MIDGETT (WMSL 418) 8K FQ2 ECK 2400 REV-1.pdf

USCGC MIDGETT (WMSL 757)

SPECIFICATION FOR

NR 1 & 2 MAIN PROPULSION DIESEL ENGINE (MPDE)

8,000 HOUR MAINTENANCE

FQ2 FY25

Developed By: LRE APM2

(Rev-1, 11 Nov 2024)

USCGC MIDGETT (WMSL-418) NR 1 & 2 MPDE 8K MAINTENANCE FQ2 FY25

ii (Rev-01)

TABLE OF CONTENTS

Revisions Record ......................................................................................................................................... iii Consolidated List of References ................................................................................................................... iv Consolidated List of Government-furnished Property ................................................................................. vi Consolidated List of Critical Inspection Items ........................................................................................... vii Principal Characteristics ............................................................................................................................ viii General Requirements WORK ITEM 1: Main Propulsion Diesel Engine (MPDE) Geislinger Coupling, Clean & Inspect WORK ITEM 2: Main Propulsion Diesel Engine, Diesel Engine Inspection, Perform WORK ITEM 3: Main Propulsion Diesel Engine, 8000hr, Maintenance, Perform WORK ITEM 4: Fire Prevention, Provide

USCGC MIDGETT (WMSL-418) NR 1 & 2 MPDE 8K HOUR MAINTENANCE FQ2 FY25

iii (Rev-01)

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

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-01)

CONSOLIDATED LIST OF REFERENCES

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at the time of specification writing and during contract execution.

All Coast guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – from links located on the SFLC website. Commercial sites provide access to their respective documents.

COAST GUARD DRAWINGS

Coast Guard Drawing FL-1204-3, Rev A, Fleet Welded Padeyes and Links

Coast Guard Drawing 750-WMSL 100-001, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750-WMSL 501-002, Rev E, Machinery Arrangements (ASC501001)

Coast Guard Drawing 750-WMSL-100-90, Rev A, General Arrangements NSC 7 And follow.

(ASC710001)

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General

Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and

Allied Processes

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2022, Auxiliary

Machine Systems

Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), 2022, Fire

Prevention and Response

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

Coast Guard Technical Publication 7231A, SWBS 233, Jan 2022, Main Diesel Engine (MDE) Model 20

V 1163 TB93 System Documentation Major Overhaul Instructions

Coast Guard Technical Publication 7024A, 27 Nov 2018, Main Diesel Engine – Model 20 V 1163 TB93 -

Removal Spaces and Weights

Coast Guard Technical Publication 7025A, 30 Oct 2017, Main Diesel Engine – Model 20 V 1163 TB93 -

Fluids and Lubricants Specifications (A001061/35E)

Coast Guard Technical Publication 7026, 31 May 07, Main Diesel Engine – Model 20 V 1163 TB93 -

Repair Tool Catalog

Coast Guard Technical Publication 7231A, 15 May 2020, Main Diesel Engine – Model 20 V 1163 TB93

– System Documentation – Major Overhaul Instructions v (Rev-01)

Coast Guard Technical Publication 9554_233_A, 01 Oct 2021, Main Diesel Engine – Model 20 V 1163

TB93 – Plant Documentation

Coast Guard Technical Publication 9553, 07 Nov 2017, Main Diesel Engine – Model 20 V 1163 TB93 –

Parts Catalog (M030298/00DE)

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Subpart E, Sep 2015, Scaffolds, Ladders and

Other Working Surfaces

The Society for Protective Coatings (SSPC) Paint Application Specification No. 1 (SSPC-PA Guide 1), 2024, Shop, Field, and Maintenance Painting of Steel ANSI/EASA Standard AR100-2020, Recommended Practice for the Repair of Rotating Electrical Apparatus

MIL-C-24757, Nov 1990, Cloth, Fiberglass, Coated vi (Draft-1)

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

WORK

ITEM

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST

($/UNIT)

2 N Parts Kit, Diesel Engine NSN: 2815-01-628-0945 PN:

584-DEI-KIT

2 ea $3,068.69

3 Y Cylinder Head Replacement Kit P/N: 584-CYL-HD-RPLM

NSN: 016192838

40 ea $15450.56

3 Y Cylinder Liner Kit P/N: 584-CYL-LNR-KIT

NSN: 016192672

40 ea $3672.81

3 N Piston Engine P/N: 5840301117

NSN: 123349610

40 ea $10180.72

3 Y LP Turbocharger Replacement Kit P/N: 584-LPTURBO-

RPLM

NSN: 016194969

10 ea. $36564.41

3 Y HP Turbocharger Replacement Kit P/N: 584-HPTURBO-

RPLM

NSN: 016200381

10 ea. $22072.33

3 Y Injector Replacement Kit 2910-01-621-1898/

584-INJ-SWAP-KIT

40 $116.62

3 Y Fuel Injection Pump Kit

584-FL-INJ-PMP-KIT

NSN: 016192228

40 ea. $3,000.00

3 Y Jacket water pump LS Replacement

Kit

584-JWPMPLS-RPLM

NSN: 016263405

2 ea. $4,000.00

3 Y Jacket water pump RS Replacement

Kit

584-JWPMPRS-RPLM

NSN: 016192545

2 ea. $4,000.00

3 Y Sea water pump Replacement Kit 584-SWPMP-RPLM

NSN: 016192264

2 ea. $8,000.00

3 Y Lube Oil Pump Kit 584-LO-PMP-KIT

NSN: 016192729

4 ea. $60,000.00

3 N Preheater Pump Replacement Kit 584-PREHTRPMP-RPLM

NSN: 016192234

2 ea. $3,035.00

3 N Conrod Bearing 5840301960 NIIN:

NIIN: 123587417

40 ea. $941.03

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

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

***Government-furnished property, which is to be supplied by either the vessel or the C4IT ServiceCenter vii (Rev-01)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5

(Inspection report particulars)):

Work

Item

Title

None viii (Rev-01)

PRINCIPAL CHARACTERISTICS

418' WMSL

PHYSICAL

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

MACHINERY

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

HULL

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"

ELECTRICAL

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 gal

Fresh water 12,454 gal

JP-5 Fuel 35,182 gal

1 (Rev-01)

00000_0824_FLT

REC_00000_FLT_Commercial Project @ CG Facility (0121)

General Requirements

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed by commercial contractors at a Coast Guard facility for Coast Guard vessels.

1.2 Term interchangeability. The terms 'Contractor', 'CG Yard', 'NAVSTA EVERETT', 'shipyard', 'Base', and 'Coast Guard Industrial' are used interchangeably in this specification. Where the primary service provider is Coast Guard personnel, references to contractor and other noted descriptors within this specification or within drawings, publications, SFLC Standard Specifications or other commercial and military references are deemed the same as prime service provider.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color

Manual

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), Latest

Version, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), Latest

Version, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), Latest

Version, Fire Prevention and Response

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), Latest

Version, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Occupational Safety and Health

Standards for Shipyard Employment

NAVSEA Technical Publication T9074-AD-GIB-010/1688, (TP 1688), July 2012, Requirements for Fabrication, Welding, and Inspection of Submarine Structure

2 (Rev-01)

3. REQUIREMENTS

3.1 General. The Contractor must conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability. The requirements in this WI applies to all work under the scope of this contract, whether explicitly stated in all following work items or not, and to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.1.1 The Contractor must conform to all requirements specified in SFLC Std Spec 5550 and in the Fire

Protection and Response work item, as applicable, during the performance of this availability.

3.1.1.1 Fire Safety Plan submission. The Contractor must submit a copy of the CFR 1915, Subpart P, Fire

Safety Plan with the Contractor’s bid when work will be conducted in a Contractor–owned facility.

Include any MOA(s) with local firefighting facilities.

3.1.1.2 Fire Plan submission. The Contractor must submit a copy of the developed availability specific fire plan, as requested in the Fire Protection and Response work item, seven (7) days before the Arrival

Conference.

NOTE

NAVSEA drawings listed will be available FOR INSPECTION ONLY from the Coast Guard Port Engineer post-award. SFLC will not redistribute

NAVSEA documents. Contractors can apply to NAVSEA headquarters directly for copies.

3.2 Contractor-provided fire watch personnel. The Contractor must provide fire watch personnel and equipment.

3.3 Preservation requirements. The Contractor must accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC

Std Spec 6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

3.3.2 Coating colors and system color schemes. The Contractor must obtain a written KO authorization to deviate from any coatings required in SFLC Std Spec 6310 Appendix C before work.

3.4 Welding and brazing requirements. The Contractor must perform all welding and allied processes, and

NDE in accordance with SFLC Std Spec 0740.

3.5 Environmental protection requirements. The Contractor must adhere to the following environmental protection requirements in accordance with the SFLC Stand Spec 0000:

3.5.1 USCG facilities. The Contractor must provide and maintain environmental protection as defined in

SFLC Std Spec 0000 Appendix B, Requirements for Environmental Protection at USCG Facilities, during the performance of this availability. Contractor must plan for and provide environmental protective measures to control pollution that develops during normal practice, as well as plan for and provide environmental protective measures required to correct conditions that develop during the project.

Contractor must comply with applicable Federal, state, and local laws, codes, ordinances, and regulations in their entirety. Any reference to a specific portion of a Federal, state, or local law, code, ordinance, or

3 (Rev-01) regulation in this or any other item must not be construed to mean that relief is provided from any other sections of the law, code, ordinance, or regulation.

3.5.1.1 USCG Generator status. The activity Generator Status for the Coast Guard Facility is

(H18690390036).

3.5.1.2 Plans and permits. The CG Facility has unit specific permits including the following:

• Spill Prevention Control and Countermeasures (SPCC) Plan: Unit has a SPCC Plan which requires certain unit-specific procedures be followed for the storage, inspection, and transfer of petroleum products in containers 55 gallons or greater.

• National Pollutant Discharge Elimination System (NPDES) Storm Water (SW) Permit: Unit has an NPDES SW permit which requires unit-specific procedures be followed for the storage and inspection of equipment and materials which may contribute contaminants to storm water discharges.

• Air Emission Permit: Unit has an Air Emission Permit which requires unit-specific procedures be followed for the emissions of VOCs and hazardous air pollutants.

3.5.2 Test and procedures. The Contractor is required to promptly conduct tests and procedures for the purpose of assessing whether operations are in compliance with applicable Environmental Laws.

Analytical work must be done by qualified laboratories; and where required by law, the laboratories must be certified.

3.5.3 Regulatory notifications. The Contractor is responsible for all regulatory notification requirements in accordance with Federal, State and local regulations. In cases where the Coast Guard must also provide public notification, such as storm water permitting, the Contractor must coordinate with the Contracting

Officer or COR, and if work is being performed at a USCG Facility, the local Facility Engineer or

Engineering Officer. The Contractor must submit copies of all regulatory notifications to the Contracting

Officer and the local Facility Engineer or Engineering Officer prior to commencement of work activities.

Regulatory notifications must be provided for including but not limited to demolition, renovation, National Pollutant Discharge Elimination System (NPDES) defined site work, and remediation of controlled substances such as asbestos, hazardous waste, and lead paint.

3.5.4 Environmental manager. The Contractor must appoint in writing an Environmental Manager for the project, who is responsible for coordinating Contractor compliance with Federal, State, local, and station environmental requirements. The Environmental Manager must ensure compliance with Hazardous Waste

Program requirements, including hazardous waste handling, storage, manifesting, and disposal;

implement the Contractors’ Environmental Management Plan; ensure that all environmental permits are obtained, maintained, and closed out; ensure compliance with Storm Water Program Management requirements; ensure compliance with Hazardous Materials including storage, handling, and reporting requirements; as well as coordinate any remediation of regulated substances such as lead, asbestos, and polychlorinated biphenyl (PCB). This may be a collateral position; however the individual must be trained to accomplish the following duties; ensure waste segregation and storage compatibility requirements are met; inspect and manage Satellite Accumulation areas; ensure only authorized personnel add wastes to containers; ensure all Contractor personnel are trained in 40 CFR requirements and individual position requirements; coordinate removal of waste containers; and maintain the

Environmental Records binder and required documentation, including environmental permits compliance and close-out.

3.5.5 HW disposal. Contractor must comply with SFLC Std Spec 0000 Appendix B, Requirements For

4 (Rev-01)

Environmental Protection At USCG Facilities for HW disposal, and ensure that waste removals are conducted during normal business hours (0800-1600) on Monday through Friday (excluding holidays).

3.5.6 Additional Requirements. The Contractor must be aware of the following:

3.5.6.1 No Contractor or Subcontractor must have the authority to sign a Hazardous Waste Manifest using the Coast Guard facility’s EPA Generator ID Number or remove contract generated hazardous waste from the Coast Guard facility without COR or KO-approval.

3.5.6.2 Local environmental regulations at the Government facilities may be more stringent. As with all environmental regulations, the Contractor must prepare for and comply with local and state regulations.

3.5.6.3 Coast Guard facilities do not maintain Facilities Response Plans (FRPs) per 33 CFR 154.

Contractor must furnish the FRP when required for over-the-water liquids transfers to and from vessels, and is required for oil/fuel transfers to/from vessels for 250 barrels (10,500 gallons) or more.

3.6 Local Policy. The Contractor must refer to site (e.g., Base) Regulations and Instructions for details regarding local policies (e.g., crane services, parking, or facility usage).

4. NOTES

None.

5 (Rev-01)

43600_BEC_0924_757

WORK ITEM 1: Main Propulsion Diesel Engine (MPDE) 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 for the Main Propulsion Diesel Engines (MPDE) listed in Table 1.

TABLE 1 – MPDE NAME PLATE DATA

EQUIPMENT MODEL NUMBER LOCATION

Main Propulsion Diesel Engine #1, 9666 HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

Main Propulsion Diesel Engine #2, 9666 HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing FL-1204-3, Rev A, Fleet Welded Padeyes and Links

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication 7231A, SWBS 233, Jan 2022, Main Diesel Engine (MDE)

Model 20 V 1163 TB93 System Documentation Major Overhaul Instructions

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2022, Auxiliary Machine Systems

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Subpart E, Sep 2015, Scaffolds, Ladders and Other Working Surfaces

6 (Rev-01)

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor must provide the services of an OEM authorized/ licensed Tech Rep for

Rolls Royce Solutions America Inc., specifically for the MTU 20V1163TB93 Diesel Engine, to accomplish the following on site:

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

WORK ITEM 1: Be present and assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé. Submit by CFR to the Coast Guard.

NOTE

The MTU America Inc. Technical Representative may be present at other times in addition to the mandatory times listed above. The above represents the minimum required Technical Representative usage.

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, (Interferences). Known interferences include, but are not limited to the following:

• Piping systems

• Electrical cables

• Catwalks

3.1.5 Scaffolding, safety, and protection. The Contractor must comply with all required and applicable safety and protection specified in SFLC Std Spec 0000, Paragraph 3.3.1 (Personnel safety and property protection - general), and all OSHA safety and health regulations, and any other applicable federal, state, and local laws, and regulations, for the protection of both personnel and property.

• Suitable Scaffolding and/or lifelines are required for working above five feet (29 CFR 1910 and 1915)

• Temporary lines or rails must be installed in place of all removed lifelines or life rails, and be retained until replacement tasks have been completed.

• Adequate illumination is required in walkways, work areas, and access to provide a safe work environment (29 CFR 1915.92(a))

3.1.6 Rigging. The Contractor is responsible for rigging of all and necessary tools, materials, including

GFP form and to the pier as well as from and to the engine room. When necessary, the Contractor must provide crane service to move materials, tools and GFE to and from pier, deck and engine room.

7 (Rev-01)

3.1.6.1 All existing padeyes that will be used for a lift must be pull tested to 1.5 times their Working Load

Limit in accordance with SFLC Standard Spec 5000 Paragraph 3.2.7. All testing must occur in the presence of a Coast Guard Inspector. Submit results to Coast Guard by CFR.

3.1.6.2 If new padeyes are required, fabricate them in accordance with Coast Guard Drawing FL-1204-3 and SFLC Standard Spec 0740. Newly fabricated padeys must be pull tested to 2 times their Working

Load Limit in accordance with SFLC Standard Spec 5000 Paragraph 3.2.7. All testing must occur in the presence of a Coast Guard Inspector.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.2 Operational test, initial. Prior to commencement of work, the Contractor must witness Coast Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR.

3.3 Disassembly, cleaning, and inspection. In the presence of the Tech Rep and Coast Guard Inspector, the Contractor must disassemble, clean, and inspect the Geislinger couplings from the MPDEs listed in

Table 1 in accordance with Section 88 of Coast Guard TP 7231A. Submit a CFR with the general condition of the coupling, and with the measurements from Section 88.5. The Contractor is only required to disassemble the coupling sufficiently to take the measurement in Section 88.5.

3.4 Assembly and reinstallation. Once the couplings are inspected and discrepancies corrected, and approval from CG Inspector is received, the Contractor must assemble and reinstall the couplings in accordance with Section 88 of Coast Guard TP 7231A and guidance from the Tech Rep.

3.5 MDE alignment check. The Contractor, in the presence of the Tech Reps and a Coast Guard

Inspector, must check MDE alignment using laser instrumentation. Deformation may occur during the day, so laser alignment must be done between 2200 and 0700 to minimize this distortion. Alignment readings must provide axial and radial dislocation, along with angular distortion between the main diesel engine output flange and the center of the reduction gear input flange. Compare alignment readings to the required alignment as detailed in Figure 1. Submit a CFR.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.6 Operational test, post repairs. After completion of work, the Contractor must thoroughly test, in the presence of the Coast Guard Inspector and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

8 (Rev-01)

Figure 1. MDE alignment targets

9 (Rev-01)

23300_TAB_0318_418

WORK ITEM 2: Main Propulsion Diesel Engine, Diesel Engine Inspection, Perform

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform Diesel Engine

Inspection (DEI) for both Main Propulsion Diesel Engines (MPDE) listed in Table 1.

TABLE 1 – MPDE NAME PLATE DATA

EQUIPMENT MODEL NUMBER LOCATION

Main Propulsion Diesel Engine,9666

HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

Main Propulsion Diesel Engine,9666

HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST ($/UNIT)

N PARTS KIT,DIESEL

ENGINE

NSN: 2815-01-628-0945

PN: 584-DEI-KIT

2 3,068.69

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL 100-001, Rev L, General Arrangements (ASC100001)

Coast Guard Drawing 750-WMSL 501-002, Rev E, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication 7024A, 27 Nov 2018, Main Diesel Engine – Model 20 V

1163 TB93 - Removal Spaces and Weights

Coast Guard Technical Publication 7025A, 30 Oct 2017, Main Diesel Engine – Model 20 V 1163

TB93 - Fluids and Lubricants Specifications (A001061/35E)

Coast Guard Technical Publication 7026, 31 May 07, Main Diesel Engine – Model 20 V 1163

TB93 - Repair Tool Catalog

Coast Guard Technical Publication 7231A, 15 May 2020, Main Diesel Engine – Model 20 V

1163 TB93 – System Documentation – Major Overhaul Instructions

10 (Rev-01)

Coast Guard Technical Publication 9554_233_A, 01 Oct 2021, Main Diesel Engine – Model 20 V

1163 TB93 – Plant Documentation

Coast Guard Technical Publication 9553, 07 Nov 2017, Main Diesel Engine – Model 20 V 1163

TB93 – Parts Catalog (M030298/00DE)

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Subpart E, Sep 2015, Scaffolds, Ladders and Other Working Surfaces

The Society for Protective Coatings (SSPC) Paint Application Specification No. 1 (SSPC-PA

Guide 1), 2004, Shop, Field, and Maintenance Painting of Steel

3. REQUIREMENTS

3.1 General.

3.1.1 CIR

None.

3.1.2 Tech Rep. The Contractor shall provide the services of an OEM authorized/ licensed Tech Rep for

MTU America Inc., specifically the MTU 20V1163TB93 Diesel Engine, to accomplish the following tasks – on site:

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

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

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé.

3.1.2.2 Submit the name of the Tech Rep to the COR at the Arrival Conference.

NOTE

The MTU America Inc. Technical Representative may be present at other times in addition to the mandatory times listed above. The above represents the minimum required Technical Representative usage.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all

11 (Rev-01) 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 handle all interferences in accordance with SFLC Std Spec 0000, par. 3.3.5 (Interferences). Known interferences include, but are not limited to the below-listed:

• Access covers.

• Exhaust stack.

• Piping.

• Vent ducting.

• Electrical Cables

• Removed Fluids (Oils and coolant)

3.1.5 Operational test - initial. Prior to commencement of work, the Contractor shall witness Coast Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.1.6 Scaffolding. The Contractor shall, in accordance with CFR Title 29, Part 1915, Subpart E, erect suitable staging or scaffolding, as required, to facilitate work.

3.1.7 Safety precaution. The Contractor shall rig suitable safety netting, to protect workers during possible falls, and to protect the Engine Room and machinery from falling tools.

3.1.8 Materials. The Contractor shall provide all consumable materials, equipment, and tools required to perform the inspection on the Port and Starboard Main Diesel Engines except for parts listed as GFP.

3.1.9 Fluid handling. The Contractor shall dispose all fluids in accordance with all applicable Federal, state, and local regulations and SFLC Std Spec 0000.

3.1.10 Rigging. The Contractor is responsible for rigging of all and necessary tools, materials, including

GFP form and to the pier as well as from and to the engine room. When necessary, the Contractor shall provide crane service to move materials, tools and GFE to and from pier, deck and engine room.

3.2 Diesel engine inspection. The Contractor shall follow directions from Tech Rep, OEM instructions and applicable Technical Publications referenced above; to perform the standard OEM recommended tasks for DEI for both MPDEs.

3.2.1 The Contractor shall submit a CFR at earliest opportunity to report any discrepancies, defects or unexpected wear discovered during this DEI for the tasks listed below:

• Visual Inspections

• Cylinder Compression Readings

• Valve Clearance Readings

• Engine coolant and Fuel

• Turbocharger Inspections

12 (Rev-01)

• Gear Case Inspections

• Cylinder Liner Inspections

• Air Bank Inspections

• Filter Element Inspection and replacement

• High pressure and low pressure air coolers

• Piston oil cooling filters

NOTE

The items inspected during a DEI have been identified by the OEM and/or

Coast Guard as being major inspection items or items that have determined that need to be inspected from prior failure.

3.2.1.1 The Contractor shall complete the DEI work within the first 40% of the contract period to allow the Coast Guard to contract for any additional repairs.

3.2.2 Download engine operation data from the LOS program aboard the cutter.

3.2.3 Submit a separate final report for each engine noting the condition of each engine, any inspection results and LOS data plots.

3.2.4 Reassemble all parts of each engine which were disassembled to perform inspections.

3.3 Operational test – post repairs. After completion of work, the Contractor shall thoroughly test, in the presence of the Coast Guard Inspector and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

3.4 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed surfaces to match existing adjacent surfaces to ASNI Gray 61 color in accordance with SFLC Std Spec 6310, paragraph

3.1.13 (Touch-ups and minor coating repairs).

4. NOTES

4.1 Parts kit. The part kit for each engine, includes the following as of 01 April 2017 and should be used as a reference:

TABLE 2- PARTS KIT

PART NUMBER DESCRIPTION INDIVIDUAL PN QTY

584-DEI-KIT Diesel Engine Inspection Kit

Head

Sealing Ring 5800110259 20

Gasket 5800980465 20

Secondary F/O Filter

F/O Element 000921705 8

O-Ring 700294014005 2

O-Ring 700294125000 4

13 (Rev-01)

PART NUMBER DESCRIPTION INDIVIDUAL PN QTY

Washer, Copper 007603021100 4

Sealing ring 8499970870 8

Sepr F/O Filter Assy

Sealing ring 8499970036 2

Primary Filter Element 0000925005 8

Cap Nut 001587008002 10

Washer 000125008427 10

Gear Case

Gasket 5840151080 2

Gasket 5840150980 1

Gasket 5731840180 1

Gasket 5841870880 1

O-ring 700429110000 2

Piston Cooling Filter

Element 0031845301 3

Oil Filters

Element 0001846026 4

O-Ring 700429190003 4

O-Ring 700429042002 4

Sealing Ring 007603039100 2

O-Ring 700429058001 2

Sealing Ring 8491840100 2

O-Ring 700429065001 4

Disc Pack Filter

Sealing Ring 007603080101 1

Washer, Copper 007603014106 1

Sealing Ring 007603012112 1

Charge Air Ducting

O-Ring 700429028000 5

Washer , Copper 007603030101 5

Crankcase Inspection Doors

Rubber, Ring 0029971248 10

O-Ring 700429095004 4

Centrifugal Oil Filter

Gasket, Kit XP58400600001 1

Paper, Element 8491840210 1

Sealing , Ring 007603026106 1

O-Ring 700429192000 1

O-Ring 700429245001 1

Washer, Copper 007603014102 1

Injector

Sealing Ring 5840170160 4

O-Ring 700429041000 8

H/P Fuel System

O-Ring 700429020003 4

O-Ring 700429017002 8

14 (Rev-01)

PART NUMBER DESCRIPTION INDIVIDUAL PN QTY

O-Ring 700429028002 8

O-Ring 700429019000 4

O-Ring 700429030000 8

L/P Fuel System

O-Ring 700429028002 40

15 (Rev-01)

23300_TAB_0817_418

WORK ITEM 3: Main Propulsion Diesel Engine, 8000hr, Maintenance, Perform

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform 8000 Hour of the

Maintenance of the Main Propulsion Diesel Engines (MPDE) listed in Table 1.

TABLE 1 – MPDE NAME PLATE DATA

EQUIPMENT MODEL NUMBER LOCATION

Main Propulsion Diesel Engine No.1

9666 HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

Main Propulsion Diesel Engine No.2

9666 HP, MTU Detroit Diesel, Inc.

20V 1163 TB 93 AFT Main Machinery Room (5-52-01-E)

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST

($/UNIT)

Y Cylinder Head Replacement Kit P/N: 584-CYL-HD-RPLM

NSN: 016192838

40 ea 15450.56

Y Cylinder Liner Kit P/N: 584-CYL-LNR-KIT

NSN: 016192672

40 ea 3672.81

N Piston Engine P/N: 5840301117

NSN: 123349610

40 ea 10180.72

Y LP Turbocharger Replacement Kit P/N: 584-LPTURBO-RPLM

NSN: 016194969

10 ea. 36564.41

Y HP Turbocharger Replacement Kit P/N: 584-HPTURBO-RPLM

NSN: 016200381

10 ea. 22072.33

Y Injector Replacement Kit 2910-01-621-1898/

584-INJ-SWAP-KIT

40 $116.62

Y Fuel Injection Pump Kit

584-FL-INJ-PMP-KIT

NSN: 016192228

40 ea. $3,000.00

Y Jacket water pump LS Replacement Kit 584-JWPMPLS-RPLM

NSN: 016263405

2 ea. $4,000.00

Y Jacket water pump RS Replacement Kit 584-JWPMPRS-RPLM

NSN: 016192545

2 ea. $4,000.00

Y Sea water pump Replacement Kit 584-SWPMP-RPLM

NSN: 016192264

2 ea. $8,000.00

Y Lube Oil Pump Kit 584-LO-PMP-KIT

NSN: 016192729

4 ea. $60,000.00

N Preheater Pump Replacement Kit 584-PREHTRPMP-RPLM

NSN: 016192234

2 ea. $3,035.00

16 (Rev-01)

N Conrod Bearing 5840301960 NIIN:

NIIN: 123587417

40 ea. $941.03

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 750-WMSL-100-90, Rev A, General Arrangements NSC 7 And follow.

(ASC710001)

Coast Guard Drawing 750-WMSL-501-002, Rev E, Machinery Arrangements (ASC501001)

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication 7231A, 15 May 2020, Main Diesel Engine – Model 20 V

1163 TB93 – System Documentation – Major Overhaul Instructions

Coast Guard Technical Publication 9554, 01 Oct 2021, Main Diesel Engine – Model 20 V 1163

TB93 – Plant Documentation

Coast Guard Technical Publication 9553, 07 Nov 2017, Main Diesel Engine - Parts Catalog

(M030298/00DE)

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 29, Part 1915, Subpart E, Sep 2015, Scaffolds, Ladders and Other Working Surfaces

The Society for Protective Coatings (SSPC) Paint Application Specification No. 1 (SSPC-PA

Guide 1), 2004, Shop, Field, and Maintenance Painting of Steel

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of an OEM authorized/ licensed Tech Rep for

MTU America Inc., specifically the MTU 20V1163TB93 Diesel Engine, to accomplish the following tasks – on site:

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

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

17 (Rev-01)

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé.

3.1.2.2 Submit the name of the Tech Rep to the COR at the Arrival Conference.

NOTE

The MTU America Inc. Technical Representative may be present at other times in addition to the mandatory times listed above. The above represents the minimum required Technical Representative usage.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near 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 handle all interferences in accordance with SFLC Std Spec

0000, par. 3.3.5 (Interferences). Known interferences include, but are not limited to the below-listed:

• Access covers.

• Exhaust stack.

• Piping.

• Pipe insulation.

• Vent ducting.

• Wiring.

• Exhaust pipe expansion joints.

• Exhaust insulation blankets.

3.1.5 Operational test - initial. Prior to commencement of work, the Contractor shall witness Coast

Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Submit a CFR.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.1.6 Scaffolding. The Contractor shall, in accordance with CFR Title 29, Part 1915, Subpart E, erect suitable staging or scaffolding, as required, to facilitate work.

3.1.7 Safety precaution. The Contractor shall rig suitable safety netting, to protect workers during possible falls, and to protect the Engine Room and machinery from falling tools.

3.1.8 Materials. The Contractor shall provide all required materials for 8000 Hour of the Maintenance of the MPDEs listed in Table 1.

3.1.9 The contractor shall dispose all fluids in accordance with all applicable Federal, state, and local regulations and SFLC STD SPEC 0000.

18 (Rev-01)

3.1.10 Rigging. The Contractor is responsible for rigging of all and necessary tools, materials, including

GFP form and to the pier as well as from and to the engine room. When necessary, the Contractor shall provide crane service to move materials, tools and GFE to and from pier, deck and engine room.

3.2 Maintenance and Inspection. The Contractor shall follow directions from Tech Rep and TP 7027 as needed to accomplish the maintenance, inspections and repairs required for the 8000 Hour Maintenance

Schedule for items listed on Table 2. Submit CFR.

TABLE 2 – MAINTENANCE ITEMS FOR EACH MPDE

ITEM MAINTENANCE TASK TASK #

Centrifugal Oil Filter Check thickness of residue layer, Clean. Fit new sleeve. W1009

Emergency Air Shut-Off Check operation of emergency shut-off flaps W1024

Valve Gear Check valve clearance, adjust if necessary W1002

Level Monitors Check coolant level monitor for correct operation, check oil level monitor for correct operation.

W1023

Fuel Filter Fit new filter or new filter insert W1001

Lubrication Points Apply lubricant at lubrication points. W1053

Intercooler (High And

Low Pressure) Clean interior and inspect for leakage

Fuel Injectors Renew all injectors

Engine Mounts Check buffer clearance of resilient mounts. Check proper seating of securing screws.

W1026

Raw Water Pump Inspect pump impeller in place

Engine Coolant Pump Renew seals

Cylinder Head Replace 20 cylinder heads

Cylinder Liner Fit new ones as appropriate. Fit new seals. Inspect fits and coolant chambers.

W1101

Turbo Charger Renew Turbo Charger W1038

Turbo Charger Switching

System

Overhaul Exhaust Flaps, Air Flaps, Actuating Cylinders and

Solenoids W1131

Piston Remove Pistons, Skirts and Crowns, Fit new Piston Rings and replace with new W2044

Component Maintenance Renew Engine Coolant Thermostat W2038

Component Maintenance Check Rockers, roller tappets, pushrods, and pushrod ball heads for wear.

W2084

Charge-air preheating Remove, clean, replace seal on the valve face of the charge air cooler temperature control (TC) valve

3.3 Inspection of removed turbochargers. The Contractor shall hand clean all accessible metallic parts of the removed turbochargers and visually inspect the turbochargers for any defects, corrosion, or damage.

Submit a CFR.

3.4 The Contractor shall use the boxes and packing materials from the new turbochargers to pack the used turbocharger cores. Deliver the boxes with the used turbochargers to COR.

3.5 Operational test – post repairs. After completion of work, the Contractor shall thoroughly test, in the presence of the Coast Guard Inspector and demonstrate all items or shipboard devices that have been disturbed, used, repaired, altered, or installed to be in satisfactory operating condition. Submit a CFR.

19 (Rev-01)

3.6 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed surfaces to match existing adjacent surfaces to ASNI Gray 61 color in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs).

This section is not applicable to this work item.

55500_0523_BJA_418

WORK ITEM 4: Fire Prevention, Provide

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to provide a fire plan, discuss fire safety procedures, maintain fire boundaries and fittings, conduct inspections and keep firefighting systems in a ready condition to address fires.

Contractors are not required to fight fires aboard USCG Cutters

None.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 5550 (SFLC Std Spec 5550), 2022, Fire

Prevention and Response

OTHER REFERENCES

MIL-C-24757, Nov 1990, Cloth, Fiberglass, Coated

20 (Rev-01)

3.1 Fire Plan. The Contractor must develop and implement a written fire plan in accordance with

Paragraph 3.1 of SFLC Std Spec 5550, including Paragraph 3.1.3.

3. 1.1 Fire Prevention Responsible Party. The Contractor must appoint a Fire Prevention Responsible

Party (FPRP) in accordance with Paragraph 3.1.4 of SFLC Std Spec 5550.

3.1.1.1. Any item in SFLC Std Spec 5550 that requires FPRP approval, also requires COR approval.

3.1.1.2. In addition to responsibilities listed in SFLC Std Spec 5550, the FPRP is responsible for the following tasks:

• Conduct all inspections per paragraph 3.7 of this work item. The FPRP may designate a representative to conduct these inspections on their behalf.

• Ensuring that contractor employees and sub-contractors understand the Fire Plan and all other requirements of this work item. This includes (but is not limited to) informing contractor/subcontractor employees of danger signals and egress procedures aboard the ship.

3.2 Fire Prevention and Response Conference. The Contractor must participate in the Fire Prevention and

Response Conference as detailed in Paragraph 3.12 of SFLC Std Spec 5550.

3.2.1 At a minimum, the following personnel from the Contractor must attend the Fire Prevention and

Response conference, the Fire Familiarization Tour and the Initial Inspection:

• Ship availability superintendent

• FPRP

3.2.2 The Fire Prevention and Response Conference, the Fire Responsibility Familiarization tour and the

Initial Inspection must occur before the start of industrial work. Coordinate schedule with the COR.

NOTE

Requirements for the Initial Inspection are covered in Paragraph 3.7 of this work item

3.3 Fire Zones. The Contractor must comply with the fire zone requirements from Paragraph 3.2 of SFLC

Std Spec 5550.

3.3.1 Paragraph 3.2.3 of SFLC Std Spec 5550 is only applicable if the requirements of Paragraph 3.2.2 of

SFLC Std Spec 5550 cannot be accomplished.

3.3.2 All material boundaries must be treated as fire boundaries.

3.3.3 All fire curtains must meet the requirements of MIL-C-24757. Disregard the NFPA 105 requirement in Paragraph 3.2.2 of SFLC Std Spec 5550.

21 (Rev-01)

Paragraph 3.2.3 of SFLC Std Spec 5550 is only applicable if the requirements of paragraph 3.2.2 of SFLC Std Spec 5550 cannot be accomplished.

3.4 Inoperable Fittings Log. The Contractor must inform the COR via CFR of fittings that are blocked or made inoperable per Paragraph 3.3 of SFLC Std Spec 5550. The Contractor does not need to maintain a separate Inoperable Fittings Log.

3.5. Firefighting systems. The Contractor must maintain fire protection systems per Paragraph 3.4 of

SFLC Std Spec 5550.

3.5.1 Contractor personnel are NOT authorized to operate fixed firefighting systems per Paragraph

3.4.6.6.1 of SFLC Std Spec 5550

3.5.2 The existing arrangement of AFFF equipment meets the requirements of Paragraph 3.4.11 of SFLC

Std. Spec 5550. This paragraph is only applicable if the Contractor blocks or moves AFFF material or equipment.

3.5.3 The existing arrangement of portable fire extinguishers meets the 50-foot requirement of Paragraph

3.4.12.1 of SFLC Std Spec 5550. This paragraph is only applicable if the Contractor blocks or moves fire extinguishers.

3.6. Fire Alarm. The Contractor must comply with the requirements of Paragraph 3.7 of SFLC Std Spec

5550 if the fire alarm system will be manipulated. The “additional personnel” mentioned in Paragraph

3.7.1 of SFLC Std Spec 5550 must be provided by the Contractor.

3.7 Fire Prevention Inspections. The Contractor must conduct inspections in accordance with SFLC Std

Spec 5550 Paragraph 3.11.

3.7.1 All inspections in paragraph 3.11 of SFLC Standard Spec 5550 must be conducted in the presence of a Coast Guard Inspector.

3.7.2 Disregard paragraph 3.11.1 of SFLC Std Spec 5550 and replace with the following:

Initial Inspection. The FPRP, along with the COR (or a designated representative), must conduct an initial inspection to evaluate potential fire hazards in all areas with scheduled work. This inspection must note the existing status of all items in Paragraph 3.11.2 of SFLC Standard Spec 5550. Submit the results of the initial inspection to the COR via a CFR. This inspection must occur before commencing industrial work.

None