BERTHOLF_UPDS_MDE_Repairs_FY13_-_Rev2((b).pdf

USCGC BERTHOLF (WMSL 750)

SPECIFICATION FOR UNPLANNED DOCKSIDE MAIN DESIEL ENGINE (MDE) REPAIRS

FY2013

Developed By: Zachariah B Hennighausen

(Rev-2, 22 August 2013)

USCGC BERTHOLF (WMSL-418) UNPLANNED DOCKSIDE MDE REPAIRS FY2013

ii (Rev-2)

TABLE OF CONTENTS

Revisions Record ...................................................................................................................................................... iii Principal Characteristics ........................................................................................................................................... iv General Requirements .............................................................................................................................................. vi WORK ITEM 1: Open, Inspect, Realign and Test USCGC BERTHOLF Cross Connect Gear Gas Turbine

Input Shaft WORK ITEM 2: Starboard Main Propulsion Diesel Engine Coolant Plate-Core Heat Exchanger, Clean &

Inspect WORK ITEM 3: Main Propulsion Diesel Engine Geislinger Coupling, Clean & Inspect WORK ITEM 4: Main Propulsion Diesel Engine HP and LP Intercoolers Saltwater and Air Sides, Chemical Cleaning & Inspection WORK ITEM 5: MPDE Turbocharger Control, Overhaul WORK ITEM 6: MPDE Exhaust Turbochargers, Renewal & Inspection iii (Rev-2)

REVISIONS RECORD

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

25 Jul 13 0 1, 4, & Gen Reqs

Changes are IAW the discussions between MTU and Renk, 22-24 Jul. Misc changes agreed upon by both parties

22 Aug 13 2 3 Work Item #3 has been changed to a definite work item.

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

iv (Rev-2)

PRINCIPAL CHARACTERISTICS

PC_418_WMSL_0909

418' WMSL

PHYSICAL CHARACTERISTICS

Length Overall 418' 0"

Length between Perpendiculars 390' 0"

Maximum Beam 54' 0"

Beam @ 01 Level 47' 9-1/8"

Depth (01 Level @ side to Baseline) 39' 2-3/4"

01 Deck Camber Foredeck 1/4" in 1'-0"

Minimum Berth Depth 20' 0"

Height of highest projection Approximately 119'

Draft, Design 14.40'

Design Displacement 3925 long tons

HULL CHARACTERISTICS

Hull Material 5086 Aluminum

HSLA-80 Steel

ABS EH 36 Steel

ABS AH 36

Frame Spacing

FWD of FR 9 2' 3"

FR 9 to FR 10 6' 9"

FR 10 to FR 98 4' 1"

FR 98 to FR 99 3'-8" v (Rev-2)

MACHINERY CHARACTERISTICS

Two Diesel Engines MTU 20V, 20-cylinder 9,730 SHP each

One Gas Turbine General Electric LM2500; 29,500 SHP

Type of Propulsion CODAG

Electrical System 24 Volt DC

Two Controllable Pitch Propellers Rolls-Royce 5 blade, 14' 0" diameter; 229 RPM max

Two Reduction Gears RENK

One Cross Connect Gear RENK

ELECTRICAL CHARACTERISTICS

Power Three 1360 kW, 450 V, 60 Hz, 3 Phase, 1800 RPM Caterpillar 3512B diesel engines with Baylor ship service generators

Shore Tie Cable Seven MIL-C-24368/2 (NATO) shore power receptacles, 400 A each

TANK CAPACITIES

Diesel Oil 220,359

Fresh Water 12,454

JP-5 Fuel 35,182 vi (Rev-2)

General Requirements

GENERAL STATEMENT:

This statement of work is to address two needs onboard the USCGC BERTHOLF. The first is the Main Propulsion Diesel Engines have come due for their 8,000 hour maintenance. This maintenance is discussed in detail in Coast Guard Technical Publications listed below. It is required to keep the high performance diesel engines installed on the BERTHOLF operating efficiently and reliably. The second is to correct excessive vibrations that have been occurring on the Cross Connect Gear onboard the CGC BERTHOLF while under power from the Gas Turbine. It covers all actions to be performed by the contractor to open, inspect, realign the turbine input shaft, verify alignment of the high speed pinion shaft, and to test and monitor the Cross Connect Gear for vibrations following the completion of repairs.

The CGC BERTHOLF is equipped with two MTU 20V1163TB63 diesel engines (serial numbers 5840250 and 5840251, RENK CODAG Marine Reduction Gear (serial number 6459550), and General Electric LM2500 MGT.

Period of Performance of Entire Contract: 06 Sep 2013 thru 3 Dec 2013 See below for WI specific performance periods.

PLACE OF PERFORMANCE:

USCGC BERTHOLF (WMSL-750)

Coast Guard Island

Alameda, CA 94601

NOTES:

1. All work performed on the Main Propulsion Diesel Engines (MPDE’s) is to be performed by an Original Equipment Manufacturer Factory Certified Field Service Technician. Contractor is responsible for providing the Contracting Officer (KO) with proof of certification before the start of the contract.

2. All work performed on the Main Propulsion Gas Turbine (MPGT) is to be performed by an Original Equipment Manufacturer Factory Certified Field Service Technician. Contractor is responsible for providing the Contracting Officer (KO) with proof of certification before the start of the contract.

3. All work performed on the Cross Connect Gear (CCG) is to be performed by an Original Equipment Manufacturer Factory Certified Field Service Technician. Contractor is responsible for providing the Contracting Officer (KO) with proof of certification before the start of the contract.

4. The Government has attempted to call out all items in the below Statement of Work that require a OEM Factory Certified Field Service Technician, however this does not relieve the contractor of the vii (Rev-2) responsibility for having a properly certified field service technician on site when work is being performed on either the MPGT or the CCG.

5. Contractor is responsible for providing the Coast Guard with a detailed project plan with their proposal.

Further they are responsible for providing weekly completion updates and progress tracking to the Coast Guard (Ex. Gantt Bar Chart generated in Microsoft Project).

6. Contractor shall provide representation at weekly progress meetings with the Coast Guard.

7. Contractor shall provide a Ships Superintendent who will be present at daily morning briefs held at a time designated by the CG on the BERTHOLF’s Quarterdeck.

8. Contractor is responsible for complying with all provision of Reference A.

Work Item Specific Performance Periods

Work Item 1 shall be completed on BERTHOLF’s CODAG Reduction Gear between 6SEP13 and 3DEC13 in order to correct system vibration conditions and premature bearing failures concurrent with BERTHOLF

CASREP 11142.

Other recommended 8000 and routine scheduled maintenance will be performed by USCG technicians between 6SEP13 – 18SEP13. In order to maintain warranty of work described in this specification, recommend MPDE OEM presence during this period to observe and verify pre-work and post-work engine conditions.

Work Items 2 through 6 are to be completed on both MDE’s between 18SEP13 and 29NOV13:

Work Item 2: Clean and inspect the starboard MPDE coolant plate-core heat exchanger in accordance with attached specifications.

Work Item 3: Clean and inspect both MPDE Geislinger couplings in accordance with attached specifications.

Work Item 4: Chemically clean and inspect the four (4) HP intercoolers, including associated pre-heaters, and ten (10) LP inter coolers from the MPDEs in accordance with attached specifications.

Work Item 5: Inspect and Overhaul both MPDE turbocharger control systems in accordance with the attached specifications.

Work Item 6: Renew A-1, A-2, B-1, B-2, B-3 (LP Turbochargers) and B-3 HP Turbochargers from both MPDEs. Inspect A-1, A-2, B-1, and B-2 (HP Turbochargers) from both MPDEs. Work to be completed in accordance with attached specifications.

8 (Rev-2)

WORK ITEM 1: Open, Inspect, Realign and Test USCGC BERTHOLF Cross Connect Gear Gas Turbine Input Shaft

General Statement: This statement of work is to to correct excessive vibrations that have been occurring on the Cross Connect Gear onboard the CGC BERTHOLF while under power from the Gas Turbine. It covers all actions to be performed by the contractor to open, inspect, realign the turbine input shaft, verify alignment of the high speed pinion shaft, and to test and monitor the Cross Connect Gear for vibrations following the completion of repairs.

REFERENCES:

a. USCG Surface Forces Logistics Center Standard Specification 0000 – General Requirements

b. U.S. Coast Guard Technical Publication 7028 (Tech Pub 7028), 2012, Main Diesel Engine – Maintenance Manual

c. MTU Technical Documentation S000082/00E, 2011, Functional Descriptions, Operating Instructions, and Instructions for General Overhaul

d. US Coast Guard Technical Publication 7073 – Reduction Gear

e. US Coast Guard Technical Publication 7018 – Main Gas Turbine- Installation Instructions – Model LM2500

f. USCG DWG 750-WMSL 234-001 GAS TURBINE REMOVAL ARRGT

DRAWING

NOTES:

1. Contractor is responsible for complying with all provisions in Reference A.

STATEMENT OF WORK:

1. In the presence of a Coast Guard Inspector, CCG OEM shall ensure MGT input shaft, SSS Clutch, and CCG hollow pinion are dynamically balanced. Balancing shall occur at an OEM approved facility. Submit a CFR documenting acceptance of all components against OEM technical requirements.

2. Tag out, with Coast Guard assistance, both Main Propulsion Diesel Engines (MPDE’s), the CODAG Reduction Gear, the Main Gas Turbine (MGT), and all auxiliary systems to ensure a safe working environment.

3. Remove all interferences that will impede initial alignment checks between the MPGT and the CCG. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician. Known interferences include:

9 (Rev-2)

a. The bulkhead seal at Frame 52

b. Gas Turbine (GT) Module panels

c. Exhaust cowl around the GT high speed coupling

4. Overhaul CCG L/O cooler with government furnished gaskets and liners, ensuring the chemically and mechanically clean all plates. Conduct operational test of the cooler to ensure proper operation prior to install, submit CFR.

5. Conduct preliminary alignment checks between the (1) CCG and MGT and (2) CCG to MRG, submit CFR documenting as found alignment conditions. Report shall include alignment numbers and measurements taken and in-service and commissioning tolerances. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician.

6. Measure run out between SSS clutch input and output flanges. Submit a CFR documenting Total Indicated Runout and how concentricity compares to OEM requirements. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician.

7. Disconnect GT high speed coupling between GT PT shaft and CCG GT input shaft. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician.

8. Remove CCG case top and all interferences to facilitate necessary component removal.

All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician. Known interferences include, but are not limited to:

a. CCG Local Operating Panels (LOP)

b. CCG Central Top Housing

c. CCG SSS Clutch

d. CCG L/O cooler

e. CCG L/O strainer.

9. Provide adequate system containment to ensure foreign materials do not enter the open gear system. Containment shall be approved by the CG Inspector prior to continuation of work.

10. Conduct alignment checks of GT Input shaft and associated bearings (C11, C12, and C13). All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician. Submit a CFR documenting as found alignment conditions. Report shall include:

a. Alignment numbers and measurements taken and in-service and commissioning tolerances.

10 (Rev-2)

b. Documentation of alignment process used

c. Clear outline of recording process

11. Remove CCG SSS clutch, GT input shaft, pinion shaft, and all associated bearings.

Ensure removed components are properly crated in preparation for shipment. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician. Submit CFR documenting the following:

a. Condition of C1, C2, C11, C12, and C13 bearing wear surfaces.

b. Condition of the GT Input Shaft at C11, C12, and C13 bearing contact areas and GT-input shaft to SSS clutch mating surfaces.

c. Condition of CCG Pinion Shaft at C1 and C2 bearing contact areas and Pinion- SSS mating surfaces.

d. Conduct NDT , in the form of ultrasonic and dye-penetrate testing, of C1, C2, C11, C12, and C13 bearings to determine the integrity of the bearing babbit to bearing shell bond.

12. Install Contractor Furnished Equipment (CFE) CCG pinion shaft. Install new, C1, C2, C11, C12, and C13 bearings. C11 bearing will be provided as GFE. C1, C2, C12, and C13 bearings are Contractor Provided. Install GFE MGT Input Shaft. Install contractor furnished SSS clutch in accordance with OEM requirements. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician. During the installation of these components, Reduction Gear OEM (RENK) shall provide a technical expert/engineer qualified to observe and make decisions on behalf of RENK.

13. Conduct alignment verification of (1) CCG internal components, (2) CCG to MGT and

(3) CCG to MRG. Submit CFR identifying post-work alignment conditions. Report shall include alignment numbers and measurements taken and in-service and commissioning tolerances. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician.

14. Measure post-work run out between SSS clutch input and output flanges. Submit a CFR documenting Total Indicated Runout and how concentricity compares to OEM requirements. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician.

15. Inspect visible gear teeth on CCG high speed pinion. Submit a CFR. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician.

16. Reassemble CCG gear case and restore CODAG Reduction Gear components. Reinstall bulkhead seal and return GT module to operational condition. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician. Restore all removed/disturbed interferences. Empty and clean CCG sump.

11 (Rev-2)

In the presence of a CG inspector, inspect gear case for foreign matter and debris. Fill with contractor provided oil (Mobil ESSO NUTO H100).

17. Tag in all associated equipment.

18. Restore and touch up all disturbed surfaces.

19. Conduct pier-side trails to validate CCG work. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician. Submit CFR documenting findings.

20. Demonstrate Full Power trials (CODAG) during sea-trials. Specific sequence for sea trials and mode shifts to be determined by the USCG and provided to contractor. Measure system vibrations. Submit CFR documenting Full Power trial results and vibration data.

CFR to include a comparison between pre and post-work vibrations. All work performed on this line item is to be supervised by the applicable OEM Factory Certified Field Service Technician. If vibration readings do not meet OEM specifications after all work is completed, contractor shall submit CFR documenting corrective actions, to include correction of potential soft-foot condition for CCG or MGT foundations and recommended areas for concentrated investigation for future repair action.

12 (Rev-2)

23300_LCM_0413_750

WORK ITEM 2: Starboard Main Propulsion Diesel Engine Coolant Plate-Core Heat Exchanger, Clean & Inspect

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to clean and inspect the starboard Main Propulsion Diesel Engine (MPDE) coolant plate –core heat exchanger located in the Aft Main Machinery Room (4-52-0-E). Refer to CG Drawings 750-WMSL 100-1, 750-WMSL 501-2, and MTU Technical manual S000082/00E. See Figure 1 below.

All Main Propulsion Diesel Engine work in this package must be completed between 18 Sep 13 – 18 Oct.

This includes, but is not limited to, the current spec, Starboard Main Propulsion Diesel Engine Coolant Plate-Core Heat Exchanger.

The Main Propulsion Diesel Engine scope of work specified in this contract shall be performed by factory certified MTU (Motor Turbine Union) series 1163 service technicians only. The MPDE work completed shall be guaranteed by a 6 month service workmanship warranty.

Figure 1. MPDE COOLANT PLATE-CORE HEAT EXCHANGER

A

B

C

D

13 (Rev-2)

1.2 Government-furnished property. Lead time for parts listed below is 6 weeks after receipt of order.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST

($/UNIT)

N Rubber insert VT402 DN125

NBR frame thickness =

40MM (MTU ALU)

4300969

4 ea. 31.50

N Rubber insert VT40 for intermediate plate

NBR thickness = 8MM

4301366

2 ea. 55.00

N Ring fur Gummiformteil Al Mg 4, 5

4130600

4 ea. 90.14

N Dichtring, 30x36 9305731 2 ea. 5.20

N Gasket VT405 glued NBR peroxide x-linked 4317522 47 ea. 80.00

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL 100-1, Rev H, General Arrangements (ASC100001) Coast Guard Drawing 750-WMSL 501-2, Rev D, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2012, General Requirements Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2012, Requirements for Preservation of Ship Structures U.S. Coast Guard Technical Publication 7028 (Tech Pub 7028), 2012, Main Diesel Engine –

Maintenance Manual

OTHER REFERENCES

MTU Technical Documentation S000082/00E, 2011, Functional Descriptions, Operating

Instructions, and Instructions for General Overhaul

14 (Rev-2)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative. The Contractor shall provide the services of an OEM-certified Tech Rep, who is familiar with the MTU 20 V Series 1163 TB93 Main Propulsion Diesel Engine and the MPDE coolant plate-core heat exchanger, to accomplish the following tasks – on site:

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

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

3.1.2.1 Ensure that the Tech Rep is a Certified Representative of Tognum America, Inc., the OEM.

3.1.2.2 Submit the Tech Rep’s name and résumé to the COR prior to start of the maintenance availability.

3.1.2.3 Tech Rep must be on sight at all times when work is going on. If a Tech Rep is to be swapped out with another Tech Rep, both Tech Reps must be on sight at the same time for 1 day; there must be a 1 day overlap. This is to ensure that the Tech Reps give a full pass down to each other with the COR present, so there is no confusion or loss of information.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all unaffected vessel components, equipment, and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph

3.3.5 (Interferences):

• Piping systems.

• Electrical cables

• Catwalks

• PCHE Cofferdam and Securing Arrangement

3.1.5 Operational test - initial. Prior to commencement of work, the Contractor and the CG Inspector shall witness Coast Guard personnel perform an initial operational test of the port and starboard MPDEs to demonstrate existing operational condition.

Submit a CFR.

3.2 Engine coolant plate-core heat exchanger removal. The Contractor shall remove the engine coolant plate-core heat exchangers from the starboard MPDEs in accordance with MTU Technical Documentation S000082/00E, Section 6.5.3.15.20.

15 (Rev-2)

3.3 Engine coolant plate-core heat exchanger cleaning. The Contractor shall clean the engine coolant plate-core heat exchangers from the starboard MPDE in accordance with MTU Technical Documentation S000082/00E, Section 6.5.3.15.21.

3.4 Engine coolant plate-core heat exchanger leakage test. The Contractor shall conduct leakage tests, in the presence of the CG Inspector, on the starboard MPDE engine coolant plate-core heat exchangers in accordance with MTU Technical Documentation S000082/00E, Section 6.5.3.15.22. Submit a CFR. If a plate-core heat exchanger fails the leakage test and corrective actions approved by the CG Inspector are taken, the leakage test shall be repeated. Submit a CFR upon completion of successful leakage tests. If the test fails two leakage tests, the USCG shall supply a PCHE from inventory and the contractor shall supply the F-condition PCHE to the CG for evaluation and repair.

3.5 Reinstall engine coolant plate-core heat exchanger . After all discrepancies are corrected and approval from CG Inspector is received, the Contractor shall reinstall the starboard MPDE coolant plate-core heat exchanger in accordance with MTU Technical Documentation S000082/00E, Section 6.5.3.15.23.

3.6 Operational test – post repairs. After completion of all authorized work, the Contractor and CG Inspector shall witness an operational test (by Coast Guard personnel) of the main diesel engine to prove satisfactory operating condition. Submit a CFR.

3.7 Touch-up preservation. The Contractor shall prepare and touch-up coat all disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, Appendix B (Cutter and Boat Interior Painting Systems). Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

1 NOTES

4.1 Cutter personnel will assist in locating all items required to be secured or isolated, and tagged for work Check and under this item.

16 (Rev-2)

WORK ITEM 3: Main Propulsion Diesel Engine Geislinger Coupling, Clean & Inspect

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to clean and inspect the Geislinger couplings in the port and starboard Main Propulsion Diesel Engines (MPDE) located in the Aft Main Machinery Room (4-52-0-E). Please note that the USCG will decide whether or not to execute this maintenance item prior to the arrival conference.

All Main Propulsion Diesel Engine work in this package must be completed between 18 Sep 13 – 18 Oct.

This includes, but is not limited to, the current spec, Main Propulsion Diesel Engine Geislinger Coupling, Clean & Inspect.

The Main Propulsion Diesel Engine scope of work specified in this contract shall be performed by factory certified MTU (Motor Turbine Union) series 1163 service technicians only. The MPDE work completed shall be guaranteed by a 6 month service workmanship warranty.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST

($/UNIT)

N Bearing Bush F

72/15/147N/R Item 15 G409456 2 481

N Bearing Bush F 72/15/147N/R Item 16

G409455 2 548

N Bearing Bush F 72/15/147N/R Item 17

G409457 2 398

N Bearing Bush F 72/15/147N/R Item 18

G304750 2 1,318

N F 72/15/147N/R Minimum Spare Part Kit

SPG411153 2 3,481

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL 100-1, Rev H, General Arrangements (ASC100001) Coast Guard Drawing 750-WMSL 501-2, Rev D, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2012, General Requirements Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2012, Requirements for Preservation of Ship Structures

17 (Rev-2)

U.S. Coast Guard Technical Publication 7028 (Tech Pub 7028), 2012, Main Diesel Engine – Maintenance Manual

OTHER REFERENCES

MTU Technical Documentation S000082/00E, 2011, Functional Descriptions, Operating

Instructions, and Instructions for General Overhaul MTU Drawing X00033903/32-F72/15/147N/R

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative. The Contractor shall provide the services of an OEM-certified Tech Rep, who is familiar with the MTU 20 V Series 1163 TB93 Main Propulsion and Geislinger OEM-certified Tech Rep who is familiar with the F72/15/147N/R coupling, to accomplish the following tasks – on site:

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

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

3.1.2.1 Ensure that the Tech Rep is a Certified Representative of Tognum America, Inc., the MDE OEM and Geislinger USA, the coupling OEM

3.1.2.2 Submit the Tech Rep’s name and résumé to the COR prior to start of this Work Item if it is turned on.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all unaffected vessel components, equipment, and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph

3.3.5 (Interferences):

• Piping systems.

• Electrical cables

• Intake Vents

18 (Rev-2)

3.1.5 Operational test - initial. Prior to commencement of work, the Contractor and the CG Inspector shall witness Coast Guard personnel perform an initial operational test of the port and starboard MPDEs to demonstrate existing operational condition.

Submit a CFR.

3.2 Removal and Disassembly. The Contractor shall remove and disassemble the Geislinger couplings from the port and starboard MPDEs in accordance with MTU TechDoc S000082/00E, Section 6.5.3.17.2 through 6.5.3.17.3. All oil and hazmat produced during removal of the Geislinger coupling shall be contained and cleaned up/removed by the contractor without any ship’s force assistance. The bilge under the working areas shall be cleaned and presented to the COR/CG Inspector prior to reinstallation of the coupling.

3.3 Coupling cleaning. The Contractor shall clean the coupling in accordance with MTU TechDoc S000082/00E, Section 6.5.3.17.4. The Contractor shall abide by the requirements outlined in SFLC Std Spec 0000 in regards to handling and disposal of hazardous waste and material.

3.4 Coupling inspection. In the presence of the CG Inspector the Contractor shall check the couplings for wear, abrasion marks, bearing clearance, and damaged screws. Submit a CFR. After approval is received from the CG Inspector, perform corrective actions for discrepancies noted as described in MTU TechDoc S000082/00E, Section 6.5.3.17.5.

3.5 Assembly and reinstallation. Once the couplings are inspected and discrepancies corrected, and approval from CG Inspector is received, the Contractor shall assemble and reinstall the couplings in accordance with MTU Tech Doc S000082/00E, Sections 6.5.3.17.6 through 6.5.3.17.7.

3.6 Operational test – post repairs. After completion of all authorized work, the Contractor and CG Inspector shall witness an operational test (by Coast Guard personnel) of the main diesel engines to prove satisfactory operating condition. Submit a CFR.

3.7 Touch-up preservation. The Contractor shall prepare and touch-up coat all disturbed surfaces to match existing adjacent surfaces in accordance with SFLC S td Spec 6310, Appendix B (Cutter and Boat Interior Painting Systems). Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

1 NOTES

4.1 Cutter personnel will assist in locating all items required to be secured or isolated, and tagged for

19 (Rev-2)

WORK ITEM 4: Main Propulsion Diesel Engine HP and LP Intercoolers Saltwater and Air Sides, Chemical Cleaning &

Inspection

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to remove and commercially/chemically clean and inspect the four (4) HP intercoolers including associated pre-heaters and ten (10) LP intercoolers (See Figures 1 & 2) from the port and starboard main propulsion diesel engines (MPDE) listed in Table 1.

All Main Propulsion Diesel Engine work in this package must be completed between 18 Sep 13 – 18 Oct.

This includes, but is not limited to, the current spec, Main Propulsion Diesel Engine HP and LP Intercoolers Saltwater and Air Sides.

The Main Propulsion Diesel Engine scope of work specified in this contract shall be performed by factory certified MTU (Motor Turbine Union) series 1163 service technicians only. The MPDE work completed shall be guaranteed by a 6 month service workmanship warranty.

FIGURE 1. HP INTERCOOLER AND PREHEATER

20 (Rev-2)

FIGURE 2. LP INTERCOOLER

TABLE 1- MPDE INTERCOOLERS

MPDE # INTERCOOLERS,

QTY

Stbd HP, 2 ea LP , 5 ea

Port HP, 2 ea LP , 5 ea

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL 100-1, Rev H, General Arrangements (ASC100001) Coast Guard Drawing 750-WMSL 501-2, Rev D, Machinery Arrangements (ASC501001) Coast Guard Drawing 750-WMSL 101-9, Rev A, Equipment Removal Route Drawing (NSC-1 &

NSC-2 Only) (ASC101009)

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2012, General Requirements Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2012, Requirements for Preservation of Ship Structures U.S. Coast Guard Technical Publication 7028 (Tech Pub 7028), 2012, Main Diesel Engine –

Maintenance Manual

21 (Rev-2)

OTHER REFERENCES

MTU Technical Documentation S000082/00E (MTU TechDoc S000082/00E), 2011, Functional

Descriptions, Operating Instructions, and Instructions for General Overhaul

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative. The Contractor shall provide the services of an OEM-certified Tech Rep, who is familiar with the MTU 20 V Series 1163 TB93 Main Propulsion Diesel Engine, to accomplish the following tasks – on site:

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

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

3.1.2.1 Ensure that the Tech Rep is a Certified Representative of Tognum America, Inc., the OEM.

3.1.2.2 Submit the Tech Rep’s name and résumé to the COR prior to start of the maintenance availability.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all unaffected vessel components, equipment, and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph

3.3.5 (Interferences):

• Piping systems.

• Electrical cables

• Engine air intake vent ducting (stack space)

• Deck grating.

3.1.5 Operational test - initial. Prior to commencement of work, the Contractor and the CG Inspector shall witness Coast Guard personnel perform an initial operational test of the port and starboard MPDEs to demonstrate existing operational condition.

Submit a CFR.

3.2 Removal and rigging of MPDE intercoolers. The Contractor shall remove the intercoolers in accordance with MTU TechDoc S000082/00E and rig the same from the cutter in accordance with the

22 (Rev-2)

Coast Guard Drawing 750-WMSL-101-9. The port and starboard MPDEs are located in the Aft Main Machinery Room (4-52-0-E). Refer to CG Drawings 750-WMSL 100-1 and 750-WMSL 501-2.

3.3 HP and LP intercoolers and Pre-heaters. The Contractor shall clean, inspect and perform leak tests of all port and STBD MPDE HP (including the pre-heaters) and LP intercoolers. The Contractor shall follow the procedures in MTU Technical manual S000082/00E. Applicable paragraphs for each step of the clean/inspect/test processes are shown in Table 2 below. Inspections and leak tests outlined in MTU TechDoc S000082/00E Section 6.5.3.10.12 (HP) and Section 6.5.3.10.18 (LP) shall be conducted in the presence of the CG Inspector. Submit a CFR.

Table 2. HP and LP INTERCOOLERS CLEANING, INSPECTION AND TESTING PROCEDURES (Applicable sections can be found in MTU TechDoc S000082/00E)

STEPS HP Intercooler LP Intercooler

Removal

§ 6.5.3.10.10 § 6.5.3.10.16

Cleaning § 6.5.3.10.11 § 6.5.3.10.17

Checks/Inspections § 6.5.3.10.12 § 6.5.3.10.18

Leak Test § 6.5.3.10.12 § 6.5.3.10.18

Installation § 6.5.3.10.13 § 6.5.3.10.19

3.4 Assembly and reinstallation. Once the intercoolers are inspected and discrepancies corrected after approval from CG Inspector is received, the Contractor shall assemble and reinstall the intercoolers in accordance with the applicable sections in Table 2 above.

3.8 Operational test – post repairs. After completion of all authorized work, the Contractor and CG Inspector shall witness an operational test (by Coast Guard personnel) of the main diesel engines to prove satisfactory operating condition. Submit a CFR.

3.9 Touch-up preservation. The Contractor shall prepare and touch-up coat all disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, Appendix B (Cutter and Boat Interior Painting Systems). Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

4.1 NOTES

4.1 Cutter personnel will assist in locating all items required to be secured or isolated, and tagged for

23 (Rev-2)

WORK ITEM 5: MPDE Turbocharger Control, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect and overhaul the port and starboard Main Propulsion Diesel Engines (MPDE) turbocharger control, specifically, 1) the exhaust flow control flaps, 2) air intake flow control flaps, and 3) intake and exhaust air actuating cylinders. The MPDEs are located in the Aft Main Machinery Room (4-52-0-E).

All Main Propulsion Diesel Engine work in this package must be completed between 18 Sep 13 – 18 Oct.

This includes, but is not limited to, the current spec, Main Propulsion Diesel Engine Turbocharger Control.

The Main Propulsion Diesel Engine scope of work specified in this contract shall be performed by factory certified MTU (Motor Turbine Union) series 1163 service technicians only. The MPDE work completed shall be guaranteed by a 6 month service workmanship warranty.

1.2 Government-furnished property.

None

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL 100-1, Rev H, General Arrangements (ASC100001) Coast Guard Drawing 750-WMSL 501-2, Rev D, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2012, General Requirements Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2012, Requirements for Preservation of Ship Structures U.S. Coast Guard Technical Publication 7028 (Tech Pub 7028), 2012, Main Diesel Engine –

Maintenance Manual

OTHER REFERENCES

MTU Technical Documentation S000082/00E (MTU TechDoc S000082/00E), 2011, Functional

Descriptions, Operating Instructions, and Instructions for General Overhaul

24 (Rev-2)

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative. The Contractor shall provide the services of an OEM-certified Tech Rep, who is familiar with the MTU 20 V Series 1163 TB93 Main Propulsion Diesel Engine and its intake air and exhaust turbocharger controls, to accomplish the following tasks – on site:

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

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

3.1.2.1 Ensure that the Tech Rep is a Certified Representative of Tognum America, Inc., the OEM.

3.1.2.2 Submit the Tech Rep’s name and résumé to the COR prior to start of maintenance availability.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all unaffected vessel components, equipment, and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph

3.3.5 (Interferences):

• Piping systems.

• Electrical cables

• Intake vents

3.1.5 Operational test - initial. Prior to commencement of work, the Contractor and the CG Inspector shall witness Coast Guard personnel perform an initial operational test of the port and starboard MPDEs to demonstrate existing operational condition.

Submit a CFR.

3.2 Turbochargers control overhaul. The Contractor shall overhaul the following turbocharger control on the Port and Stbd MPDEs: 1) exhaust flow control flaps, 2) air intake flow control flaps, and 3) intake and exhaust air actuating cylinders. See Figures 1, 2, and 3 below.

25 (Rev-2)

FIGURE 1. INTAKE HOUSING WITH AIR FLAP

FIGURE 2. EXHAUST FLAP WITH BELLOWS

26 (Rev-2)

FIGURE 3. INTAKE AIR AND EXHAUST FLAP CONTROL

The Contractor shall follow the procedures in MTU TechDoc S000082/00E. Applicable sections for each step of the overhaul processes are shown in Table 2 below. Inspections and measurements outlined in MTU Techman in sections 6.5.3.11.12, 6.5.3.12.14, and 6.5.3.11.5. shall be conducted in the presence of the CG Inspector. Document unsual findings or out of tolerenace measurements via CFR.

Table 1. TURBOCHARGER CONTROL OVERHAUL PROCEDURES

(Applicable paragraphs can be found in MTU Techman S000082/00E)

STEPS Intake Control Flap

Exhaust Control Flap

Intake and Exhaust Actuating Cylinders

Removal § 6.5.3.11.9 § 6.5.3.12.11 § 6.5.3.11.2

Disassembly § 6.5.3.11.10 § 6.5.3.12.12 § 6.5.3.11.3

Cleaning § 6.5.3.11.11 § 6.5.3.12.13 § 6.5.3.11.4

Checks/Inspections § 6.5.3.11.12 § 6.5.3.12.14 § 6.5.3.11.5

Tolerances § 6.5.3.11.13 § 6.5.3.12.15 n/a

Assembly § 6.5.3.11.14 § 6.5.3.12.16 § 6.5.3.11.6

Installation § 6.5.3.11.15 § 6.5.3.12.17 § 6.5.3.11.7

27 (Rev-2)

3.3 Operational test – post repairs. After completion of all authorized work, the Contractor and CG Inspector shall witness an operational test (by Coast Guard personnel) of the port and starboard MPDEs to prove satisfactory operating condition. Submit a CFR.

3.4 Touch-up preservation. The Contractor shall prepare and touch-up coat all disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, Appendix B (Cutter and Boat Interior Painting Systems). Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

1 NOTES

4.1 Cutter personnel will assist in locating all items required to be secured or isolated, and tagged for

28 (Rev-2)

WORK ITEM 6: MPDE Exhaust Turbochargers, Renewal & Inspection

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to 1) renew the designated port and starboard Main Propulsion Diesel Engines (MPDE) low pressure (LP) and high pressure (HP) turbochargers and 2) clean and inspect the designated port and stbd MPDE HP turbochargers . Table 1 below lists the turbochargers designated for renewal and inspection.

All Main Propulsion Diesel Engine work in this package must be completed between 18 Sep 13 – 18 Oct. This includes, but is not limited to, the current spec, Main Propulsion Diesel Engine Exhaust Turbochargers.

The Main Propulsion Diesel Engine scope of work specified in this contract shall be performed by factory certified MTU (Motor Turbine Union) series 1163 service technicians only. The MPDE work completed shall be guaranteed by a 6 month service workmanship warranty.

TABLE 1- MPDE LP & HP TURBOCHARGERS – RENEWAL

MDE # LP TURBOCHARGERS HP TURBOCHARGERS

STBD

A-1, A-2, B-1, B-2, B-3

Overhaul B-3;

Inspect A-1, A-2, B-1, B-2

PORT A-1, A-2, B-1, B-2, B-3

Overhaul B-3;

Inspect A-1, A-2, B-1, B-2

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY PRICE

($/UNIT)

Y HP TURBO KIT 01-LG0-2789 2 $21,165.35

Y LP TURBO KIT 01-LG0-2970 10 $33,855.48

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL 100-1, Rev H, General Arrangements (ASC100001)

29 (Rev-2)

Coast Guard Drawing 750-WMSL 501-2, Rev D, Machinery Arrangements

(ASC501001)

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2012, General Requirements Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2012, Requirements for Preservation of Ship Structures U.S. Coast Guard Technical Publication 7028 (Tech Pub 7028), 2012, Main Diesel

Engine – Maintenance Manual

OTHER REFERENCES

MTU Technical Documentation S000082/00E (MTU TechDoc S000082/00E), 2011, Functional Descriptions, Operating Instructions, and Instructions for General Overhaul

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative. The Contractor shall provide the services of an OEM-certified Tech Rep, who is familiar with the MTU 20 V Series 1163 TB93 Main Propulsion Diesel Engine and its exhaust turbochargers ZR 170 and ZR 210, to accomplish the following tasks – on site:

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

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

3.1.2.1 Ensure that the Tech Rep is a Certified Representative of Tognum America, Inc., the

OEM.

3.1.2.2 Submit the Tech Rep’s name and résumé to the COR prior to start of maintenance availability.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all unaffected vessel components, equipment, and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

30 (Rev-2)

3.1.4 Interferences. The Contractor shall be aware that interferences in way of work include, but are not limited to the below-listed. Handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences):

• Piping systems.

• Electrical cables

• Intake vents

3.1.5 Operational test - initial. Prior to commencement of work, the Contractor and the CG Inspector shall witness Coast Guard personnel perform an initial operational test of the port and starboard MPDEs to demonstrate existing operational condition.

Submit a CFR.

3.2 HP and LP turbochargers removal. The Contractor shall remove and turn over to the COR the following turbochargers: 1) LP turbochargers A-1, A-2, B-1, B-2, and B-3 from the Port and Stbd MPDEs, and 2) HP turbocharger B-3 from the Port and Stbd MPDEs. Removal shall be in accordance with the procedures in MTU Technical Manual S000082/00E. Applicable sections are listed in Table 2.

3.2.1 Packaging MTI items. In the presence of the Coast Guard Inspector, the Contractor shall pack the turbochargers that were removed from the MPDEs before turning them over to the COR as MTI items. Utilize the same packing materials and crates used for the new turbochargers if still in reusable form.

3.3 HP and LP turbochargers renewal. The Government will furnish new LP (10 ea) and HP (2

ea) exhaust turbochargers for installation in place of the ones removed in para 3.2 above.

Installation of the new turbochargers shall be in accordance with the procedures in MTU Technical Manual S000082/00E. Applicable sections are listed in Table 2.

Table 2. HP and LP TURBOCHARGER REMOVAL & INSTALLATION

PROCEDURES

(Applicable sections can be found in MTU TechDoc S000082/00E)

STEPS HP Turbocharger LP Turbocharger

Removal

§ 6.5.3.9.2

§ 6.5.3.9.10

Installation § 6.5.3.9.8 § 6.5.3.9.16

3.4 HP turbochargers A-1, A-2, B-1, and B-2 inspection. The Contractor shall remove, clean, and inspect in the presence of the CG Inspector, the following HP turbochargers from each of the Port and Stbd MPDEs: A-1, A-2, B-1, and B-2. Remove the turbochargers in accordance with MTU TechDoc S000082/00E, Section 6.5.3.9.2. DO NOT DISASSEMBLE THE TURBOCHARGERS. Hand clean all accessible metallic parts with cleaning agent Snow-White 11-0 (Part No. 40460) then rinse with cleaning agent Hakupur 312 (Part No. 30390). Blow off all components thoroughly with compressed air. Inspect the turbocharger for the following:

31 (Rev-2)

• Check the turbine housing for cracks in accordance with MTU Techman S000082/00E, para. 6.5.3.9.5, pg 1617

• Check the compressor housing for cracks in accordance with MTU Techman S000082/00E, para. 6.5.3.9.5, pg 1618

• Check the gap clearances in accordance with MTU Techman S000082/00E, para.

6.5.3.9.5, pgs 1622-1623

Submit a CFR.

3.4.1 Installation of HP turbochargers A-1, A-2, B-1, and B-2. Once the turbochargers are inspected and discrepancies corrected after approval from CG Inspector is received, the Contractor shall install the turbochargers in accordance with MTU Technical Documentation S000082/00E. Applicable sections are listed in Table 2 above.

3.5 Operational test – post repairs. After completion of all authorized work, the Contractor and CG Inspector shall witness an operational test (by Coast Guard personnel) of the main diesel engines to prove satisfactory operating condition. Submit a CFR.

3.6 Touch-up preservation. The Contractor shall prepare and touch-up coat all disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, Appendix B (Cutter and Boat Interior Painting Systems). Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

1 NOTES

4.1 Cutter personnel will assist in locating all items required to be secured or isolated, and tagged for work Check and under this item.