Statement of Work 20Q4131.docx

ABSTRACT:

This item describes the requirement to provide OEM Labor, Technical Services, Material, and Industrial Support to accomplish 8,000 hour scheduled maintenance of the Electro-Motive Division, Main Diesel Engines QTY two (2) 20-645-E7B.

REFERENCES/ENCLOSURES:

References:

Technical Manual 0941-LP-054-8010, 645E7 Turbocharged Marine Engine Systems

1.1.1 ELECTRO-MOTIVE M.I.1722 MAINTENANCE INSTRUCTION

1.2 Enclosures:

1.2.1 Diesel Engine Maintenance Start-up and Dormant Start-up Readiness Assessment (One Checklist per Diesel Engine)

2.0 ITEM LOCATION/DESCRIPTION:

2.1 Location/Quantity:

2.1.1 Location: Engine Room (3-53-0)

2.1.2 Quantity: Two (2) Main Diesel Engines.

2.2 Item Description/Manufacturer's Data:

2.2.1 Main Engine STARBOARD

NOMEN: ENG DSL 20 L20-645-E7B 900RPM CCW MANUFACTURER: ELECTRO-MOTIVE DIESEL INC DBA EMD Serial Number:79E1-1167 STBD

2.2.2 Main Engine PORT

NOMEN: ENG DSL 20 R20-645-E7B 900RPM CW MANUFACTURER: ELECTRO-MOTIVE DIESEL INC DBA EMD Serial Number: 79F1-1025 PORT

3.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

3.1 Government Furnished Equipment (GFE): None.

3.2 Government Furnished Material (GFM):

3.2.1 Lube oil as required.

3.2.2 Engine coolant additive as required.

3.3 Government Furnished Services (GFS):

4.3.1 ABS Surveyor

4.0 NOTES:

4.1 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 including but not limited to GTRs 1 through 7, 22, 23, 28, and 29.

5.0 QUALITY ASSURANCE REQUIREMENTS:

5.1 In addition to the contractor’s duties under 29CFR1910.147 or similar local safety regulation, the contractor shall comply with all requirements of equipment lock-out/tag-out (LOTO) program as established by MSC SMS procedure 2.1-004-ALL Lock-out/Tag-out. The Chief Engineer shall administer the program. Prior to the start of work, the contractor shall contact the REP and / or the Chief Engineer to coordinate the implementation of the LOTO program for the entire performance period of this item. The prime contractor shall be responsible for compliance by both prime and subcontractor personnel.

5.2 Make known to all personal working on the Electro-Motive Division 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.

Chief Engineer will inspect crank case upon notification by contractor that work is complete.

6.0 STATEMENT OF WORK REQUIRED

Provide all material and special equipment IAW Ref 2.1.1 and 2.1.2. Make all removals and restorations. Remove and replace all interferences, rig and unrig, stage and unstage, make all disassemblies and subsequent reassemblies, provide and operate equipment, and supply all services and assistance to accomplish the following work. (Material, unless specifically stated as Government Furnished Material (GFM) shall be supplied by the contractor).

6.1 Only OEM authorized or qualified representatives will be permitted to temporarily remove, inspect, refurbish, and reinstall diesel engine components.

6.1.1 The lead Original Equipment Manufacturer (OEM) representative is to be 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, ensure a proper turnover is accomplished with the MSCREPs.

6.2 At the halfway point of the engine overhaul, the contractor representative will contact the Port Engineer to schedule 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, 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.

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

6.3 Provide and accomplish the disassembles, cleaning, inspections, replacement of parts and testing associated with the 8,000 Hour Service Diesel Engine maintenance IAW Reference 2.1.1 and 2.1.2.

6.4 Using engine model and serial number found in para 3.0 check for any Technical Service Bulletins, recalls or warranty repairs that may be required on the engines.

NOTE: SHIP'S FORCE WILL TREAT ENGINE FRESH WATER WITH GFM ADDITIVE IDENTIFIED IN 4.2.2.

6.5 Inspection/Test:

6.5.1 Prior to disassembly and after completion of the 8000 hour maintenance, test all engine alarms and safety devices. Record all alarm and safety device set points and submit to MSCREP.

6.5.2 Notify the Chief Engineer and the attending Port Engineer when the serviced engine is ready to be tested for an approximately two hours during dock trials. Notify the ABS Surveyor to witness. Record cylinder operating temperatures, fluid operating temperatures and pressures. Submit an “as found” condition report.

a. Prior to engine start-up the checklist in Enclosure 2.2.1 shall be completed. This evolution is to be accounted for in the scheduling of work under this item and related items.

6.5.3 Verify proper protection is provided by installed engine heat screening and insulation to protect from fire in the event of oil or fuel spray. Use a thermal imaging camera to note any surfaces hotter than the maximum SOLAS requirement of 220 Deg C (428 Deg F). Inspect for the below noted conditions and provide a condition report for any noted discrepancies.

a. Screening and insulation are in place and mounted correctly.

b. Gaps in screening where fuel or oil spray can contact hot surfaces.

c. Where insulation mats are used, evaluate if an oil leak can contaminate or soak the material and be a fire risk.

d. Inspect insulation and screening around exhaust bellows and expansion joints for exhaust smell, discoloration and cracks.

e. Inspect insulation and screening for oil contamination or soaking. Any insulation or screening found in this condition should be noted in a condition report for replacement.

Test serviced engine during dock and sea trials.

6.6 Reports:

6.6.1 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).

6.6.2 Provide the MSCREP with a report for each engine no more than seven (7) days after the completion of all work. Provide three (3) typewritten copies and one (1) electronic copy in Portable Document Format (PDF). The report will contain the following, at 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 and critical clearances and adjustments. "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 maintenance on engine.

g. Include a listing of all parts used during maintenance. Identify all parts rebuilt, renewed or exchanged. The parts list to include the Sub-Assembly drawing number and Electro-Motive Division part number.

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

i. Valve lash measurements with OEM acceptable limits.

Fuel valve injection pressure before and after testing.

6.7 Paint/Lagging:

Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces. Renew lagging where existing lagging was removed.

6.8 Manufacturer's Representative:

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

6.8.2 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 are to 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 and sea trials.

6.8.3 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.

6.8.4 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.

6.8.5 Assist ship in completion of Enclosure 2.2.1 checklist.

6.8.6 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.

6.9 Preparation of Drawings: None.

USNS Apache

( T-ATF 172 )

7.0 GENERAL REQUIREMENTS: None additional.

0292 - 9

ENCLOSURE 2.2.1

USNS/USS ________________________ Hull No: _______

Diesel Engine Examined for Start-up: ____________________________________

Port / Shipyard: __________________________ Date: ________

72 Hours (notional) Prior to Dock Trial (Machinery Space Turnover)

48 Hours (notional) Prior to Startup

24 Hours (notional) Prior to Startup

Pre-Start