0227_A_MDG_Attached_Lube_Oil_Pump_Rebuilds.doc

USNS CARL BRASHEAR

(T-AKE 7)

500 MACHINERY, PROPULSION

N32205-19-R4260

20 November 2018

ITEM NO. 227

Category “A”

MSC/N756/JCO

MDG Attached lube oil pumps rebuildS

1.0 ABSTRACT:

1.1 This work item describes the requirements to provide technical services to perform an in-depth engineering inspection, evaluation and rebuilding of the Main Diesel Engine (MDE) Attached Lube Oil Pumps (8 ea).

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. (Available Onboard)

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. (Available Onboard)

2.3 T/M T9233-CF-IMC-040; Diesel Engines, Main Power Generation, Models 9L 48/60 and 8L 48/60, Volume B3, Spare Parts. (Available Onboard)

2.4 T/M T9233-CF-IMC-070; Diesel Engines, Main Power Generation, Models 9L 48/60 and 8L 48/60, Volume E1-E4, Engine Operating Instructions. (Available Onboard)

2.5 Work Card 300.01; Lube Oil Pump Disassembly and Assembly

3.0 ITEM LOCATION AND DESCRIPTION:

3.1 Location/Quantity/Contractor Supplied Material.

3.1.1 Location: Main Machinery Room 5-66-0

3.1.2 Quantity: Eight Pumps on MDE No. 1,2,3, & 4

3.1.3 Item Description/Manufacturer's Data:

-MAN B&W 8L 48/60 Diesel Engine (8 cylinder)

-MAN B&W 8L 48/60 Diesel Engine (9 cylinder)

3.1.4 Bill of Materials:

3.1.4.1 Contractor is to review this statement of work and provide any additional tooling, rigging and parts required that are not provided as GFM.

3.2 Contractor Furnished Material (CFM).

3.2.1 O-Ring – 2-383 354,97X5,33-NBR70 RICKMEIER

(P/N: K11.30001-0387) – 24 ea

3.2.2 O-Ring – 2-155 101, 27X2,62-NBR70 RICKMEIE

(P/N: K11.30087-0067) – 8 ea

3.2.3 Seal Ring

(P/N: K06.56190-0732) – 8 ea

3.2.4 Cylinder Pin

(P/N: K06.22140-1117) – 8 ea

3.2.5 O-Ring – 2-262 177, 39

(P/N: K11.30001-0424) – 4 ea

3.2.6 Cylinder Pin

(P/N: K06.22140-1121) – 4 ea

3.2.7 Cylindrical Screw M6X25 DIN 912 8.8

(P/N: K06.02093-0309) – 12 ea

3.2.8 Bush 161219-1 RICKMEIER R93A

(P/N: K11.30099-0028) – 32 ea

3.2.9 Hexagon Bolt

(P/N: K06.01013-1526) – 32 ea

3.2.10 Hexagon Bolt M16X100 DIN 931 8.8

(P/N: K06.01013-1525) – 32 ea

3.2.11 Hexagon Nut M16 DIN 934 8

(P/N: K06.11064-0118) – 32 ea

3.2.12 Screw Plug

(P/N: K06.08062-0111) – 2 ea

4.0 GOVERNMENT FURNISHED EQUIPMENT/ MATERIALS/ SERVICES: 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 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:

7.1 Pump Rebuilding. Provide the service of authorized MAN OEM reps and support personnel needed to rebuild the MDE attached lube oil pumps (8ea).

7.2 All work to be performed in accordance with manufacturer’s specifications.

7.3 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.

7.4 Contractor to overhaul the attached Lube Oil Pumps in accordance with Reference 2.5 and the following:

7.4.1 Replace all ring seals, gaskets, and spring washers with Contractor Furnished materials.

7.4.2 Disconnect the pipes and blank flanges (4) from the lube oil pump, allowing the oil to drain into the tank.

7.4.3 Disassemble attached lube oil pumps.

7.4.4 Perform visual inspection of the Vibration Damper, both Exhaust side and Cam side attached lube oil pumps, shafts, etc., and report all findings.

7.4.5 Visually inspect the engine and sump for any abnormal damage. Report all findings.

7.4.6 Separate Pumps from each other, but be carefully not to damage the cylindrical pins. Remove adapter disk.

7.4.7 Loosen and unscrew the hexagon-head bolts between the pump casing and the drive cover.

7.4.8 Mark the drive shafts, impeller axles, and bearing units on both pumps, so that they can be re-installed in the same position.

7.4.9 Remove the drive shafts, impeller axles, and bearing units.

7.4.10 Remove the taper pins on the drives cover with suitable equipment, and remove the drive cover with the bolted-on bearing unit.

7.4.11 Unscrew two opposite hexagon-head screws on the valve cover, and replace them by two M8 size threaded spindles, about 100 mm long.

7.4.12 Screw two M8 hexagon- head nuts all the way onto the two spindles, until they rest against the valve cover, and unscrew the other hexagon-head screws.

7.4.13 Relieve the initial tension of the compression springs by backing off the two M8 hexagon nuts uniformly, steady with the two threaded spindles.

7.4.14 Remove the valve cover and the compression spring with valve disk.

7.4.15 During disassembly inspect all LO pumps and NDT all components.

7.4.16 Clean all parts and check them for damage; check appearance and wear of the bearing and sliding surfaces. Replace all ring seals, gaskets, and spring washers.

7.4.17 Check all surfaces of bearings, grooves, and gears for visible signs of damage and provide a condition found report prior to re-assembly.

7.4.18 Minor edge damage can manually be smoothed out using emery cloth. All residues from liquid sealing have to be removed completely before the pump can be remounted using a new sealing agent.

7.4.19 Replace all suspect parts with Contractor Furnished material provided above. Document all fits, clearances, and gear backlash. Replace all O-rings, gaskets, and Loctite where applicable.

7.4.20 Reassemble the pumps in the reverse order of disassembly.

7.4.21 Lubricate all moving parts with oil.

7.4.22 Do not change the setting of the pressure relief valve (opening pressure set to 7.5 bars).

7.4.23 Do not insert paper gaskets between the drive cover, casing, and pressure relief valve.

7.4.24 Coat the threads of the hexagon head bolts with oil, screw them in including the spring washers and tighten with the specified tightening torque.

7.4.25 If Pump 2 is mounted onto Pump 1 make sure the teeth of the drive shafts engage correctly.

7.4.26 Check the entire pump for ease of movement.

7.4.27 Remount the drive gear wheel, place it on the lightly oiled tapered section of the drive shaft and slide the pipe on.

7.4.28 Oil nut and screw it onto the drive shaft and tighten it with the specified initial torque.

7.4.29 Measure and note the distance between the end of the face of the drive shaft and the nut with a depth gauge.

7.4.30 Tighten the nut with the specified tightening torque. Repeat the measurement accordingly and compare the two values. The spacing must have increased by 0.6 mm to 1.5 mm.

7.4.31 Secure the nut by tightening the cap screw firmly.

7.4.32 Before installing clean, the sealing surface between the pump and engine and coat it with Hilmar SW32M sealant.

7.4.33 Fill the pump with oil.

7.4.34 Connect the pipes (unpressurized) to the pump, and screw on the blank flanges.

7.5 Engineering Inspection and Evaluation. Provide the service of an authorized MAN Diesel OEM to perform an engineering inspection, evaluation of the MDE attached lube oil pumps (8 ea)

7.6 Evaluation to be accomplished in conjunction with the attached lube oil pumps rebuilding.

7.6.1 Inspection/Testing:

a. Inspection to be completed in conjunction with Work Card 300.01 steps 1-6. This procedure can be used separately from Work Card 300.01 by following the steps provided below.

b. Remove interferences from the free end of the engine such as lube oil piping in order to access the lube oil pumps.

c. Remove the lube oil pumps from the engine and place on a suitable work bench. Perform the remaining steps for each lube oil pump being inspected.

d. Inspect Drive Gear-Wheel for damage and the condition of the cap screw (item #24) installed in the lube oil pump nut (item #1) for deformation, spalling and gear tooth wear. Note any abnormal conditions found.

e. Measure the distance between the back side (face of gear closest to the pump housing) of the gear and the pump case with feeler gauges in four locations – 12 o’clock, 3 o’clock, 6 o’clock and 9 o’clock. Record these values in the appropriate data table.

f. Attempt to place a feeler gauge between the head of the cap screw and the lube oil pump nut itself to determine whether the screw has loosened during operation. Record this value in the appropriate data table, or write “0” if a feeler gauge cannot be inserted between the screw head and nut.

g. Measure the width of the slot in the lube oil pump nut at its smallest opening, and record this value in the appropriate data table. (For reference, the nominal, un-tightened gap is 2mm.)

h. Measure breakaway torque of the cap screw in the lube oil pump nut, and record this value in the appropriate data table. Verify presence of thread lock material on the threads of the capscrew.

i. Measure breakaway torque of the lube oil pump nut, and record this value in the appropriate data table.

j. Record the values of steps 4-8 for the reassembly of the pump. Use Loctite 706 or other appropriate thread cleaner on any threads with thread lock material present, then reapply thread lock material on the threads of the fastener prior to reassembly.

k. Mark the location of the cap screw to the drive gear wheel and the drive gear wheel to the pump shaft with permanent oil resistant marker.

l. Reassemble and reinstall the lube oil pump according to the references above.

m. CHECKPOINT: Perform operational test of system performed at system pressure. No leaks accepted.

7.6.2 Reports: Provide electronic service reports in pdf format. One copy of the report shall be turned over to the Chief Engineer. One copy of the report shall be turned over to the Port Engineer.

7.7 Preparation of Drawings: None additional.

7.8 Manufacturers Rep:

7.8.1 Provide MAN OEM Technical Representative to perform this work item.

Point of Contact for OEM Technical Services:

Gregg Bellows

MSC Project Lead

Fairbanks Morse

1545 Tidelands Ave, National City, CA 91950

(619) 637-9784

(858) 414-6996

8.0 GENERAL REQUIREMENTS: None additional.

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