0501_ADG_Engine_Overhaul_SOW_Rev_C.doc

USNS MERCY

(T-AH 19)

MACHINERY, AUXILIARY SYSTEMS

Class Std Item

ITEM NO. 501 REV C

CATEGORY “A”

AUXILIARY DIESEL ENGINE OVERHAUL

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

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, pistons with Connecting Rods and Turbocharger Cartridges.

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.

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 Disassemble each Turbocharger Cartridge. Clean, inspect, take dimensions and accomplish ABS required NDT requirements. Assemble each Turbocharger Cartridge using new bearings, Hardware and Consumables.

7.2.24 Install each Turbocharger Cartridge using new hardware and Consumables.

7.2.25 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.

7.2.26 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

7.4.1 At the completion of the overhaul the onsite service representative shall notify the MSCREP that the engine is ready for operational testing.

7.4.2 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

501-1