501_EDG_Repairs.doc

USNS JOSHUA HUMPHREYS

T-AO 188

MACHINERY, AUXILIARY

MAY 2015

ITEM NO. 501 CATEGORY “A”

MSC/N43A/HR

EMERGENCY DIESEL GENERATOR REPAIRS

1.0

ABSTRACT

1.1 This item describes the repair of the Emergency Diesel Generator (EDG)

2.0

REFERENCES/ENCLOSURES

2.1 References:

2.1.1 NAVSEA Tech. Manual T9312-AE-MMC-010, 600 KW Emergency Diesel Generator Set, Model DGS-8673, Energy Power Products. (Available onboard)

3.0

ITEM LOCATION/DESCRIPTION/MANUFACTURER’S DATA

3.1 Location:

EDG Room, 06-96-0.

3.2 Description:

Contractor shall provide the following contractor furnished material (hose lengths provided are estimates, to be used for estimation purposes. See note in 7.1):

3.2.1 Fuel Hoses

Qty 5 of No. 10 x 35 ft total Qty 6 of No. 6 X 30 ft total Qty 3 of No. 4 X 15 ft total 3.2.2 Water Hoses:

Qty 2 of no.16 X 10 ft total 3.2.3 Oil Hoses:

Qty 6 of No.4 X 24 ft total

Qty 6 of No. 6 X 25 ft total

Qty 4 of No. 16 X 8 ft total

3.2.4 Fittings:

QTY 4 -16 flare to NPT adapter (2 straight, 2 elbow)

3.2.5P Clamps:

30 ea P-clamps of various sizes from 1/2" to 1" 3.2.5 Brackets:

Fabricate 10 brackets out of 3/4" flat bar; contractor to determine proper length.

3.3 Engine Manufacturer’s Data:

Detroit Diesel Corp.

16V-92T, 960 HP

Model: 8162-7400 4.0

GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Engine/Radiator coolant to be provided by ship’s force.

4.2 Engine oil to be provided by ship’s force.

5.0

NOTES

5.1 Coordinate efforts with electrical contractor to ensure electrical cabling is properly routed and secured to the engine. All electrical wiring & securing will comply with ABS & USCG requirements.

6.0

QUALITY ASSURANCE REQUIREMENTS

6.1 All work performed shall be to the satisfaction of the Port Engineer, Chief

Engineer, ABS and USCG.

7.0

STATEMENT OF WORK REQUIRED

7.1 Provide labor and material to remove, convey and fabricate thirty two (32) flex hoses, for emergency diesel generator as described in para. 3.2, to a local Hydraulic hose fabrication and repair facility.

NOTE: length of hoses will vary in length from what is currently installed; hose length should be corrected to improve routing & reduce chaffing in accordance with OEM recommendations.

7.1.1 In conjunction with ship’s force, isolate and tag out the EDG prior to commencement of repairs.

7.1.2 Convey the hoses to a local hose repair facility.

7.1.3 Upon completion of all pressure testing, fabricate tags for each hose with date and pressure tested to, and re-install all hoses as per OEM specifications.

7.1.4 Provide labor and material for fabrication of clamps and brackets to facilitate installation of hose Governor Solenoid as described in Para 3.2

7.2 Provide OEM Detroit Diesel service rep to service EDG for fuel leaks, water leaks, oil leaks and oversight for flex hose fabrication and installation.

7.2.1 Provide material and labor for replacement of rear main seal.

7.2.1.1 Contractor is responsible for arranging material and labor for removal, reinstallation, and alignment of generator.

7.2.2 Provide material and labor to replace oil cooler gasket and oil pan gasket.

7.2.3 Provide material & labor to relocate JW heater to support frame, from current location on oil pan.

7.2.4 Provide material and labor to replace lagging on exhaust manifolds Qty(4)

7.2.5 Provide material and labor to remove unused sensors, gear drives (tach) and replace with OEM cover plates & new gaskets.

7.2.6 Provide material and labor to fix pipe / wire brackets located on engine and foundation that have cracked or failed. For estimation purposes anticipate repairs to nine (9) brackets.

7.3.

Contact the Chief Engineer to remove all danger tags and to light off the EDG for operational tests. OEM shall bleed air from the system and verify correct operating pressures. Ships force will operate EDG under supervision of OEM Rep to prove proper operation.

7.3.1 Contractor shall submit a condition found report for additional repairs and leaks found while testing EDG.

7.4 Upon completion of work. Contractor shall submit a detailed report indicating all work performed including part numbers used for repairs, photographs.

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

8.0

GENERAL REQUIREMENTS

8.1 None additional.

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