WI_0201_1B MAIN PROPULSION DIESEL ENGINE REPAIR_Specification.pdf

USNS GRASP

( TARS 51 )

PROPULSION MACHINERY N4044321Q0105

ITEM NO. 0201 CATEGORY "A" 2021-07-09

MAIN PROPULSION DIESEL ENGINE

REPAIR

Cost, Benjamin

0201-1

1.0 ABSTRACT:

The purpose of this item is to provide the OEM labor, technical services, material, and industrial support to accomplish repair of 1B Caterpillar (CAT) D399TA Engine.

2.0 REFERENCES/ENCLOSURES:

2.1 References:

2.1.1 Technical Manual S9233-BN-MMM-010, Main Propulsion Engines, Caterpillar M/D 399B-TA.

2.1.2 QMS_N2.35.6100.1-Q COVID-19 Command Response Plan_Rev-8

2.1.3 QMS_N2.35.6100.1-Q Enclosures 1-18_Rev-8

2.2 Enclosures:

2.2.1 Caterpillar D399TA Main Propulsion Diesel Engine Model 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: Main Machinery Room (3-53-0-E).

3.1.2 Quantity: Two(2) Main Diesel Engines.

3.2 Item Description/Manufacturer's Data:

3.2.1 Caterpillar Engine Model D399TA.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE): None.

4.2 Government Furnished Material (GFM):

4.2.1 Lube oil as required.

4.2.2 Engine coolant additive as required.

4.3 Government Furnished Services (GFS): 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 including but not limited to GTRs 1 through 7, 22, 23, 28, and 29.

5.2 The following definitions explain the terminology used in Section 7 for the service that is performed during an overhaul. These terms are used by Caterpillar to define diesel engine inspection and repair and complement definitions in Work Item 001:

5.2.1 Inspect – Inspect the components according to the instructions that are in

Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”.

5.2.2 Rebuild – The component is reconditioned by OEM or authorized representative in order to comply with reusability guidelines.

5.2.3 Replace – The service life of the part is exhausted. The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional specifications. The replacement part may be a new CAT part or a CAT remanufactured part. Some parts have an associated core charge for

PROPULSION MACHINERY N4044321Q0105

ITEM NO. 0201 CATEGORY "A" 2021-07-09

MAIN PROPULSION DIESEL ENGINE

0201-2 which credit is received when returned to a CAT dealer.

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 main diesel work is being accomplished.

6.2 Make known to all personal working on the engine and generator unit, 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.

6.4 Chief Engineer or MSC Port Engineer will inspect crank case upon notification by contractor that work is complete.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Tagout all required systems and equipment. Drain and dispose of any liquid in accordance with all federal, state and local regulations.

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

7.2.1 The lead OEM representative is to remain on-site from the beginning of work until completion of work with satisfactory dock and sea trials. If there is a need to change the lead OEM representative during this scheduled maintenance action, the shipyard quality assurance department is to schedule a turnover meeting with the departing and arriving lead OEM representatives, shipyard quality assurance personnel and MSCREPs in attendance to ensure a proper turnover is accomplished.

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

7.5 Provide and accomplish the replacement of 12 of 16 pistons, rings, liners, rod bearings and associated gaskets/seals IAW Ref 2.1.1 Section 6-3.3 through 6-3.4. Please note:

Cylinders 3, 4, 5, 7, 8, 10, 11, 12, 13, 14, 15, and 16 require replacement.

7.6 Remove and disassemble cylinder heads IAW Ref 2.1.1 Section 6-3.2.

7.6.1 Inspect intake and exhaust valves IAW Ref 2.1.1 Section 6-3.2.2 and 6-3.2.3.

Lap valves as required to meet OEM Specification IAW Ref 2.1.1.

7.6.2 Inspect cylinder heads IAW Ref 2.1.1 Section 6-3.2.8.

7.6.3 Install cylinder head IAW Ref 2.1.1 Section 6-3.2.9.

7.7 Inspection/Test:

7.7.1 Notify the Chief Engineer and the attending Port Engineer when the repaired engine unit is ready to be tested. 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 testing. 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.

PROPULSION MACHINERY N4044321Q0105

ITEM NO. 0201 CATEGORY "A" 2021-07-09

MAIN PROPULSION DIESEL ENGINE

0201-3

7.7.2 Test overhauled engine during dock and sea trails.

7.8 Reports:

7.8.1 Provide the MSCREP with a completed electronic report. The report will contain the following, at minimum:

a. Engine operating hours and serial number.

b. All work completed by tech rep.

c. Valve lash and timing measurements with OEM acceptable limits

d. Dock and Sea Trail results.

7.9 Painting/Lagging:

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

7.10 Manufacturer's Representative:

7.10.1 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.

7.10.2 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 and sea trials.

7.10.3 Provide the MSCREP with a signed letter of qualification from the OEM and certificate of training for the field service representative for the equipment listed in paragraph 3.0 prior to the start of any work.

7.10.4 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.

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

7.10.6 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.

7.10.7 Follow all COVID 19 protocols specified in reference 2.1.2 and 2.1.3 to travel to USNS GRASP located in Naval Base San Diego and while onboard Ship (masks required).

7.11 Preparation of Drawings: None.

8.0 GENERAL REQUIREMENTS: None additional.

PROPULSION MACHINERY N4044321Q0105

ITEM NO. 0201 CATEGORY "A" 2021-07-09

MAIN PROPULSION DIESEL ENGINE

0201-4

ENCLOSURE 2.2.1

CATERPILLAR D399TA MAIN PROPULSION DIESEL ENGINE MODEL DATA

MPDE 1B

Model: D399TA Serial Number: 91B01474

PROPULSION MACHINERY N4044321Q0105

ITEM NO. 0201 CATEGORY "A" 2021-07-09

MAIN PROPULSION DIESEL ENGINE

0201-5

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 fresh water 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.

24 Hours (notional) Prior to Startup

Remove stack covers.

PROPULSION MACHINERY N4044321Q0105

ITEM NO. 0201 CATEGORY "A" 2021-07-09

MAIN PROPULSION DIESEL ENGINE

0201-6

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 salt water cooling / fresh water 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