0501_ADG_Engine_Overhaul_SOW_Rev_B.pdf

USNS MERCY

(T-AH 19)

MACHINERY, AUXILIARY SYSTEMS

Class Std Item

ITEM NO. 501 CATEGORY “A”

AUXILIARY DIESEL ENGINE OVERHAUL

501-1

1.0 ABSTRACT

1.1 This item describes the requirements for the contractor to overhaul the NO. 2 auxiliary diesel engine.

2.0 REFERENCES: Available upon request onboard the ship

2.1 MAN Operating and Repair Manual for Diesel Engines Type

V25/30; D365615-E.

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Auxiliary Machinery Room, 5-84-0

3.1.2 One (1) Diesel Engine

3.1.3 MAN Diesel (formerly known MAN B&W)

Model: 12ASV 25/30

S/Ns: 1045-137

Rated Power: 2021 EkW @ 900 rpm.

MAN NR 26/98 Twin Turbocharger with

Charge Air Cooler

Fuel: DFM/MGO

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment/Material: None

4.2 Government Furnished Services:

4.2.1 Crane support between pier and ship’s exterior deck

4.2.2 Drain and refill all engine liquid systems

4.2.3 Lock out/tag support

4.2.4 Two Engine Department Crew members to assist

5.0 NOTES:

5.1 Period of Performance: 12 June – 22 July 2017

5.2 Location: NAVSTA San Diego

MACHINERY, AUXILIARY SYSTEMS

501-2

5.3 Contractor is responsible for all labor, rigging, parts/material, shipping, etc to complete scope of work unless specifically addressed in this work item.

5.4 Contractor shall provide at minimum One (1) Supervisor

for the entire duration of the overhaul and one (1) assistant. The

Supervisor assigned shall remain onsite from start to job completion for continuity.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 Contractor shall strictly follow the instructions described in the Work Cards in MAN Operating and Repair Manual for Diesel

Engines Type V25/30; D365615-E and execute all recommendations described in technical/service bulletins issued for these engines.

7.0 STATEMENT OF WORK REQUIRED

7.1 Arrangement/Outfitting

7.1.1 Ship’s force shall tag out and secure power to

the engine and auxiliaries. Upon completion of all work notify ship’s force to remove tags and restore power.

7.1.2 Remove all interference in the way of

accomplishing this work including but not limited to deck plates, piping, hand rails, deck plate frames, lighting fixtures, labels and signs, etc. to facilitate removal and installation of the equipment.

Reinstall all removed interference upon completion work.

7.1.3 Ship’s Force will drain the Lube Oil from

Crankcase and refill with new Lube Oil when all work is complete prior to operational tests.

7.1.4 Open inspection covers and completely wipe clean

the crankcase. When cleaning is complete and directed by the MSCREP reinstall inspection covers using CFM new Gaskets and Hardware.

7.2 Mechanical/Fluid

7.2.1 Remove all Fuel Injectors and Injection Pumps, Exhaust Manifold Piping, Cylinder Heads and rocker arm, cylinder liners, charge air cooler, and pistons with Connecting Rods.

MACHINERY, AUXILIARY SYSTEMS

501-3

7.2.2 Take all readings and inspect all removed

components and parts and submit an ”as found conditions” report with digital pictures for significant findings to MSCREP. Discard all piston rings and bearings.

7.2.3 Inspect the Governor and provide recommendation

as to future overhaul or repairs to the MSCREP.

7.2.4 Completely clean and degrease the engine using

lint free rags and degreaser solvent like break cleaner.

7.2.5 Remove and discard one bearing at a time the

Main, Thrust and Cam Shaft Bearings. Take and record bearing journal readings from Crankshaft and Cam Shafts. Install new Contractor

Furnished bearings right after readings are taken from journals.

Crankshaft and Camshafts shall never be left unsupported during the work.

7.2.6 Take and record bearing clearance readings and

side thrust bearing clearance readings.

7.2.7 Reconditioned cylinder Liners and reinstall with

Contractor furnished Hardware and Consumables.

7.2.8 Remove Connecting Rods from pistons and discard

all used big and small end bearings and piston pin bushings after inspections. Recondition connecting rods and reinstall.

7.2.9 Disassemble pistons. Clean crowns and skirts;

remove all grease, carbon and growth. Inspect for fretting on mating surfaces and take readings from ring grooves and mating surface side clearance. When all inspections are complete, all parts are completely cleaned and all readings are taken and recorded reassemble pistons with new Contractor Furnished Hardware and Consumables.

7.2.10 Install new contractor furnished Piston Rings.

7.2.11 Install new Contractor Furnished Small End

Bushings, new Piston Pins and Big End Bearings.

MACHINERY, AUXILIARY SYSTEMS

501-4

7.2.12 When all work is complete on Pistons, Connecting

Rods, Crankcase with Crankshaft and Cam Shafts install Pistons and secure them in their liners. Torque all Big End Bearing and Main

Bearing Caps.

7.2.13 Reconditioned Cylinder Heads including rocker

arm, and reinstall with contractor furnished Hardware and

Consumables. Torque Cylinder Heads to Engine Block.

7.2.14 Inspect torsion vibration damper and provide

report to MSCREP of recommended future servicing.

7.2.15 Recondition charge air cooler and reinstall.

7.2.16 Remove, recondition and reinstall Fuel Injection

Pumps.

7.2.17 Disassemble, recondition, and reinstall Fuel

Injectors.

7.1.18 Disassemble intake and exhaust valves and Clean

and Inspect the internals. Reassemble them with contractor furnished hardware. Upon completion of servicing install them in Cylinder

Heads with new contractor furnished Hardware and Consumables.

7.2.19 Clean all exhaust piping and manifolds internals.

Contractor shall exercise upmost attention not to damage the special insulation on the exterior surfaces of the pipes and manifold.

Reinstall piping and manifold using new contractor furnished Hardware and Consumables.

7.2.20 Check Injection Timing, Adjust Exhaust and Intake

Valve Clearances.

7.2.21 Take Cold Crankshaft Deflection Readings and

Record. Take hot Crankshaft Readings after test run the engine and

Lube Oil and Jacket Water Temperature are at working values.

7.2.22 Close up the engine using new Contractor

furnished Gaskets and Hardware when directed by MSCREP after crankcase and cam gallery inspections.

7.2.23 Not used.

MACHINERY, AUXILIARY SYSTEMS

501-5

7.2.22 Fill all liquids. Operate the ADG priming pump

to flush engine. Replace all LO filters with Contractor furnished filters after running the priming pump and barring over the engine.

Inspect filters for hard particulate and repeat flush as needed until no hard particulate is found.

7.2.23 Prime and bleed fuel oil system, run jacket water

and lube oil keep warm system to warm the engine up, run the lube oil priming pump to circulate the warm oil through out the engine.

Prepare the engine for test run.

7.3 Inspection/Test

7.3.1 Operationally test engine in accordance with OEM

break in and operational procedures.

7.4 Reports / Documentation

7.6.1 At the completion of the overhaul the onsite

service representative shall notify the MSCREP that the engine is ready for operational testing.

7.6.2 Submit MSCREP a detailed service report including

all as found conditions and readings with digital pictures, as released conditions, readings with digital pictures and spare parts used.

8.0 GENERAL REQUIREMENTS: None additional