0208_A_MDG_2_AND_3_9_CYL_30000_HR_SCHEDULED_MAINTENANCE_REV1.docx

USNS CHARLES DREW

(T-AKE-10)

MDG 2 AND MDG 3 - 9 CYLINDER 30,000 HOUR SCHEDULED MAINTENANCE

1.0 ABSTRACT:

1.1 This item describes the requirement to provide the technical services and industrial support to accomplish 30,000-hour scheduled maintenance 9 cylinder MDG 2 and MDG 3.

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

2.4 T-AKE FM-MAN 48/60 Main Diesel Engine 30,000 Hour 8/9L Scheduled Maintenance Service Report

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity:

3.1.1 Location: Main Machinery Room 5-66-0

3.1.2 Quantity: 2 Main Diesel Engines (MDGs 2 and 3)

3.2 Item Description/Manufacturer's Data:

3.2.1 Fairbanks Morse Diesel Engine Model 9L 48/60

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE):

4.1.1 Nine (9) cylinder heads per engine.

4.2 Government Furnished Material (GFM):

4.2.1 Two (2) 30K FME P/N (M12702371)9L parts kit (Parts listed are for one engine):

4.2.2 Lube oil

4.2.3 Engine coolant additive

4.3 Government Furnished Services (GFS): Attending ABS Surveyor.

4.4 Government Furnished Information (GFI): None.

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 other work items under this contract, including but not limited to Work Items 004, 011 and 022, to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

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 ELECTRICAL CABLES TO ENSURE THEY ARE DE-ENERGIZED PRIOR TO WORKING ON THE ITEM.

5.5 Items listed in paragraph 4.2.1 are identified by FME part number. Equivalent items, identified by MAN part number, may instead be provided as GFM.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 During the performance of this work item, the shipyard quality assurance department is to schedule and provide a representative to attend a daily meeting onboard the vessel with MSC port engineers, ship's force representatives, shipyard personnel, and original equipment manufacturer (OEM) representatives to review data collected for Reference 2.4, T-AKE Main Diesel FM-MAN 48/60 9L 30,000 Hour Scheduled Maintenance Service Report and the work planned for the next twenty four (24) hour period.

6.2 At least one member of ship's force will be assigned to assist with quality assurance efforts whenever main diesel work is being accomplished.

6.3 To assist with quality assurance efforts and trending main diesel component wear across the T-AKE class, at completion of work "as found" and "as released" data, including clearances and torques, is to be documented in completed Reference 2.4 T-AKE Main Diesel FM-MAN 48/60 9L 30,000 Hour Scheduled Maintenance Service Report.

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) technical field service representative(s) and OEM qualified diesel engine mechanics identified in 7.14. Only OEM authorized or qualified representatives will be permitted to temporarily remove, inspect, refurbish, and reinstall main diesel components.

7.3 Provide all tools and material required, including, but not limited to special tools, rags, degreaser, lubricant, and loctite for accomplishment of all elements of this work item. Ship’s force will NOT provide any tools.

7.4 The shipyard quality assurance department is to schedule and provide a representative to attend a daily meeting onboard the vessel with MSC port engineers, ship's force representatives, shipyard personnel, and OEM representatives to review data collected for Reference 2.4, T-AKE Main Diesel FM-MAN 48/60 9L 30,000 Hour Scheduled Maintenance Service Report and the work planned for the next twenty four (24) hour period.

7.5 Accomplish the requirements associated with 30,000 operating hours as found in Reference 2.1, Section 4, as listed below in Table 213–1. Work cards are available in Reference 2.2.

Table 213–1

055.02

113.02 113.03

114.01 114.02

140.02

221.02 221.03 221.04

200.05

7.6 Receive cylinder heads/engine identified in para 4.1.1. Install same in lieu of performing maintenance task serial number 173.

7.6.1 Ensure crating is not damaged for reuse.

7.7 Performance Period shall be coordinated by the contractor to allow other work impacted by this item to be completed on time. (Including turbocharger). The use of the GFM material described in paragraph 4 listed as GFM is essential to stay within this POP dates. Refurbish cylinder heads removed by work accomplished above by performing maintenance task serial number 173.

7.7.1 The refurbishment and shipment of the existing heads may follow at a later date not to exceed the period of performance. Package each cylinder head separately. Each package shall include a copy of the service report and ABS report inside. Each package shall be suitable for overseas shipment including use of certified bug free wood. Each package shall be clearly marked on the exterior indicating the heads serial #. Cylinder heads shall be shipped to the following address;

MSC BATS WAREHOUSE

9284 BALBOA AVENUE

SAN DIEGO, CA 92123

POC: Blake Nam, 619-553-6053 email: blake.nam@navy.mil Marked as “Refurbished Cylinder Heads”

7.8 Accomplish the requirements associated with 30,000 operating hours as found in Reference 2.3, Volume C1, Section 4.7, as listed below in Table 213–2 for the Turbo Charger. Work cards are available in Reference 2.3, Volume C2.

Table 213-2

500.19

Remove, clean and check all components of the turbocharger. Check gaps and clearances on reassembly 000.31 500.06 500.10 500.15 500.23 500.26

7.9 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 Reference 2.4.

7.10 Provide labor and material to temporarily install valves, fittings, and hoses to assist ship's force in filling the engine(s) with GFM lube oil identified in paragraph 4.2.2 and shipyard provided deionized water.

NOTE

SHIP'S FORCE WILL TREAT ENGINE HIGH TEMPERATURE FRESH WATER WITH GFM ADDITIVE IDENTIFIED IN 4.2.3.

7.11 Inspection/Test:

7.11.1 Test all engine alarms and safety devices and accomplish the requirements of Section 3.4.4 (Engine Running-in) of Reference 2.1. Record all alarm and safety device set points and submit to MSCREP.

NOTE:

100% LOAD TEST IS REQUIRED TO BE ACCOMPLISHED DURING SEA TRIALS UNDER WORK ITEM 022 DOCK TRIALS AND SEA TRIALS

7.11.2 Complete a 100% load test on each engine repaired for one hour. Record all operating temperatures and pressures and submit to MSCREP.

7.12 Paint/Lagging:

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

7.13 Preparation of Drawings:

7.13.1 Provide the MSCREP with a completed electronic version of Reference 2.4 for EACH engine no more than seven (7) days after the completion of all work. The report shall contain the following as minimum:

a. Engine operating hours and serial number, all data required in Reference 2.4.

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. "As found", "as released", and acceptable ranges for measurements are to 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 and/or MAN 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 213-1 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 213-1.

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 213-1.

l. Photos of pistons prior to disassembly and after disassembly as accomplished in maintenance task serial numbers 153, 154 and 155 of Table 213-1.

m. Cylinder liner dimensions for all cylinder liners as accomplished in maintenance task serial number 163 of Table 213-1.

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 213-1.

o. Fuel injection valve condition as accomplished in maintenance task serial number 322 of Table 213-1.

7.14 Manufacturer's Representative:

7.14.1 Provide authorized OEM representatives for MAN 48/60 diesel engines. Suggested Points 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

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

Motor Services Hugo Stamp (MSHS) Adel Mousa 3190 S.W 4th Avenue Fort Lauderdale, Fl 33315 Adel.Mousa@mshs.com Office: 954-763-3660 Fax: 954-763-2872 Cell: 954-684-2372

8.0 GENERAL REQUIREMENTS: None additional.

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