JH20 Main Engine 24K Hour Overhaul SOW (122619).docx

USNS Joshua Humphreys

( TAO 188 )

1.0 ABSTRACT

1.1 This item describes accomplishing the scheduled 24,000-hour overhaul of the Port main propulsion diesel engine.

2.0 REFERENCES/ENCLOSURES

2.1 References:

2.1.1 NAVSEA Tech. Manual No. T9233-AF-MMC-010, Colt-Pielstick Main Propulsion Diesel Engine, Operation Instructions and Maintenance Procedures.

(available aboard vessel)

2.1.2 Fairbanks Morse Engine Reference Maintenance Schedule of Engines, dated 02/08/08 (available onboard ship)

2.1.3 SEMT Bulletin 482287 dated 11/23/2001 for vertically honed Liners., Running-In Engine (available aboard vessel)

2.2 Enclosures:

2.2.1 List of Government Furnished Material

2.2.2 Main Engine Forms for Final Report

2.2.3 Wear and Clearance Tables

2.2.4 Main Engine Tightening Torque Tables

2.2.5 Engine Pre-Start Check Sheet two (2) Pages to be filled out by OEM Representative Contractor, Chief Engineer, and Port Engineer

2.2.6 Coltec Industries Inc., Fairbanks Morse Engine Division, Conrod Bolt NDT Procedure, five (5) pages

3.0 ITEM LOCATION/DESCRIPTION/QUANTITY

3.1 Location/Quantity:

3.1.1 Location: Engine Room, 5-60-0.

3.1.2 Quantity: One (1) main propulsion diesel engines to be dealt with

3.2 Description/Manufacturer’s Data:

3.2.1 Description: Colt-Pielstick

10 Cylinder Model: PC 4.2V 570

3.2.2 Manuf. Data: Colt Industries

Fairbanks Morse Engine Division Beloit, Wisconsin 53511

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Government Furnished Equipment: None.

4.2 Government Furnished Equipment / Material:

4.2.1 Original Equipment Manufacturer (OEM) repair parts (enclosure 2.2.1) and onboard main engine special tools.

4.2.2 Main engine lube oil

4.3 Government Furnished Services: None.

5.0 NOTES

5.1 The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTR’s.

5.2 The contractor and all subcontractors regardless of tier are advised to review other work items under this contract to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

5.3 The contractor shall remove and properly dispose of all lube oil, waste oil and chemically treated jacket cooling water in accordance with work items 021 and 023 and found elsewhere in this specification.

5.4 This item shall be worked in conjunction with any other contractor work being accomplished in the engineering spaces.

5.5 All engine component parts, piping and equipment (i.e. hand rails, ladders, gratings, valve covers, piping, etc.) removed as interferences but not designated for repair shall be properly marked, tagged, protected and removed from the vessel to a secure shipyard indoor storage facility. Engine components removed as interferences shall not be stored in the engine room or aboard the vessel.

5.6 The period of performance for this repair will be For the summer MTA (July through 27 August 2020 at a location to be determined).

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 Government reserves the right to witness/verify/require additional checkpoints for critical overhaul items to include torqueing, measurements, assembly and component inspections. These inspections shall include all required regulatory inspections. The contractor shall be responsible for scheduling and notifying all parties.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Provide the below listed labor, material, shop services, transportation and OEM authorized technical field service representative team necessary to perform the scheduled 24,000-hour overhaul of the PORT main propulsion diesel using references 2.1.1 through 2.1.3 and enclosure 2.2.1 for guidance.

7.1.1 Provide the services of OEM Authorized PC4.2 Technical Field Service Representative Team to accomplish the 24,000-hour overhaul of the PORT Main Engine. The OEM Authorized PC4.2 Technical Field Service Representative Team shall accomplish all work on the engines and components.

7.1.1.1 The OEM Authorized PC4.2 Technical Field Service Representative Team shall begin on first day of shipyard availability to ensure all work will be accomplished and required reports are submitted prior to engine light off. Se paragraph 7.9

7.1.1.2 The OEM Authorized PC4.2 Technical Field Service Representative Team shall be present for testing, light off, dock and sea trials. See paragraph 7.3.

7.1.2. Provide the services of an OEM authorized PC4.2 repair shop facility to perform all main engine component cleaning, disassembly, shop inspection, overhaul, repair and reassembly described below in accordance with references 2.1.1 & 2.1.2.

7.1.2.1 All material shall be Contractor Furnished Material (CFM).

7.1.3 Provide all rigging, crane, and transportation (trucking) services for the above listed main engine components and overhaul parts both to and from the engine room and to and from the OEM authorized repair shop facility. Coordination for pick-ups and deliveries of the components shall be made through the onsite OEM authorized technical field service representatives.

7.1.4 Fabricate wooden crates for each of the components listed in paragraph 7.1.2.2 (a through i) to ensure no damage during shipping and handling. Crates shall be capable of being lifted by a pallet jack, fork truck and crane.

7.1.5 Material:

7.1.3.1 Provide consumable cleaning materials, i.e. rags, solvents, degreasers, detergents, cleaning agents, wire brushes, etc. throughout the performance of this work item.

7.1.3.2 Provide weather-proof tags, indelible (permanent) marker pens, and colored steel marking pens throughout the performance of this work item.

7.1.6 Flushing: accomplish flushing of the port and starboard main engine lube oil systems via the associated by-pass (static) filter units using muslin bags.

7.1.6.1. The ship’s main engine lube oil pumps shall be used to circulate the oil during the flushing evolution. Heating of the oil shall be accomplished via the lube oil sump tank heating coils. The Contractor shall provide an external steam supply to the main engines lube oil sump heating coils to maintain the required flushing temperature. Ship’s force will refill engine sump tanks with government-furnished engine lube oil as required.

7.1.6.2. For estimating purposes, the flushing evolution shall take no more than forty-eight (48) continuous hours, per engine.

7.1.6.3. Monitoring of the flushing evolution, cleaning of the basket filter units and changing of the muslin bags shall be accomplished by the assist labor described in paragraph 7.1.1.

7.2 The following is a summary of the work to be performed by contractor during the overhaul of the PORT main engine, under the direction of the OEM authorized technical field service representatives:

7.2.1 Crankshaft Deflection Readings

a. Take and record “cold” crankshaft deflection readings of the port and starboard main engines both prior to and after completion of repairs in accordance with section 6-90 of Ref. 2.1.1.

7.2.2 Valve Covers and Rockers Arm Assemblies

a. Accomplish removal, disassembly, cleaning, shop inspection, machining and restoration of Ten (10) rocker arm assemblies and Valve Covers in accordance with sections 6-57.1 through 6-57.5 of Ref. 2.1.1.

b. Inspect all inlet and exhaust bushes on rocker arm assemblies.

c. Inspect all spherical and pressure tappets.

d. Inspect all rocker arm pins and renew ten (10) intake pins (P/N T53026) (CFM).

e. Reassemble and reinstall the rocker arm assemblies in accordance with sections 6-57.6 through and 6-57.8 of Ref. 2.1.1

7.2.3 Cylinder Heads

a. Accomplish removal, disassembly, cleaning, shop inspection, machining, restoration and hydraulic testing of all Ten (10) cylinder heads in accordance with section 6-56.1 through 6-56.8 of Ref. 2.1.1. Contractor shall arrange for an American Bureau of Shipping (ABS) Surveyor to attend, witness, inspect and certify repairs in accordance with applicable rules and regulations of the classification society.

b. Accomplish chemical cleaning of all cylinder head water circuits in accordance with section 6-56.3 of Ref. 2.1.1.

c. Inspect the rocker arm landing surface on the cylinder head (flattening).

d. Inspect the nut landing surfaces (flattening).

e. Inspect head gasket landing surfaces.

f. Renew the indicator cock washers.

g. Renew inlet valve seats.

h. Inspect cylinder head studs Qty 80

i. Re-install on engine upon return to the ship.

7.2.4 Exhaust Valves

a. Accomplish removal, disassembly, shop inspection, cleaning, machining, restoration, and hydro testing of Twenty (20) exhaust valves and cages in accordance with sections 6-59.1 through 6-59.5 of Ref. 2.1.1

b. Recondition the exhaust valves in accordance with section 6-59.6 of Ref. 2.1.1.

c. Reassemble and reinstall all exhaust valves and cages in accordance with sections 6-59.7 through 6-59.10 of Ref. 2.1.1.

7.2.5 Cylinder Safety Valves

a. Accomplish removal, disassembly, cleaning, shop inspection, machining and restoration of ten (10) safety valves in accordance with sections 6-62.1 through 6-62.3 of Ref. 2.1.1.

b. Reassemble and reinstall the safety valves in accordance with sections 6-62.4 and 6-62.5 of Ref. 2.1.1

7.2.6 Intake Valves

a. Accomplish removal, disassembly, shop inspection, cleaning, machining and restoration of twenty (20) intake valves in accordance with sections 6-60.1 through 6-60.3 of Ref. 2.1.1

b. Recondition the intake valves in accordance with section 6-60.4 of Reference 2.1.1.

c. Reassemble and reinstall all intake valves in accordance with sections 6-60.5 through 6-60.6 of Ref. 2.1.1

7.2.7 Air Starting Valves

a. Accomplish removal, disassembly, cleaning, shop inspection, machining and restoration of ten (10) air starting valves in accordance with sections 6-61.1 through 6-61.3 of Ref. 2.1.1.

b. Reassemble and reinstall the air starting valves in accordance with sections 6-61.4 and 6-61.5 of Ref. 2.1.1

7.2.8 Cylinder Liner

a. Accomplish removal, disassembly, cleaning, shop inspection, machining and restoration of all ten (10) cylinder liner in accordance with sections 6-70 through 6-73 of Ref. 2.1.1.

b. Accomplish dye-penetrant inspection of cylinder liner bore cooling spaces. Prior to shipping to designated OEM repair facility.

c. Conduct visual inspection of entablature landing surface condition.

d. Conduct dimensional check of liner guides in the block for ovalization.

e. Conduct dimensional check of water jacket upper and lower bores.

f. Hone all cylinder liners in the vertical position in accordance with the OEM’s most current procedures.

g. Replace all cylinder liner “O”rings.

h. Reassemble and reinstall the ten (10) cylinder liner in accordance with sections 6-75 through 6-76 of Ref. 2.1.1

7.2.9 Fuel Injection Pumps

a. Check pump shims for proper injection advance in accordance with section 6-33.3 of Ref. 2.1.1.

b. Inspect fuel rack and pinion assemblies for excessive wear.

c. Final performance checks and adjustments of the pumps and rack settings shall be accomplished during dock and sea trials.

7.2.10 Piston and connecting rod assemblies

a. Accomplish removal, disassembly, cleaning, shop inspection and restoration of all ten (10) piston/connecting rod assemblies in accordance with sections 6-63 through 6-66 of Ref. 2.1.1.

b. Inspect piston tie rods and nuts. Replace the Big End Bolts and Nuts IAW with Enclosure 2.2.6 utilizing GFM Provided Nuts and Bolts.

c. Re-fit piston with new piston rings and replace piston head o-ring.

d. Replace the big end bearings and small end bushings.

e. Inspect the connecting rod bearing bores for fretting.

f. Polish the running surfaces of the ten (10) piston pins.

g. Reassemble and reinstall the ten (10) piston/connecting rod assemblies in accordance with section 6-67 of Ref. 2.1.1

7.2.11 Timing & Barring Gears

a. Accomplish a visual inspection of the Port and Starboard main engines timing and barring gears in accordance with sections 6-46 through 6-48.3 of Ref. 2.1.1.

b. Measure backlash of the timing and barring gears in accordance with sections 6-49 through 6-50.3 of Ref. 2.1.1.

7.2.12 Cam Shafts, Gears and Rollers

a. Accomplish visual inspection of the Port and Starboard main engines and backlash measurement of all camshaft gears, cams and cam rollers in accordance with sections 6-52.2 and 6-79 of Ref. 2.1.1.

b. Accomplish inspection of the camshaft gearwheel springs in accordance with section 6-54 of ref. 2.1.1.

c. Inspect the inlet and exhaust Tappet and Rollers.

d. Inspect all camshaft bearings.

e. Check injection timing after assembly in accordance with section 6-53 of Ref. 2.1.1.

7.2.13 Crankshaft, Crankcase & Bearings

a. Remove, clean and inspect all crankcase inspection doors and safety valves in accordance with sections 6-86.1 and 6-86.2 of Ref. 2.1.1. Replace the gaskets of the inspection doors and safety valves. Upon completion of repairs, reinstall inspection doors and safety valves in accordance with section 6-86.3 of Ref. 2.1.1.

b. Accomplish removal, disassembly, cleaning and inspection of four (4) main bearing shells, one-by-one, in accordance with sections 6-87.1 through 6-87.5 of Ref. 2.1.1. Check bearing clearance before dismantling with a feeler gauge. Conduct a visual inspection of all main bearing journals. Stone journals, bearing saddle surfaces and cage surfaces to remove irregularities. Reassemble and replace with new main bearings in accordance with sections 6-87.6 and 6-87.7 of ref. 2.1.1.

c. Conduct a visual inspection of all crank pin journals. Check and remove cam wear effect on all crankpins as per OEM Service Bulletin.

d. Conduct a thorough visual inspection of the crankcase including all crankcase welds.

7.2.15 Fluid Systems

a. Disassemble, clean, inspect and overhaul the One (1) main air start valves in accordance with section 6-36.2 of Ref. 2.1.1. Reassemble main air start valves in accordance with section 6-36.3 of Ref. 2.1.1 all material shall be Contractor Furnished (CFM)

b. Disassemble and clean the Fuel Oil Filters. Ultrasonically clean all filter elements (candles). Reassemble filters with new o-rings and gaskets.

c. Open, clean and inspect the two (2) jacket water expansion tanks. Close up using new gaskets and bolting conforming to system requirements.

7.2.16 Mechanical Over-speed Trip Assemblies

a. Accomplish removal, disassembly, cleaning, inspection and repair of One (1) Over-speed trip mechanisms in accordance with sections 6-108.1 and 6-108.2 of Ref. 2.1.1. Reassemble, reinstall and adjust the electrical over-speed trip assemblies in accordance with section 6-108.3 of Ref. 2.1.1. Test the electrical over-speed trips (stop and half-speed) in accordance with section 6-24.2 of Ref. 2.1.1.

7.2.17 Intake and Exhaust Valve Clearances

a. Check and adjust the tappet clearance of the twenty (20) each intake and exhaust valves in accordance with section 6-58 of Ref. 2.1.1.

b. Tappet clearance (cold) for both intake and exhaust valves is .0453” (1.15mm).

7.2.18 Governors

a. Crate and ship the PORT main engine governors to a manufacturers authorized service facility.

Diesel Engine Governors: Governor including Tandem booster Servomotor, Woodward Governor Model PGA 200, RPM: 480-960 (Governor Drive Shaft) p/n: 8572-766SU, Control Air Pressure: 10.15-43.5. Governor Assembly is fitted with accumulator and power cylinder, also fitted with Tandem Booster Model:8901-065.

b. Completely disassemble the governors and Tandem boosters, clean and inspect all parts. Governors and boosters shall be overhauled to like new condition. This includes tear down, cleaning, inspection and replacement of all worn or defective parts, including bearings, bushings, pins, springs, gaskets, seals, and O-rings. All Normal replacement parts shall be CFM including Gaskets, bearings and springs any additional parts shall be addressed with a change order.

c. MSCREP shall witness in shop test.

d. Submit a written report noting as found and released conditions, along with any additional recommended repairs.

e. Upon completion of repairs and shop testing, carefully package, crate and ship the governors and boosters back to the vessel.

f. Reinstall the governors using new gaskets. Fill governors with new oil provided by ships force.

g. Conduct an operational test of the governors during dock and sea trails. Check and adjust governor linkage and settings for optimal performance.

7.2.19 Fuel Injectors

a. Conduct shop overhaul of all twenty five (25) fuel injector assemblies in the engines in accordance with sections 6-32.1 through 6-32.6 of Ref. 2.1.1. Injectors will need to be removed from the engines and reinstalled once complete. All Material shall be CFM.

b. Test, calibrate and adjust the spray pattern and operating pressure of all fuel injectors. All checks of the injectors are to be carried out on a calibrated test stand using clean and filtered fuel oil. Replace defective injector nozzle tips as necessary.

c. Accomplish machining of the injector nut landing surface (flattening).

d. Reassemble and reinstall the twenty five (25) fuel injector assemblies in accordance with section 6-32.7 through 6-32.8 of Ref. 2.1.1.

7.3 Inspection/Test:

7.3.1 The contractor and OEM shall accomplish with the assistance of the Chief Engineers and Port Engineer Enclosure 2.2.5. Once this check sheet is accomplished and the Chief Engineer and Port Engineer receives in writing from the OEM that the Engine is ready to light off per Para 7.9.2 the engine can be started and the testing in 7.3.2 can be accomplished

7.3.2 Accomplish an operational test and break-in of the main engine for a minimum of eight (8) hours during the scheduled dock trial and sixteen (16) hours during the scheduled sea trial. Engine break in shall be accomplished in accordance with reference 2.1.3. Monitor and record all applicable pressures and temperatures. Identify and repair any loose or leaking joints, components or fittings.

7.4 Insulation/Lagging:

7.4.1 Remove and inspect all insulation and lagging pads necessary to gain access to repairs during the performance of this work item.

7.4.2 Submit two (2) copies of a written report of the condition of the removed insulation and lagging pads, along with recommended repairs or replacements, to the Port Engineer.

7.4.3 Upon completion of repairs, reinstall all insulation and lagging pads as original.

7.5 Contractor shall throughout the performance of this work item refer to the Wear and Clearance Tables provided in Enclosure 2.2.3 when determining if parts or assemblies are acceptable for use/reuse

7.6 Contractor shall throughout the performance of this work item refer to the Main Engine Tightening Torque Tables provided as Enclosure 2.2.4 to ensure proper Torque values are applied during reassembly of parts, assemblies, components and engine.

7.7 All dirt and debris resulting from this work item shall be removed from the ship daily and all areas left clean and in good order.

7.8 Manufacturer’s Representative:

7.8.1 Contractor shall provide the services of an Original Equipment Manufacturer (OEM) Authorized PC4.2 Technical Field Service Representative and OEM authorized PC4.2 repair shop facility for the equipment specified in paragraph 3.2 throughout the performance of this work item. The equipment addressed in this Statement of Work (SOW) is categorized as critical equipment in accordance with MSC policy on the classification of critical shipboard systems and equipment. Only Original Equipment Manufacturer (OEM) authorized technical field service representatives, repair shop facility and OEM parts shall be used to accomplish the requirements of this SOW for this critical equipment including oversight and guidance on all aspects of equipment as-found condition inspection, removal, disassembly, reassembly, repairs, modifications, reinstallation and testing as applicable.

7.8.1.1 An OEM Authorized Technical Field Service Representative and repair shop facility is defined as either a direct employee of the OEM, or an employee of a company which has a current written agreement with the OEM to provide service and repair for that equipment. The OEM authorized technical field service representative and repair shop facility shall have full access to the OEM drawings, technical service bulletins, special tools and OEM replacement parts. The OEM Authorized Technical Field Service Representative and repair shop facility shall provide documentation from the OEM authorizing the company to perform maintenance and repair on their behalf.

7.8.1.2 Provide the services of an Original Equipment Manufacturer (OEM) Authorized PC4.2 Technical Field Service Representative to supervise/ accomplish all onsite work required by this statement of work requiring the inspection, overhaul, replacement and testing of the main engines and components of the Port and Starboard Main Propulsion Engines using Reference 2.1.1 through 2.1.3 as guidance.

7.8.1.3 The OEM Authorized Technical Field Service Representative and repair shop facility to support this work item are listed below. The identification of an OEM Authorized Technical Field Service Representative and repair shop facility herein is provided for reference and informational purposes only and does not constitute or imply an endorsement, recommendation, or favoring by the United States Government:

7.9 Upon completion of the aforementioned overhaul, repairs, inspections, and tests, provide three (3) copies of a typewritten report to Include the Main Engine Forms provided in Enclosure 2.2.2, prepared by the OEM authorized technical field service representatives, to the MSCREP detailing the results of all visual inspections, clearance readings, repairs performed, test results, corrective actions, photographs taken, and any recommendations for future repairs. Report shall be submitted to the MSCREP no later than 48 hours after completion of sea trials.

7.9.1 OEM Authorized Technical Field Service Representative shall submit overhaul report consisting of (at a minimum) the information identified in enclosure 2.2.2 days prior to engine light off.

7.9.2 Upon Completion of overhaul the OEM Authorized Technical Field Service Representative shall certify in writing to the Chief Engineer and Port Engineer that the engine(s) is ready for light off prior to the Light Off Milestone date per Work Item 013 “Project Planning and Production Status Monitoring Reports and Work Item 022 “Machinery Space Turn-Over, Dock Trials and Sea Trials”.

8.0 GENERAL REQUIREMENTS: None

Enclosures 2.2.1 List of Government Furnished Material

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 1 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 2 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 3 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 4 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 5 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 6 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 7 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 8 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 9 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 10 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 11 of 12)

ENCLOSURE 2.2.2 - ME FORMS FOR FINAL REPORT (Page 12 of 12)

ENCLOSURE 2.2.3 WEAR AND CLEARANCE TABLE (Page 1 of 3)

ENCLOSURE 2.2.3 WEAR AND CLEARANCE TABLE (Page 2 of 3)

ENCLOSURE 2.2.3 WEAR AND CLEARANCE TABLE (Page 3 of 3)

ENCLOSURE 2.2.4 - ME TIGHTENING TORQUE TABLE (Page 1 of 4)

ENCLOSURE 2.2.4 - ME TIGHTENING TORQUE TABLE (Page 2 of 4)

ENCLOSURE 2.2.4 - ME TIGHTENING TORQUE TABLE (Page 3 of 4)

ENCLOSURE 2.2.4 - ME TIGHTENING TORQUE TABLE (Page 4 of 4)

ENCLOSURE 2.2.5 Diesel Engine Pre-Start Check Sheet (Page 1 of 2)

ENCLOSURE 2.2.5 Diesel Engine Pre-Start Check Sheet (Page 2 of 2)

ENCLOSURE 2.2.6 Coltec Industries Inc., Fairbanks Morse Engine Division, Conrod Bolt NDT Procedure (Page 1 of 5).

ENCLOSURE 2.2.6 Coltec Industries Inc., Fairbanks Morse Engine Division, Conrod Bolt NDT Procedure (Page 2 of 5).

ENCLOSURE 2.2.6 Coltec Industries Inc., Fairbanks Morse Engine Division, Conrod Bolt NDT Procedure (Page 3 of 5).

ENCLOSURE 2.2.6 Coltec Industries Inc., Fairbanks Morse Engine Division, Conrod Bolt NDT Procedure (Page 4 of 5).

ENCLOSURE 2.2.6 Coltec Industries Inc., Fairbanks Morse Engine Division, Conrod Bolt NDT Procedure (Page 5 of 5).

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