contractor's facility.

4.8. RECORDS - The Contractor shall maintain records by serial number of all inspections and tests.

4.8.1. The records shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.8.2. Copies of all records shall be maintained for Coast Guard inspection at any time during the duration of any Contract referencing this specification.

4.9. DISCARDED PARTS - All parts scrapped by the Contractor shall be saved until rendered scrap by a Coast Guard representative.

4.10. PACKING INSPECTION – The Contractor shall notify the Contracting Officer a minimum of ten (10) calendar days prior to the scheduled preservation, packing, and marking of the completed units.

5.0. PRESERVATION, PACKING, & MARKING

5.1. PRESERVATION

5.1.1. INTERNAL:

a. Internal oil passages and bearings shall be spray/fogged and drained with Code 10, Grade 30 preservative as specified by MIL-STD-2073-1D APPENDIX J, TABLE J.III.

b. Internal water passages shall be spray/fogged and drained with Grade 3 preservative as specified by MIL-PRF-16173E(SH).

5.1.2. EXTERNAL: Unpainted surfaces shall be coated with Code 19, Grade 4, corrosion preventative as specified by MIL-STD-2073-1D APPENDIX J, TABLE J.III.

a. All fittings or openings that would allow foreign material to enter the unit shall be plugged or capped.

1. VPI paper shall be placed between the flanges and the bolted on cap.

5.2. PACKING - Each turbocharger shall be individually crated in accordance with ASTM D7478/D7478M, Class 2, Style A.

5.2.1. Top, side and end panels shall be fabricated and assembled (screwed vice nailed) to each other as specified for Type I, and the combination fastened (bolted) to skid as specified for Type II.

5.2.2. Each turbocharger shall be supplied with a gasket installation kit to facilitate installation using the correct gaskets and seals. This kit shall be made part of the package. The contents shall be in a plastic bag and placed in a cardboard and clearly marked “installation gasket kit”.

5.3. MARKING - Each preserved and packed turbocharger shall be marked in the upper left-hand side of the two longest sides, (two opposite sides if square).

5.3.1. The markings shall be made with machine-made stencils; the lettering / numbering shall be 1” high, in permanent black printed characters on a highly contrasting “painted” background.

a. All previous markings and labels shall be completely removed from the reusable shipping container prior to the applications of any new markings.

5.3.2. Bar Coding – A Bar Code label shall be attached to each turbocharger shipping container prior to shipment from the Contractor’s facility.

a. All bar coded labels shall be in accordance with SFLC specification D-000-100.

1. The actual label shall be Type "V", Grade "2", Style "2", Composition "b" with plastic laminate.

2. Each label shall contain encoded data for the Stock Number.

a The marking required in 5.3 can be applied separately or as part of the Bar Code Label.

5.3.3. The marking shall consist of the following:

Marking layout for Model 131

STOCK NUMBER

2950-01-233-3468

ITEM NAME

Turbocharger

MODEL NUMBER

PART NUMBER

22602171-2

SERIAL NUMBER

"As per Enclosed Item"

CONTRACT NUMBER

See Contract Page 1

DELIVERY ORDER NUMBER

for example: 01-0001

SHIPPING DATE

"The Delivery Date to SFLC"

WARRANTY EXPIRATION DATE

As Determined by Contractor

SHIPPING WEIGHT

As Determined by Contractor

QUANTITY & UNIT OF ISSUE

1- EA

CONDITION CODE “A”

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER, DO NOT DESTROY,

REMOVE BOLTS, LIFT CRATE FROM SKID.

Marking layout for Model 165

STOCK NUMBER

2950-01-118-7979

ITEM NAME

Turbocharger

MODEL NUMBER

PART NUMBER

22602128-2

SERIAL NUMBER

"As per Enclosed Item"

CONTRACT NUMBER

See Contract Page 1

DELIVERY ORDER NUMBER

for example: 01-0002

SHIPPING DATE

"The delivery date to SFLC" WARRANTY EXPIRATION DATE As Determined by Contractor

SHIPPING WEIGHT

As Determined by Contractor

QUANTITY & UNIT OF ISSUE

1- EA

CONDITION CODE “A”

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER, DO NOT DESTROY,

REMOVE BOLTS, LIFT CRATE FROM SKID.

Marking layout for Model 720

STOCK NUMBER

2990-01-363-1644

ITEM NAME

Turbocharger

MODEL NUMBER

PART NUMBER

22600172-4

SERIAL NUMBER

"As per Enclosed Item"

CONTRACT NUMBER

See Contract Page 1

DELIVERY ORDER NUMBER

for example: 01-0002

SHIPPING DATE

"The delivery date to SFLC" WARRANTY EXPIRATION DATE As Determined by Contractor

SHIPPING WEIGHT

As Determined by Contractor

QUANTITY & UNIT OF ISSUE

1- EA

CONDITION CODE “A”

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER, DO NOT DESTROY,

REMOVE BOLTS, LIFT CRATE FROM SKID.

6.0. NOTES

6.1. GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1. GOVERNMENT DOCUMENTS

a. Department of Defense Single Stock Point (DODSSP)

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA 19111-5094

215-697-2667/2179

FAX 215-697-1462

b. DOD & Navy Publications & Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2197

c. USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, Md. 21226-5000

6.1.2. COMMERCIAL DOCUMENTS

a. American National Standards Institute (ANSI)

25 West 43rd Street (Between 5th and 6th Avenues) 4th Floor

New York, NY 10036 610-832-9585

FAX 610-832-9555

www.astm.org

b. Society for Protective Coatings

Steel Structures Painting Council (SSPC)

4516 Henry Street, Suite 301

Pittsburgh, Pa. 152-3728

(412) 687-1113

(412) 687-1153

c. ASTM International 100 Barr Harbor Drive P.O. Box C700 West Conshohocken, PA 19428-2959

APPENDIX A

MANDATORY REPLACEMENT PARTS - MODEL 131

Part Number Description Quantity

APPENDIX B

MANDATORY REPLACEMENT PARTS - MODEL 165

Part Number Description Quantity

APPENDIX C

MANDATORY REPLACEMENT PARTS - MODEL 720

Part Number Description Quantity

APPENDIX D

CONTINGENCY REPLACEMENT PARTS - MODEL 131

Part Number Description Quantity

APPENDIX E

CONTINGENCY REPLACEMENT PARTS - MODEL 165

Part Number Description Quantity

APPENDIX F

CONTINGENCY REPLACEMENT PARTS - MODEL 720

Part Number Description Quantity

APPENDIX G

TABLE OF CLEARANCES FOR MODEL 131

REFER TO ILLUSTRATION #1

Measurement Location

33) Not Shown

Note: All diametrical clearances to be equalized radially.

APPENDIX H

MODEL 131 TURBOCHARGER ROTOR ASSEMBLY TABLE OF CLEARANCES

REFER TO ILLUSTRATION #2

1. Thrust Disc

8. Blower End Oil Slinger (screw type)

2. Thrust Collar

9. Shaft

3. Impeller

10. Tablock

4. Inducer

11. Turbine Blade

5. Nose Piece

12. Ferrule

6. Ring Nut

13. Stub Shaft

7. Lockwasher

14. Nut and Cotter Pin

Measurement Location

APPENDIX I

TABLE OF CLEARANCES FOR MODEL 165

REFER TO ILLUSTRATION #3

Measurement Location

Note: All diametrical clearances to be equalized radially.

APPENDIX J

MODEL 165 TURBOCHARGER ROTOR ASSEMBLY TABLE OF CLEARANCES

REFER TO ILLUSTRATION #4

1. Turbine Disc 7. Ring Nut 12. Turbine Blade

2. Shaft 8. Lockwasher 13. Ferrule

3. Thrust Collar 9. Blower End Oil Slinger 14. Stub Shaft

4. Air Impeller Slinger (Screw type) 15. Nut and Cotter Pin

5. Inducer 10. Impeller Insert 16. Key

6. Nose Piece 11. Tablock Measurement Location

APPENDIX K

TABLE OF CLEARANCES FOR MODEL 720

REFER TO ILLUSTRATION #5

Measurement Location

Notes:

1) Item 2 minimum clearance not to be less than 0.030” at any point.

2) Check item 5 and item 9 clearances with rotor in extreme position toward blower end of turbocharger.

3) All diametrical clearances to be equalized radially.

4) Item 16 and 19 maximum clearance at any point to be not less than 0.002” with shaft in slanted position.

APPENDIX L

MODEL 720 TURBOCHARGER ROTOR ASSEMBLY TABLE OF CLEARANCES

REFER TO ILLUSTRATION #6

1. Disc

7. Nut

2. Shaft

8. Lockplate

3. Center Stud

9. Key

4. Air Impeller

10. Thrust Collar

5. Inducer

11. Tablock

6. Nose Piece

12. Disc Blade