SO-16-001_-6K_Hour_Main_Engine_Overhaul_MDE_1_and_3.doc

USNS RICHARD E BYRD

(T-AKE 4)

GENERAL REQUIREMENTS

SO 16-001

06 September 2015

SO 16-001

Category "A"

MSFSC/PM1CM2/BVV

6K Hour Main Engine Overhaul MDE 1 and 3

1.0 ABSTRACT:

1.1 This item describes the requirement to provide the services of a MAN B&W/FME (OEM) Authorized Technical Representative to perform a 6,000 Hour Scheduled Maintenance/Overhaul on the No. 1 & 3 Main Diesel Engines.

2.0 REFERENCES/ENCLOSURES:

2.1 References:

2.1.1 T/M T9233-CF-IMC-010, Rev. 1; Diesel Engines, Main Power Generation, Models 48/60 8L & 9L, Volume B1, Engine Operating Instructions

2.1.2 T/M T9233-CF-IMC-020, Rev. 1; Diesel Engines, Main Power Generation, Models 48/60 8L & 9L, Volume B2, Engine Working Instructions

2.1.3 T/M T9233-CF-IMC-040, Rev. 1; Diesel Engines, Main Power Generation, Model 8L 48/60, Volume B3, Spare Parts Catalog

2.1.4 T/M T9233-CF-IMC-050, Rev. 1; Diesel Engines, Main Power Generation, Models 48/60 8L & 9L, Volume B6 & C6, Engine/Turbocharger Spare Parts/Tools

2.1.5 T/M T9233-CF-IMC-070; Diesel Engines, Main Power Generation, Models 9L 48/60 and 8L 48/60, Volume E1-E4, Engine and Systems Accessories

2.2 ENCLOSURES:

2.2.1 None

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity

3.1.1 Location:

Main Machinery Room 5-66-0

3.1.2 Quantity:

Two (2) each, Main Diesel Engines

3.2 Item Description/Manufacturer's Data

3.2.1 MAN B&W/FME - 8L and 9L 48/60 Diesel Engine

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIALS/SERVICES:

4.1 Government Furnished Materials:

4.1.1 Two (2) each, eight (8) and nine (9) Cylinder 6000 Hour Maintenance Inspection Repair Kit.

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 including but not limited to GTR’s 1 through 7, 23, and 29.

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.

5.3 This ship contains High Voltage (HV) electrical systems. The contractor and subcontractors shall obey all posted and verbal instructions regarding safety and exclusion from High Voltage areas. At no time shall a contractor or subcontractor approach, work on, or enter a High Voltage area without proper authorization.

5.4 THE USNS RICHARD E BYRD ELECTRICAL COLOR CODING DOES NOT FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK AND WHITE. THE CONTRACTOR SHALL ASSUME ALL ELECTRICAL CABLES ARE ENERGIZED UNTIL TESTED AND PROVEN OTHERWISE. THE CONTRACTOR SHALL TEST ALL ELECTRICAL CABLES TO ENSURE THEY ARE DE-ENERGIZED PRIOR TO WORKING ON THE ITEM.

5.5 All welding shall be in accordance with ABS rules for building and classing steel ships.

5.6 MSC Representative (MSCREP) is to be notified prior to performing any/all final tests and inspections.

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Arrangements/Outfitting: None additional.

7.2 Structural: None additional.

7.3 Mechanical/Fluids

7.3.1 Provide the services of a MAN B&W/FME (OEM) Authorized Technical Representative to perform a 6,000 Hour Scheduled Maintenance/Overhaul on No. 1 & 3 Main Diesel Engine.

7.3.2 The MAN B&W/FME (OEM) Authorized Technical Representative shall be a Senior Service Technical Representative experienced with MAN B&W 9L 48/60 & 8L 48/60 engines.

7.3.3 The MAN B&W/FME (OEM) Authorized Technical Representative shall be experienced with the T-AKE Class of ships.

7.3.4 Ship’s force may assist with all work as described herein. The MAN B&W/FME (OEM) Authorized Technical Representative shall provide technical training to ship’s force as an addition to performing work.

7.3.5 Contractor will be given access to onboard MDG special tooling. Tooling may not be a complete complement. Contractor shall provide all tooling to perform 6K overhaul. Contractor shall provide calibrated tools.

7.3.6 All maintenance shall be performed in accordance with (OEM) recommended practices and procedures.

7.3.7 MAN B&W/FME (OEM) Authorized Technical Representative shall use Reference 2.1.1 thru 2.1.5 as guidance, to accomplish a 6,000 Hour Scheduled Maintenance/Overhaul on the No.1 & 3 Main Diesel Engines.

7.4 Electrical: None additional.

7.5 Electronics: None additional.

7.6 Preparation of Drawings/Documentation

7.6.1 MAN B&W/FME (OEM) Authorized Technical Representative shall submit a final detailed inspection/condition report which, at a minimum shall include the following:

a. Engine Operating Hours and Serial No.

b. Photographs of the engine condition at disassembly and any unusual conditions noted.

c. Description of any abnormal or usual conditions found during maintenance.

d. A positive statement indicating that each of the maintenance items was completed. Example: Item 017 - Oil drainage of piston big-end and main bearings checked on the gear box and found to be satisfactory.

e. Measurements taken and recorded shall be included in the report and compared with specified values listed in reference 2.1.1 Operating Instructions. Both the specified value and the recorded value shall be listed in the report.

f. Include comments on any defects found in arrangements for removals and lifting of engine components.

g. Include a listing of any additional special tools found to be needed for successful maintenance on engine.

h. Include a listing of all parts used during maintenance. The parts list shall include the Sub-Assembly Drawing No. and Part No. (MAN B&W/FME Part No.)

i. Include a listing of all parts included in the parts kit or ordered and not used.

j. Include resilient mount measurements as per applicable work card.

k. Flexible coupling alignment measurements per the applicable work card and reference 2.1.4 Appendix C Alignment Log Sheet.

l. Crankshaft Deflection readings per the applicable work card and reference 2.1.4 Appendix D Crankshaft Deflection Record Sheet.

m. Main Bearing axial clearance.

n. Main bearing lower cap condition on the one bearing per engine removed. Include photos.

o. Big-End bearing shell condition on the one bearing per engine removed. Include photos

p. Piston condition on the one piston per engine removed. Include photos. Include axial clearance of the piston rings in the grooves.

q. Cylinder liner dimensions per the applicable work card. One liner per engine.

r. Cylinder head condition.

s. Camshaft gearwheel back lash.

t. Inlet valve condition including valve rotators, and valve seats. Two inlet valves per engine.

u. Exhaust valve condition including valve rotators, and valve seats. Two exhaust valves per engine.

v. Include the electronic speed governor pick-up space.

w. Include all start air valve tightness check results.

x. Include injection pump and cam follower condition. One per engine is removed and disassembled. Measure and make note of the radial and axial play of the fuel pump drive cam follower rollers and compare against permitted value.

y. Fuel injection valve condition. All valves per engine.

7.6.2 Final Report to include “As Found” condition, meaning the condition which was found upon close inspection by an individual with knowledge of the item(s) in question. It is intended that the observations will find all relative conditions, both those requiring repairs and those not. The representative will report all conditions, normal and degraded. When reporting “As Found” condition the information shall be stated, clearly and concisely. Identify actual readings/dimensions taken. Include annotated sketches, graphs, photographs, and/or video documentation.

7.6.3 Final Report to include “As Released” condition, meaning the condition of the item that exists at the time it is returned to the government. Include annotated sketches, graphs, photographs, and/or video documentation. Identify actual readings/dimensions taken. Include a summary of work accomplished by the contractor and any corrective actions taken to address any known degraded conditions or discrepancies. List any additional recommended repairs that may be required due to degraded conditions or discrepancies that could not be addressed during this survey.

7.6.4 MAN B&W/FME (OEM) Authorized Technical Representative shall submit three (3) legible, bound, hard (paper) copies and one (1) electronic copy of the final detailed inspection/condition report. The electronic copy of the report shall be submitted in (.pdf) format.

7.7 Inspection/Test

7.7.1 MAN B&W/FME (OEM) Authorized Technical Representative shall assist MSCREP in presenting any and all findings to ABS Attending Surveyor as required.

7.7.2 MAN B&W/FME (OEM) Authorized Technical Representative shall, on completion of reassembly assist ship’s force in demonstrating all engine safeties for ABS Attending Surveyor as required. MSCREP to be notified prior to final testing.

7.8 Painting: None additional.

7.9 Marking: None additional.

7.10 Manufacturer’s Representative: None additional.

8.0 GENERAL REQUIREMENTS: None additional.

SO 16-001-1