0296_A_TEPF-CSI-MPDE MAINTENANCE (12K HRS) (SCSI) Rev1.pdf

USNS TRENTON (T-EPF 5)

PROPULSION MACHINERY SOR 25-XXX

ITEM NO. 0296 CATEGORY "A" 2025-06-30

TEPF-CSI-MPDE MAINTENANCE (12K HRS) (SCSI) LEFEBVRE

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1.0 ABSTRACT

This item describes the requirement to provide the technical services and industrial support to accomplish 12,000 hour scheduled maintenance, and the replacement parts from MTU Report

# 90P240153 of the Main Propulsion Diesel Engines.

2.0 REFERENCES/ENCLOSURES

2.1 References

2.1.1 Tech Manual S9233-EM-MMC-010; Main Propulsion Diesel Engine

Operation, Maintenance, Service, Special Tools, Troubleshooting, and

Repair Manual

2.1.2 Tech Manual S9233-EN-MMC-010; Main Propulsion Diesel Engine

Parts Manual

2.1.3 Tech Manual MS50094/04E Maintenance Schedule

2.1.4 MTU Service Report 90P240153

2.2 Enclosures

2.2.1 T-EPF 5 MTU Diesel Engine Data

2.2.2 Diesel Engine Maintenance Start-up and Dormant Start-up Readiness

Assessment (One Checklist per Diesel Engine)

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity

3.1.1 Location

a. Engine Room 1 (5-52-1)

b. Engine Room 2 (5-52-2)

3.1.2 Quantity

a. Four (4) Main Propulsion Diesel Engines

3.2 Item Description/Manufacturer's Data

3.2.1 MTU Series 8000 Diesel Engine, 9100kW/455kW per cylinder, Model

20V8000M71L.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Government Furnished Equipment (GFE):

4.1.1 Power Packs (40ea), pn# EX56901300002/90, NIIN# 016587413

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4.2 Contractor Furnished Material (CFM)

Item Name Quantity per Engine Part Number in Ref 2.1.2

Easy-Change Fuel Filter 4 0020922101

Coolant Filter 2 0002043697

Fuel Injector 20 X00028337/87

Air Starter Motor Bearings 1 8691740190

Air Starter Motor Bearings 1 8691740210

Thermal Actuator 5 XP56820200002

Air Flap Stop 4 5240980146

Coolant Pump Rotary Seal 1 8592040005

Coolant Pump Shaft Seal 1 8592040003

Raw Water Pump Rotary Seal 1 8592040005

Raw Water Pump Shaft Seal 1 8592040003

Rocker Arm Inlet 20 X56905500019

Rocker Arm Exhaust 20 X56905500020

Rocker Shaft Support 20 X56905500008

Crankshaft Bearing (lower shell) 10 OEM

Exhaust Pipe Bellows 20 X56914200099

Valve Rotator (Rotocap) 80 0000534435

Valve Guide Exhaust 40 X56804200003

V-Band Clamps 40 X56999100019

Rectangle-sect Ring 20 X56903700001

Rectangle-Sect Ring 20 X56903700002

Oil Control Ring 20 0120373518

Cylinder Liner 20 X56801300010/87

Sealing Ring 40 5680110459

Sealing Ring 20 5680110059

Conrod Bearing 20 OEM

4.3 Government Furnished Materials (GFM)

4.2.1 Lube oil.

4.2.2 Engine coolant additive.

4.4 Government Furnished Services (GFS): None

5.0 NOTES

5.1 The individual maintenance intervals are assigned to the qualification levels QL1 to QL4.

QL1: Operational monitoring and maintenance work which does not require disassembly of the product.

QL2: Exchange of components and parts (corrective only, not part of the maintenance schedule).

QL3: Maintenance work which requires partial disassembly of the product.

QL4: Maintenance work which requires complete disassembly of the product.

6.0 QUALITY ASSURANCE REQUIREMENTS

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

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6.2 Make known to all personal working on the engine, that electrical and electronic controls and devices are present and may require necessary precautions and isolations that must be protected from damage during the overhaul period.

6.3 Enclosure 2.2.1 for engine specific model and serial number data. This information is required for identification of correct parts for completion of work identified in Section 7.0.

7.0 STATEMENT OF WORK REQUIRED

7.1 Provide the OEM parts and services for completion of replacement recommendations from MTU Report 90P240153 and perform the 12,000-hour engine overhaul.

7.2 Coordinate with ship’s force to tagout all required systems and equipment. Drain and dispose of any liquid, to vessel tanks.

7.3 Only lead Original Equipment Manufacturer (OEM) authorized or qualified representatives will be permitted to temporarily remove, inspect, refurbish, and reinstall main diesel components.

7.3.1 The OEM representative is to remain on-site from the beginning of work until completion of work with satisfactory dock trials. If there is a need to change the lead OEM representative during this scheduled maintenance action, ship’s force is to schedule a turnover meeting with the departing and arriving lead OEM representatives to ensure a proper turnover is accomplished.

7.4 At the halfway point of the engine overhaul, the contractor representative will contact ABS to conduct an inspection for credit towards the unit's Continuous Machinery Survey.

The unit will not be closed until approval is granted by the ABS surveyor. Provide the attending

ABS Surveyor, MSC Port Engineer and Chief Engineer with a minimum of 24-hour notice as to when the unit will be open and ready for inspection by the ABS Surveyor.

7.5 The OEM will 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.

7.6 Only OEM parts are to be used in the accomplishment of work under this work item.

7.7 Ship’s force is to schedule and provide a representative to attend a daily meeting onboard the vessel with OEM representatives to review data collected and the work planned for the next twenty-four (24) hour period.

7.8 Accomplish the requirements associated with 12,000 operating hours as found in

Reference 2.1.3, as listed below in Table 296–1, using References 2.1.1 and 2.1.2 as guidance.

Maintenance Tasks are available in Reference 2.1.1.

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Table 296-1

Qualification

Level

Interval

(Hours)

Item Maintenance Task Task

QL1 500

Automatic engine oil filter Check and clean oil indicator filter.

W1047

QL1 500 Starter Grease starter ring gear. W1075

QL1 500 Screw Connections Check secure seating of screw connections: Safety valves on cylinder heads.

W1072

QL1 500 Air Intake Grease air flap shaft in intake housing. W1439

QL1 500 Centrifugal oil filter Check thickness of oil residue layer. Clean. Fit new sleeve, at the latest, each time the engine oil is changed.

W1009

QL1 1000 High-pressure pump Check secure seating of screw connections: Connection of high-pressure pump on gearcase.

W1074

QL1 1000 Fuel filters

Check differential pressure and fit new easy-change filter if necessary (fit new filter at latest when time limit

[years] is reached).

W1057

QL1 1000 Air filters Check filters and fleece for contamination and damage. W1032

QL1 2000

Engine mounts

(Rubber Design)

Check buffer clearance of resilient mounts. Check proper seating of securing screws.

W1424

QL1 2000

Engine mounts

(Super D)

Visually inspect for cracks. Check tightness of securing screws.

W1685

QL1 2000 Engine mounts Check static deflection. W1686

QL1 2000 Air filters Fit new filters and fleece. W1040

QL1 2000 Starting ring gear

Check secure seating of screw connections: Starter ring gear on intermediate ring and intermediate ring, starter/coupling.

W1073

QL1 2000 Valve gear Check valve clearance, adjust if necessary. W1002

QL1 2000

Misalignment-accommodating coupling

Check condition visually X5355

QL1 2000 Air filters Clean air filter(s) X7650

QL1 3000 Coolant Filters Fit new coolant filters W1036

QL1 4000 Intercooler Check operating data, remove and clean intercooler, if required.

W4079

QL1 6000

Combustion

Chambers Inspect cylinder chambers using endoscope W1011

QL1 6000 Fuel Injectors Replace rings. W4222

QL1 6000 Fuel Injectors Replace fuel injectors W1006

QL3 12000 Air Starter Disassemble air starter motor. Check condition. Change grease. Fit new bearings.

W1049

QL3 12000

Component maintenance

Before starting maintenance work, carry out test run and record operating parameters. Then drain coolant and flush cooling systems.

W2012

QL3 12000

Component maintenance Clean intercooler and inspect for leakage. W2003

QL3 12000

Component maintenance

Inspect centrifugal oil filter for wear, overhaul if necessary.

W2009

QL3 12000

Component maintenance Check engine alignment W2036

QL3 12000

Component maintenance Coolant thermostat. Fit new thermal actuator. W2038

QL3 12000

Component maintenance

Fit new seals/sealing materials for all disassembled components.

W2062

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Qualification

Level

Interval

(Hours)

Item Maintenance Task Task

QL3 12000

Component maintenance Exhaust system: Inspect condition of insulation. W2064

QL3 12000

Component maintenance

Air and exhaust flaps: Inspect stops and seals and fit new ones if necessary. Inspect bearings of actuator levers.

W2065

QL3 12000

Component maintenance Engine coolant pump: Fit new rotary seal and new seals. W2066

QL3 12000

Component maintenance Raw water pump: fit new rotary seal and new seals. W2067

QL3 12000

Component maintenance Disassemble and clean coolant cooler. Check for leaks. W2068

QL3 12000

Component maintenance Check function of monitoring devices. W2069

QL3 12000

Component maintenance

Check exhaust manifold upstream of turbine of primary turbocharger in the ETC carrier housing and exhaust diffusers downstream of turbine for cracks. If necessary, replace.

W2165

QL3 12000

Component maintenance

Inspect exhaust flaps, shafts and housing for cracks;

inspect bearings.

W2168

QL3 12000 Equipment carrier Check for general condition (visual inspection), repair if necessary. Check mounting of HP pump.

W1617

QL3 12000 Rocker arm Check rocker arm with rocker shaft support, replace if necessary.

W1618

QL3 12000 Crankshaft Replace crankshaft bearings (lower shells). W1609

QL3 12000

Exhaust pipe bellows Replace pipe bellows. W1331

QL3 12000 Power Unit

Overhaul cylinder heads. Fit new Rotorcaps and valve guides (exhaust) for cylinder heads. Inspect valve springs (visual inspection). Check rocker arms and bearing pedestal and overhaul if necessary.

W1155

QL3 12000 Power Unit Clean intermediate housing. W1156

QL3 12000 Power Unit

Inspect exhaust T-piece for cracks. Level off sealing surface. Inspect insulation and renew if cracked. Fit new

V-band clamps if required.

W1157

QL3 12000 Power Unit Clean pistons and inspect for cracks. Fit new piston new piston rings.

W1158

QL3 12000 Power Unit Fit new seals/sealing materials for all disassembled components.

W1170

QL3 12000 Power Unit Remove cylinder liners, check, replace if necessary.

Replace sealing rings, inspect fits and coolant chambers.

W1208

QL3 12000 Power Unit Fit new conrod bearings. W1253

QL3 12000

Supplementary oil tank Clean, check sealing points and pipes. X5513

QL3 12000

Pressure reducing station Overhaul pressure-reducing station. X7654

7.9 All parts that are required to be IMO certified for IAPP shall be procured directly from the OEM to meet IMO requirements.

NOTE: SHIP'S FORCE WILL FILL THE ENGINE’S WITH GFM LUBE OIL AND TREAT

ENGINE HIGH TEMPERATURE FRESH WATER WITH GFM ADDITIVE IDENTIFIED IN

4.2. SHIP’S FORCE WILL PROVIDE DEIONIZED WATER.

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7.10 Inspection/Test

7.10.1 Test all engine alarms and safety devices using Reference 2.1.1. as guidance. Record all alarm and safety device set points and submit to MSCREP.

7.10.2 Notify the Chief Engineer when the overhauled engine is ready to be tested during dock trials for an approximate period of one hour. Notify the ABS Surveyor in order to attend the final testing so credit can be given for the Continuous Machinery Survey on the unit.

Record cylinder operating temperatures, fluid operating temperatures and pressures during load test. Submit an “as found” condition report.

a. Prior to engine start-up the checklist in Enclosure 2.2.2 is to be completed. This evolution is to be accounted for in the scheduling of work under this item and related items.

7.10.3 Complete a performance test on each overhauled engine for a minimum of four hours. Record all operating temperatures and pressures and submit to MSCREP.

7.11 Reports

7.11.1 When inspection, service and testing reveal any deficiency a condition report is to be submitted to the MSCREP with recommended repairs and parts required. Submit three (3) typewritten copies and one (1) electronic copy in Portable Document Format (PDF).

7.11.2 Submit a report that includes “as released” condition of each Main

Propulsion Diesel Engine. Submit three (3) typewritten copies and one (1) electronic copy in

Portable Document Format (PDF).

a. The report is to include as a minimum, engine hours, engine serial number, all parts removed and installed, and combustion parts associated with ABS NOX rules with serial numbers.

7.11.3 All reports and checklists are to be completed and signed by the person who carried out the inspection and maintenance work and countersigned by the Company’s representative.

7.12 Paint/Lagging

7.12.1 Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces.

7.12.2 Renew lagging where damaged or disturbed.

7.13 Manufacturer's Representative

7.13.1 Provide the services of an OEM authorized field service representative to accomplish all work and testing on the diesels identified in Paragraph 3.0 ensuring compliance with the manufacturer’s standards and performance specifications.

7.13.2 This work item requires maintenance and repair actions to be performed on a MSC ship critical safety item. Only original equipment manufacturer (OEM) authorized technical field service providers or MSC qualified non-OEM technical field service providers and

OEM authorized or MSC qualified non-OEM parts shall be used to accomplish the requirements of this work item for this ship critical safety item including oversight and guidance on all aspects of equipment as-found condition inspection, removal, disassembly, reassembly, repairs, modifications, reinstallation, and testing as applicable. The technical service provider is to attend dock trials.

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7.13.3 Contractors interested in gaining MSC qualification as a non-OEM parts and/or service provider should visit this website for qualification and submittal requirements:

https://www.msc.usff.navy.mil/Business-Opportunities/Contracts/Qualification-for-Items-

Critical-to-Shipboard-Safety-on-MSC-Vessels/.

7.13.4 Possible Source

Larry Oberti

Project Manager – Large Engine Group

MTU America Inc.

3504 Shipwright Street

Portsmouth, VA 23703

Phone: 757-469-9241

E-Mail: Larry.Oberti@MTU-Online.com

7.13.5 Provide the MSCREP with a signed letter of qualification from the

Original Equipment Manufacturer and certificate of training for the field service representative for the equipment listed in Paragraph 3.0 prior to the start of any work.

7.13.6 All reports and checklists are to be completed and signed by the person who carried out the inspection and maintenance work and countersigned by the Company’s representative.

7.13.7 Assist ship’s force in completion of Enclosure 2.2.2 checklist.

7.13.8 Prepare and submit an Engine Start-Up Certification to MSCREP within one (1) day of work completion. This document certifies that work is compete and the engine may be started.

7.14 Preparation of Drawings: None additional.

8.0 GENERAL REQUIREMENTS:

8.1 None additional.

mailto:Larry.Oberti@MTU-Online.com

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Enclosure 2.2.1 - T-EPF 5 MTU DIESEL ENGINE DATA

MPDE 1

Model 20V8000M71L

Serial Number: 569100247

MPDE 2

Serial Number: 569100246

MPDE 3

Serial Number: 569100249

MPDE 4

Serial Number: 569100248

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Enclosure 2.2.2 - DIESEL ENGINE MAINTENANCE START-UP AND DORMANT

START-UP READINESS ASSESSMENT (ONE CHECKLIST PER DIESEL ENGINE)

USNS/USS ________________________ Hull No: _______

Diesel Engine Examined for Start-up: ____________________________________

Port / Shipyard: __________________________ Date: ________

72 Hours (notional) Prior to Dock Trial (Machinery Space Turnover) Verification received from Contractor / Tech Rep that all work is complete, and Engine is ready and safe to start.

Verify machinery space fire and smoke detection systems are fully operational.

Verify all Lockout / Tag out locks / tags are cleared IAW SMS 2.1-004-ALL “Lockout /

Tag out.”

Verify that diesel exhaust systems are intact, and no fire hazards exist in the uptake spaces.

Verify all tanks are closed.

Verify all machinery space doors are operating correctly including any installed door closers.

Verify fixed, semi-portable and portable firefighting systems are fully certified and operational.

Verify Damage Control Locker and equipment are available.

Verify that all machinery space reach rods and remote pull stations are fully functional where fitted.

Verify all hoses, staging, covers, rigging, etc., temporarily installed in support of ship maintenance and repair, are removed from the machinery spaces.

Verify machinery space bilges are clean with no accumulations of liquids or debris.

Verify that machinery space supply and exhaust ventilation and fire dampers are functioning properly.

Verify that all installed engine hoses have been checked for wear and compliance with the COMSC 5-year replacement mandate.

48 Hours (notional) Prior to Startup Check engine oil level in sump.

Check governor oil level.

Check cooling water level.

Check central freshwater treatment and level.

Check oil levels in reduction gear, lineshaft bearings and auxiliary sumps.

Verify fuel oil lines on engine are secure.

Transfer fuel oil from storage tanks to settler.

Check fuel oil service tanks for water or contamination. Conduct fuel oil analysis.

Check lube oil service tanks and sumps for water or contamination. Conduct lube oil analysis.

Verify all engine filters cleaned or renewed.

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24 Hours (notional) Prior to Startup Remove stack covers.

Walk around the engine and check for leaks on and under the engine.

Verify 115V / 24VDC control voltage available.

Perform lamp test locally and at EOS console.

Run the lube oil and fuel oil purifiers on sumps and service tanks.

Run auxiliary systems; check pressures and temperatures.

Verify auto start of standby pumps.

Verify machinery space bilges are clean with no accumulations of liquids or debris.

Pre-Start Check oil level in sump.

Check head tank levels.

Disengage barring gear.

Review USCG Periodic Safety Test Plan (PSTP) and verify that all engine related safety and alarm features are functioning properly.

Verify that saltwater cooling / freshwater cooling systems and heat exchangers are on-line and fully operational.

Verify that lube oil service pumps / lube oil service system is fully functional.

Verify that lube oil purifiers are operating properly.

Verify that fuel oil service pumps / fuel oil service system is fully functional.

Verify that fuel oil purifiers are operating properly.

Verify that compressed air / start air systems are fully functional.

Verify shafts and props are clear to spin.

Stop all fuel transfers.

Test sliding watertight doors.

Verify EDG is available and ready; test run off line.

Open all Engine cocks and roll the engine.

Check local emergency stop.

Check remote emergency stop.

Chief Engineer to notify Master and Port Engineer that start-up readiness assessment has been completed for all prime movers, and associated support systems and that machinery is ready / not ready for start-up.

Master to provide concurrence for start-up or not and conveys same to Type Desk and PM for information.

Chief Engineer Port Engineer