STATEMENT OF WORK.pdf

20001_JLW_1024_154WPC

WORK ITEM 1: MDE, 8000 Hour Maintenance (QL3), Perform

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform all MTU 6000 hour (QL3) maintenance tasks on both Main Diesel Engines (MDEs) at the 8000 operational hour interval.

General work item note.

Work contained herein applies to engines acquiring their initial 8,000 hours of run time. This maintenance is commonly referred as a QL3 (top end overhaul).

Subsequent top end overhauls are conducted at 16,000 hours and referred as QL3+. This maintenance action includes additional inspections and renewal of the FO delivery pump and HP fuel pump. (see QL3+ for details)

Engines on hulls 1107 – 1118, 1123, 1124, and 1125 have already completed a QL3 at 6,000 hours, thus are due a QL3+ at 14,000 hours not 16,000 hours.

1.2 Government-furnished property.

APM: Validate all GFP data. If the Spec Package's Consolidated List of GFP is changed, ensure it is changed in the source WI and GFP style is applied.

IF GFP IS UNAVAILABLE

If all material is to be “Contractor furnished” then delete the GFP list in its entirety and type in “None.” This will make all material “Contractor furnished”. See para 3.1.5 below.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y STARTER #1 NSN: 2920-12-385-6663 PN:

0041519901 2 ea. 1,060.65

Y STARTER #2 NSN: 2920-12-385-6651 PN:

0051510001

2 ea. 1,060.65

Y Injector NSN: 2910-12-396-9474 PN:

EX59407500022

40 ea. 2,660.16

Y Jacket Water Pump NSN: 2930-12-408-5714 PN:

EX54920200040

2 ea. 2,350.13

Y Head NSN: 2815-12-401-6623 PN:

EX52904100073

40 ea. 2,433.44

Y Raw Water Pump NSN: 4320-12-420-2316PN:

EX59420700080/87

2 ea. 6,373.10

Y Turbo A2 NSN: 2950-12-390-3213 PN:

X59610100194

2 ea. 23,271.00

Y Turbo B1 NSN: 2950-12-390-3739 PN:

X59610100195

2 ea. 23,271.00

Y Turbo B2 NSN: 2950-12-390-5601 PN:

X59610100196

2 ea. 23,271.00

Y Turbo A1 NSN: 2950-12-390-3341 PN:

X59610100197

2 ea. 23,271.00

Y Slide-in Chassis for Cooler NSN: 2930-12-408-5926 PN:

XP59611400056

2 ea. 30,871.80

Y Cooler, Oil NSN: 2930-12-395-6730 PN:

X59618300046/87

2 ea. 9,370.00

N **Turbo Charger Outlet Exhaust Expansion Joints

NIIN: 016240847

PN: FLP-0005-15 3/16-LS-M5

8 ea, 4,312.77

*Government-loaned property, which must be returned to the vessel upon completion of the availability.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by either the vessel or the C4IT Service Center.

INSTRUCTIONS FOR APM/PE/COR/CUTTER

To allow for a more extensive analysis of Pre-QL3 and Post-QL3 propulsion plant health, crew needs to complete an unscheduled FRC FPT MPC (A15005.0) for each engine. The contractor performing this maintenance must also capture pre-QL3/post QL3 sea trial data (See second bullet paragraph 3.3.) After contract award coordination is required between cutter and contractor to schedule and preform sea trial.

Note. Per the Memorandum of Agreement (Engine Lifecycle Extension Test Plan) initiative between the PBPL, Pro Lockport, and MTU hulls 1107, 1128, and 1148 require 4-hour full power trial. Contact PBPL Project Branch for additional details and coordination with MTU tech rep.

Two key goals for this:

This will provide PBPL and the contractor a more extensive view of pre QL3 propulsion plant performance and/or issues. This will point to possible unforeseen factors of performance and help target areas of attention.

Key data for the FRC FPT data analysis program is good baseline data. The post QL3 sea trial should provide that very baseline. Key to the post QL3 sea trial for a valid baseline is a clean hull. A good definition of clean hull is “No Visible Growth” on the hull, propeller blades, propeller hub, shaft, rudders, etc. MPC B10015.D provides good information in reference to clean hull. A hull cleaning should be included prior to the sea trial.

POC for questions in this block is Paul Schaefer, SFLC ESD NAME Main Prop, paul.a.schaefer2@uscg.mil, 757-846-4123.

2. REFERENCES

APM: Ensure all references are latest version in CG-LIMS. If editing a WI's References, change the same ref. in the Spec's Consolidated List of References mailto:paul.a.schaefer2@uscg.mil and contact the SES spec writer to change the source WI. Ensure any MS Word “Comments” and Tracked Changes are removed before uploading the Spec package or delivering to CPD.

COAST GUARD DRAWINGS

Coast Guard Drawing 154 WPC 085-201, Rev A, Propulsion System, SSDG, EDG Installation

Drawings Coast Guard Drawing 154 WPC 200-301, Rev -, Machinery Arrangement Drawings Coast Guard Drawing 154 WPC 204-301, Rev F, Equipment Removal Plan

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 8019A, SWBS 233, Aug 2019, Main Propulsion Diesel

Engine (MDE), MTU 20V4000M93L (154 WPC A & B-Class Cutters) Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures

OTHER REFERENCES

None

3. REQUIREMENTS

3.1 General.

3.1.1 CIR. The Contractor must submit a CIR for the inspections listed in the following paragraph(s):

• 3.3 Maintenance tasks.

3.1.2 Tech Rep. The Contractor must provide onsite at least one QL3 certified technician on MTU4000 series engines. The technician must possess a 1B dongle, have certification on ECU-7 series governors, and the Contractor must have 20V4000 engine maintenance experience.

3.1.2.1 Most current technical documentation. Prior to starting work, the QL3 certified technician must obtain from the OEM (MTU) the most current versions of the MTU documents contained within TP- 8019A (e.g. service manuals, bulletins, etc.) and abide by requirements in those current documents. After the overhauled/repaired engines have been accepted satisfactory by the Coast Guard, turn over all new versions of documents to the Coast Guard.

3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection).

3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.1.5 Contractor vs Government Furnish Material. The Contractor must furnish all material necessary to perform the work that is not listed beneath paragraph “1.2 Government-furnished property”; all material that is listed beneath that paragraph will be Government furnished.

3.1.6 Overhaul or Renew. When “Overhaul or Renew” is designated, and the component is Contractor-furnished, the Contractor may overhaul (i.e. completely disassemble, renew all consumable/wearing components, inspect all non-consumable/non-wearing components, etc. in accordance with TP-8019, Volume 3, Appendix D, Instructions for Overhaul or Sub-Assemblies) or completely renew the designated component(s) pending which action is most economical for the Govt. When “Overhaul or Renew” is designated, remanufactured component(s) are acceptable.

3.2 Ad-hoc test and inspections. After the start of work, when warranted/appropriate, Coast Guard may request various inspections and tests (e.g. engine performance data collection, etc.) and may request engine performance data whenever the engine is running. If it is determined that the test or inspection will add significant new costs or schedule impacts to the requirement, pricing will be negotiated and contract terms will be modified at that time.

3.3 Maintenance Tasks. The Contractor must perform the following to identify all discrepancies that may affect engine performance and to accomplish various other maintenance tasks.

NOTE

Ship’s Force will perform all electrical isolation, tag-out procedures, etc.

Coordinate with Ship’s Force and ensure all Tag-Outs are complete prior to performing any maintenance.

• During disassembly and reassembly in conjunction with performing the tasks specified below, renew all disturbed seals, gaskets, o-rings, rubber sleeves, and all other soft wearing parts.

• Remove and re-install all interferences, as required, to perform the following maintenance.

• Perform a sea trial and pre-test to identify all existing discrepancies/conditions. Upon completion of the sea trial, and prior to any disassembly, submit a CFR that describes all discrepancies that can be identified prior to disassembly (e.g. external damage to any component, all component/equipment performance discrepancies, etc.) and recommended repairs. To support recommendations, collect and submit a minimum of 30 min of ECU/MCU engine data.

Note for A Team.

If saltwater intrusion is found while inspecting the air inlet system ensure the Contractor inspects demisters as part of a growth inspection/repair CR.

• Clean and inspect, for saltwater intrusion, the air flexible ducting leading to the air turbo inlets from the transition piece on each engine.

NOTE

The charge air cooler is too large to be removed as a unit from the vessel. It must first be disassembled, and the core must be removed separately.

• Renew the charge air coolers and inspect for leakage on each engine. Prior to disassembling the charge air cooler submit a CFR detailing a disassembly and removal plan. Initiate disassembly after the Coast Guard approves the plan.

• Drain and dispose of jacket water/coolant and engine oil on each engine.

Note for EPO. Coordinate coolant flush with contractor prior to engine tag out. Review MTU A001061, chapter 10.3 Flush Procedures. Contractor may need to flush multiple times. A successful flush is when the difference between the make-up flush water pH and post flush water pH is < 1pH.

• Flush coolant circuit (refer to A001061, Fluids and Lubricants Specification) on each engine.

Dispose of flush water.

Note for EPO. MTU MA15071, chapter 8.2.2, lists the cylinder liner surface accept/reject criteria and the ‘terms’ to describe condition. Ensure contractor use these terms when submitting the CIR.

• Inspect each cylinder chamber on both engines and Submit a CIR detailing the condition of each using the terms listed for endoscopic examination (refer to MA15071, Operating Instructions).

• Inspect all Turbo Charger Outlet Exhaust Expansion Joints; submit an inspection report in conjunction with the above CIR.

• Renew all Fuel Rail Plugs. Turn over all old plugs to Ship’s Force.

• Renew the high-pressure fuel sensors on each engine.

• Inspect centrifugal oil filter and check bearing for wear. (Refer to MA25014, Instruction for overhaul of assemblies) on each engine.

• Overhaul or Renew two starters on each engine.

• Clean each engine coolant/fuel cooler.

• Overhaul or Renew engine oil cooler engine on each engine.

• Overhaul or Renew the coolant pump on each engine.

• Overhaul or Renew the raw water pump on each engine.

• Inspect all rocker arms and valve bridges for wear on each engine. Insert an endoscope through the pushrod bore to visually inspect swing followers and camshaft running surfaces.

Submit CFR.

• Renew the thermostats and verify proper thermal actuation on each engine.

• Remove the engine to RG coupling and perform an engine output flange to RG input flange alignment check on both engines to the nearest 0.001”. Include the alignment data collected and any recommended corrective actions in the engine mount CFR described below.

Reinstall the coupling only after satisfactory final alignment is confirmed and the MDEs and reduction gears are secured in-place; renew norlock washers.

• Inspect engine mounts and verify proper engine to RG alignment. Measure the buffer clearance of the resilient mounts and verify proper seating of securing screws. Check for cracks in the rubber elements, measure the size of any cracks found. Measure the height of each rubber elements. Verify proper alignment between the engine output and reduction gear input flanges. Submit a CFR detailing all findings and describe all recommended repairs.

• Overhaul or Renew all cylinder heads (i.e. Renew all cylinder head wearing components (e.g.

springs, seals, etc.) and repair all defects found to all other cylinder head components (e.g.

repair individual defects, or provide new or remanufactured heads, etc.). Submit a report detailing the maintenance actions taken to each head.

o If one or more new heads provided have coating discrepancies (e.g., only a primer coat of paint has been applied vs. a full two coats of paint, etc.), or any other significant discrepancies, Submit a CFR describing the condition. After the KO releases a CR, perform the work described therein. Heads must be coated with a general purpose 2 part polyurethane enamel, high gloss white, two coats with a dry film thickness 3 - 4 mil (Valspar LIC50, color RAL9010 or equivalent).

• Overhaul or Renew the turbochargers on each engine (i.e. Renew all turbocharger wearing components (e.g. springs, seals, etc.) and repair all defects found to all other turbocharger components (e.g. repair individual defects, or provide new or remanufactured turbochargers, etc)). Submit a report detailing the maintenance actions taken to each turbocharger.

• All reports, except the final test report below, are due no later than 2/3 through the contract performance period.

• Overhaul or Renew the fuel injectors on each engine.

• Inspect and clean oil indicator filter, renew the fuel filters on each engine.

• Renew the jacket water/coolant, engine oil, all fuel filters on each engine with Contractor furnished materials. Engine oil must be MTU approved Category 3.1 (Low SAPS oil).

Coolant must be a MTU approved A216 corrosion inhibitor.

• Perform a final sea trial and post maintenance test, conducting a 2hr full power trial run.

After completion of the sea trail submit a minimum of 30 minutes of ECU/MCU engine data.

Submit a final report.

NOTE

Coast Guard personnel will operate all shipboard machinery and equipment.

3.4 Touch-up preservation. The Contractor must prepare and coat all new and disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.)

4. NOTES

This section is not applicable to this work item.