0207_A_MDG1_8_CYL_24000_HOUR_SCHEDULED_MAINTENANCE_11DEC17.docx

USNS CHARLES DREW

(T-AKE-10)

8 CYLINDER MAIN DIESEL ENGINE 24,000 HOUR SCHEDULED MAINTENANCE

1.0 ABSTRACT:

1.1 This item describes the requirement to provide the technical services and industrial support to accomplish a 24,000-hour overhaul of MDG No. 1 eight cylinder main diesel engine.

2.0 REFERENCES:

2.1 T/M T9233-CF-IMC-010; Diesel Engines, Main Power Generation, Models 9L 48/60 and 8L 48/60, Volume B1, Engine Operating Instructions

2.2 T/M T9233-CF-IMC-020; Diesel Engines, Main Power Generation, Models 9L 48/60 and 8L 48/60, Volume B2, Engine Working Instructions

2.3 T/M T9233-CF-IMC-060; Diesel Engines, Main Power Generation, Models 9L 48/60 and 8L 48/60, Volumes C1, C2 &C3 , Exhaust Gas Turbocharger

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity:

3.1.1 Location: Main Machinery Room 5-66-0

3.1.2 Quantity: No. “1” Main Diesel Engine

3.2 Item Description/Manufacturer's Data:

3.2.1 Bill of Materials:

3.3 Description of Equipment/Systems:

3.3.1 Fairbanks Morse Diesel Engine Model 8L 48/60

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE):

4.1.1 Eight (8) cylinder heads per engine.

4.2 Government Furnished Material (GFM):

4.2.1 One (1) 24K FME P/N (M12702080)8L parts kit (Same as 6k Parts 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 GTRs.

5.2 The contractor and all subcontractors regardless of tier are advised to review the 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. OBEY ALL POSTED AND VERBAL INSTRUCTIONS REGARDING SAFETY AND EXCLUSION FROM HIGH VOLTAGE AREAS. AT NO TIME APPROACH, WORK ON, OR ENTER A HIGH VOLTAGE AREA WITHOUT PROPER AUTHORIZATION.

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

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Tag-Out all required systems and equipment. Drain and dispose of any liquid in accordance with all federal, state, and local regulations.

7.2 Provide the services of the Original Equipment Manufacturer (OEM) representatives identified in paragraph 7.10.

7.3 Provide all tools required, including special tools, for accomplishment of all elements of this work item. Ship’s force will NOT provide any tools.

7.4 Accomplish the requirements associated with 18,000 operating hours as found in reference 2.1 section 4, as listed below in Table 209 – 1. Work cards are available in reference 2.2.

Table 209 – 1

034.02 050.05 -All cylinders Engine # 1.

034.03 034.04 -One Piston, Engine # 1

050.05 -All Cylinders Engine # 1

102.01 -Two Camshafts Bearings MDG#1

113.02 113.03 113.04 113.05

-All cylinder MDG #1

113.04 113.05 114.01 114.02

-All Cylinders MDG #1

140.02 Engine # 1

140.02 140.03 Engine # 1

140.02 140.03 Engine # 1

140.02 140.03 Engine # 1

161.02

- Engine #1

200.01 201.01 Engine # 1

200.05 Engine # 1

221.02 221.03 221.04 Engine # 1

7.5 Accomplish the requirements associated with 24,000 operating hours as found in reference 2.3, volume C1, section 4.7, as listed below in table 209 – 2. Work cards are available in reference 2.3 volume C2.

Table 209 - 2

500.14 Engine # 1

7.6 All parts that are required to be IMO certified for IAPP shall be procured directly from the OEM to meet IMO requirements. These parts shall be noted and included in the service report.

7.7 Inspection/Test

7.7.1 Accomplish the requirements of section 3.4.4 (Engine Running-in) of reference 2.1.

7.7.2 Following requirements of 7.7.1, complete a 100% load test on each engine repaired for one hour.

7.8 Paint/Lagging:

7.8.1 Renew lagging where old lagging was removed. Paint all new and disturbed surfaces to match surrounding surfaces.

7.9 Preparation of Drawings:

7.9.1 Contractor shall provide both the Chief Engineer and the Port Engineer with an electronic Service Report no more than fourteen (14) days after the completion of all work. The report shall contain the following as minimum:

a Engine operating hours and Serial number.

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

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

d Measurements taken and recorded. Both the specified value and the recorded value shall be listed in the report.

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

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

g Include a listing of all parts used during maintenance. The parts list shall include the Sub-Assembly drawing number and part number, the FME part number .

h Include a listing of all parts included in the parts kit or ordered and not used as well as items turned over to ship’s Force.

i Crankshaft Deflection readings found in maintenance task serial number 113 of table 209-1 and recorded on the Crankshaft Deflection Record Sheet.

j Photos of Main bearing lower cap condition on the one bearing per engine removed as accomplished in maintenance task serial number 123 of table 209-1 k Photos of Big-End Bearing shell condition on the one bearing per engine removed as accomplished in maintenance task serial number 142 of table 209-1 l Photos of pistons prior to disassembly and after disassembly as accomplished in maintenance task serial numbers 153, 154 and 155 of table 209-1 m Cylinder liner dimensions for all cylinder liners as accomplished in maintenance task serial numbers 163 of table 209-1 n Radial and axial play of the fuel pump drive cam follower rollers compared against permitted value as accomplished in maintenance task serial numbers 303 of table 209-1 o Fuel injection valve condition as accomplished in maintenance task serial numbers 322 of table 209-1

7.10 Manufacturer's Representative: Provide authorized service provider for Man 48/60 design engines. Suggested Source Point of Contact For OEM Services:

Fairbanks Morse Engine (FME) Gregg Bellows 1545 Tidelands Ave. Suite J National City, CA 91950 Gregg.Bellows@fairbanksmorse.com Office 619-477-3218 x104 Mobile 858-414-6996 Or Fairbanks Morse Engine (FME) Brad Clouse 981 Scott Street Norfolk, VA 23502 Brad.Clouse@fairbanksmorse.com Office 757-623-2711 x1004 Mobile 757-335-2498

8.0 GENERAL REQUIREMENTS: None additional

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