USS Gunston Hall SSDG NR 2

Contractor shall complete remaining work on the attached SAP SSDG #2 Attached Lube Oil Pump, Injection Pumps and Nozzles, Attached Fuel Oil Pump, Generator Bearing Drain Pump, Attached Sea Water Pump, attached Jacket Water Pump, Air Start Distributor, Air Start Check Valves, Resilient Mounts, Exhaust Piping, Lube Oil Pre-lube Pump, Vertical Drive, Blower, Lube Oil Cooler, Jacket Water Cooler, Over-Speed Device, Piston and Liner Assemblies, Complete a flush of the entire lube oil system, Conduct the bearing run in, load testing for breaking in cylinders and post inspections with a load bank. - Justification for Sole Source are that OEM Fair Banks Morse (FME) has already completed 80 percent of the work on NR2 Ships Service Diesel Generator (SSDG). FME is also the original manufacture of the equipment. Government will mitigated all non-serviceable parts. Contractor shall provide to the Government, a report listing non-serviceable parts in the form of a hard copy or approved transferrable media.  Government to provide isolating and tagging out of system, draining, disposal, filling and venting system fluids.

Contractor shall install and remove temporary closure to prevent entrance foreign matters and maintain system cleanliness of Level II. Prior to starting, ensure no foreign material exists on adjacent surfaces that could contaminate the internal areas upon reassembly of piping joints. Inspect each fastener intended for reuse for wear and defects. Submit one legible copy, in hard copy or approved transferrable media of each enclosures to the Government.

Equipment (NR 2 SSDG Located in Auxiliary Machinery Room Number One 5-43-0-E):

Attached Lube Oil Pump

Injection Pumps and Nozzles

Attached Fuel Oil Pump

Generator Bearing Drain Pump

Attached Sea Water Pump

Attached Jacket Water Pump

Air Start Distributor

Air Start Check Valves

Resilient Mounts

Exhaust Piping

Lube Oil Pre-lube Pump

Vertical Drive

Blower

Lube Oil Cooler

Jacket Water Cooler

Over-Speed Device

Piston and Liner Assemblies

Attached Lube Oil Pump

Process Control Procedures (PCP) for planned availabilities, submission shall be no later than 14 days prior to start of the required process, or as otherwise approved by the SUPERVISOR. Attachment A shall be used for PCP development; ensure each element is contained within its respective section.

Develop and submit one legible copy of a Process Control Procedure (PCP), in approved transferrable media, to the SUPERVISOR for approval the requirements of for the accomplishment of MS3112-OP-002-3, Enclosure 2, Section 3.7.2, step D thru P of ref b.  Install the equipment in accordance with MS3112-OP-002-3, Enclosure 2, Section 3.7.2, step D thru P of ref b. Government shall witness each backlash in accordance with MS3112-OP-002-3, Enclosure 2, Section 3.7.2, step D and M of ref b.

Accomplish an operational test of the equipment at 100 percent engine load at normal operating system temperature and pressure in accordance with MS3112-OP-002-3, Enclosure 2, Section 3.8 of ref b, and under the direction of the Diesel Engine Inspector (DEI).  Allowable leaks, abnormal noise or vibration at normal operating pressure and temperature: None, Repair any leaks found.

Submit one legible copy, in hard copy or approved transferrable media, of a report listing the result of the requirements of MS3112-OP- 002-3, Enclosure 2, Section 3.10, Examination, Test, and Repair Action Record of 2.2, including each inspection, torque value, and reading required to the SUPERVISOR.

Injection Pumps and Nozzles

Accomplish an operational and tightness test of the injections pumps and nozzles, using Chapter 2 of ref a, and under the direction of the Diesel Engine Inspector (DEI).  Final testing shall be completed at 100 percent engine load. Allowable leaks, abnormal noise or vibration at normal operating pressure and temperature: None, Repair any leaks found.

Attached Fuel Oil Supply Pump

Develop and submit one legible copy of a Process Control Procedure (PCP), in approved transferrable media, to the SUPERVISOR for approval the requirements of for the accomplishment MS3112-OP-002-4, Enclosure 2, Section 4.6.3, step A thru G of ref b.   Install the equipment in accordance with MS3112-OP-002-4, Enclosure 2, Section 4.6.3, step A thru G of ref b.

Accomplish an operational test of the equipment at 100 percent engine load at normal operating system temperature and pressure in accordance with MS3112-OP-002-4, Enclosure 2, Section 4.8 of ref b, and under the direction of the Diesel Engine Inspector (DEI).  Allowable leaks, abnormal noise or vibration at normal operating pressure and temperature: None, Repair any leaks found.

Bearing Drain Pump

Develop and submit one legible copy of a Process Control Procedure (PCP), in approved transferrable media, to the SUPERVISOR for approval the requirements of for the accomplishment MS3112-OP-002-5, Enclosure 2, Section 5.6.3, step A thru G of ref b.  Install the equipment in accordance with MS3112-OP-002-5, Enclosure 2, Section 5.6.3, step A thru G of ref b.

Accomplish an operational test of the equipment at 100 percent engine load at normal operating system temperature and pressure in accordance with MS3112-OP-002-4, Enclosure 2, Section 5.8 of ref b, and under the direction of the Diesel Engine Inspector (DEI).  Allowable leaks, abnormal noise or vibration at normal operating pressure and temperature: None, Repair any leaks found.

Attached Seawater Pump

Develop and submit one legible copy of a Process Control Procedure (PCP), in approved transferrable media, to the SUPERVISOR for approval the requirements of for the accomplishment of MS3112-OP-002-1, Enclosure 2, Section 1.7.2, step D thru P of ref b. Install the equipment in accordance with MS3112-OP-002-1, Enclosure 2, Section 1.7.2, step D thru P of ref b.

Government shall witness each backlash in accordance with MS3112-OP-002-6, Enclosure 2, Section 1.7.2, Step F and Step J of ref b.

Accomplish an operational test of the equipment at 100 percent engine load at normal operating system temperature and pressure in accordance with MS3112-OP-002-1, Enclosure 2, Section 1.7 of ref b, and under the direction of the Diesel Engine Inspector (DEI).   Allowable leaks, abnormal noise or vibration at normal operating pressure and temperature: None, Repair any leaks found.

Submit one legible copy, in hard copy or approved transferrable media, of a report listing the result of the requirements of MS3112-OP- 002-1, Enclosure 2, Section 1.10, Examination, Test, and Repair Action Record of ref b, including each inspection, torque value, and reading required to the SUPERVISOR.

Attached Jacket Water Pump

Develop and submit one legible copy of a Process Control Procedure (PCP), in approved transferrable media, to the SUPERVISOR for approval the requirements of for the accomplishment of MS3112-OP-002-2, Enclosure 2, Section 2.7.2, step E thru T of ref b. Install the equipment in accordance with MS3112-OP-002-2, Enclosure 2, Section 2.7.2, step E thru T of ref b.

Government shall witness each backlash in accordance with MS3112-OP-002-2, Enclosure 2, Section 2.7.2, Step H and Step J of ref b.

Accomplish an operational test of the equipment at 100 percent engine load at normal operating system temperature and pressure in accordance with MS3112-OP-002-2, Enclosure 2, Section 2.7 of ref b, and under the direction of the Diesel Engine Inspector (DEI).  Allowable leaks, abnormal noise or vibration at normal operating pressure and temperature: None, Repair any leaks found.

Submit one legible copy, in hard copy or approved transferrable media, of a report listing the result of the requirements of MS3112-OP- 002-2, Enclosure 2, Section 2.10, Examination, Test, and Repair Action Record of ref b, including each inspection, torque value, and reading required to the SUPERVISOR.

Air Start Distributor

Develop and submit one legible copy of a Process Control Procedure (PCP), in approved transferrable media, to the SUPERVISOR for approval the requirements of for the accomplishment ref a, section 6-6.34.4, step A thru F. Install the equipment in accordance with ref a, section 6-6.34.4, step A thru F.

Government shall witness the timing in accordance with ref a, 6-6.34.4 step D.

Accomplish an operational and tightness test of the air start distributor, using Chapter 2 of ref a, and under the direction of the Diesel Engine Inspector (DEI). Allowable leaks, abnormal noise or vibration at normal operating pressure and temperature: None, Repair any leaks found.

Air Start Check Valves

Accomplish an operational test of the equipment listed at 100 percent engine load at normal operating pressure and temperature, using ref a for guidance. Allowable leakage: None, Repair any leaks found.

Resilient mounts

Accomplish visual inspection and verify height using ref g for guidance. Government MARMC code 264 Diesel Inspector shall witness height inspection.

Exhaust piping

Align exhaust piping to exhaust elbows and bellows, replace exhaust gaskets. Accomplish an operational test of the equipment at 100 percent engine load at normal system pressure and temperature, using ref a for guidance. Allowable leakage: None, Repair any leaks found.

Lube Oil Pre-lube Pump

Accomplish an operational test of the equipment at normal operating temperature and pressure in accordance with MS3112-OP-002-7, Enclosure 2, Section 7.8 of ref b. Government MARMC code 264 Diesel Inspector shall witness inspection. Allowable leakage: None. Repair any leaks found.

Ensure pump discharge pressure is 50 PSIG at 130 degrees Fahrenheit.

Vertical Drive

Accomplish an operational test of the equipment listed at 100 percent engine load at normal operating pressure and temperature, using ref a for guidance. Conduct a post operational inspection of the equipment listed, in accordance with ref a, 4-3.10.

Blower

Accomplish an operational test and certification of the equipment listed at 100 percent engine load at normal operating pressure and temperature, using ref a for guidance. Allowable leakage, abnormal noise or vibration at normal operating pressure and temperature: None, Repair any leaks found.

Lube Oil Cooler

Accomplish an operational test of the equipment at 100 percent engine load at normal system pressure and temperature, using ref f for guidance. Allowable leakage: None, Repair any leaks found.

Jack water Cooler

Accomplish an operational test of the equipment at 100 percent engine load at normal system pressure and temperature, using ref f for guidance. Allowable leakage: None, Repair any leaks found.

Over-Speed Device

 

Accomplish a test of engine over-speed device after the loaded run in is completed, using ref a for guidance. Government MARMC code 264 Diesel Inspector shall witness Over-speed. Make adjustments as required.

Flexible Drive Gear Train

Accomplish a post 100 percent loaded run in inspection on the flexible drive gear train and a post run inspection of equipment listed using ref a for guidance. Government MARMC code 264 Diesel Inspector shall witness inspection.

Timing Chain

Accomplish a post 100 percent loaded run in on equipment listed, and a post run inspection to verify tension on the timing chain, using ref a for guidance. Government MARMC code 264 Diesel Inspector shall witness inspection. Adjust as required to attain proper tension.

Piston and Liner Assemblies

Fill and flush out jacket water system with distilled water provided by ships force to ensure there is no debris prior to engine start. 

Accomplish the alignment of engine block and generator using ref h as guidance. Couple and torque engine to generator coupling using ref h as guidance. Government MARMC code 264 Diesel Inspector shall witness alignment and coupling torque.

Develop and submit one legible copy of a Process Control Procedure (PCP), in approved transferrable media, to the SUPERVISOR for approval the requirements of for the accomplishment of ref C for a Hot Lube Oil Flush. All check points shall be witnessed by government MARMC code 264 Diesel Inspector. Maintain and submit completed copies of enclosures 1 through 7 of ref C upon completion of hot lube oil flush.

Develop and submit one legible copy of a PCP, in approved transferrable media, to the SUPERVISOR for approval the requirements of the bearing run in, load testing for breaking in cylinders and post inspection of NR 2 SSDG in accordance with ref d, paragraph 6-2.2.1, steps A through H and table 6-1b. All inspections shall be witnessed by government MARMC code 264 Diesel Inspector.

Provide a load bank for load testing NR 2 SSDG at 100 percent load.

Make a temporary access cut for the routing of the load bank cables. Submit one legible drawing or sketch of a temporary access cut to the ship structure for the load bank testing cables to the SUPERVISOR 3 days prior to making the cuts or removing the bolted/riveted access. Include a copy of the weld procedure or approved weld procedure number with the proposed access sketch. Prior to cutting access in the ship/vessel's structure and after layout checkpoint, accomplish positive verification by drilling a pilot hole in the path of the cut to be accomplished.

Accomplish welding on temporary access cut in accordance with MIL-STD-1689, Fabrication, Welding, and Inspection of Ships Structure, paragraph 13, joint design shall be in accordance with MIL-STD-22, Welded Joint Design, workmanship requirements MIL-STD-1689, paragraphs 12 and 14, and final weld inspection shall be in accordance with MIL-STD-1689, paragraphs 6, 7, and 8 / MIL-STD-2035, paragraph 4 / T9074-AS-GIB-010/271, paragraph 8.

Accomplish a completion air test of welds on temporary access. Air hose nozzle shall be placed at less than 3 inches, but greater than zero inches, from the area to be tested and pressure directed at the structure under test in a manner most likely to disclose leaks. The minimum nozzle diameter shall be 3/8 inch and the nozzle pressure shall be 90 plus or minus 5 PSIG as monitored at the nozzle. Apply a soapy solution to the opposite side of the structure, associated tank piping, overflow and air escape piping, and inspect for leaks. Government shall witness air test.

Restore System

Reconnect piping to each component. Piping shall be supported independently and not be pulled or forced into place in such a manner as to impose a strain on connected piping, machinery, equipment and bolting material. Install new piping joint gaskets and fasteners. New materials shall conform to requirements of MIL-STD-777. Allowable leakage: None.

Restore the systems to operational status and accomplish an operational test of # 2 SSDG to include testing of components repaired under this SOW, using component tech manual, TME guidance, ship's procedures to prove proper operation and tightness of new and disturbed joints. Allowable external leakage: None

References:

a:  S9311-EK-MMA-010 Rev 3, 1600 KW/900 RPM Diesel Engine Generator Set, LSD 41 Class Ships SSDG Midlife Model Number 38ND8-1/8

b:  S9311-DM-HBK-010 Rev 1, US Navy Diesel Engines Fairbanks Morse, 38D 8 1/8 Opposed Piston LSD 41/49 Class Ships

c:  S9233-DM-HBK-010-002, Flush LSD-41/49 Class Fairbanks Morse 38ND 8-1/8 Diesel Generator Engine Lubricating Oil System and Engine

d: S9312-AH-MMA-020 Rev 7, Generator Set Emergency Diesel Submarine

e:  MIL-STD-777, Schedule of Piping, Valves, Fittings, and Associated Piping Components for Naval Surface Ships

f:  S9311-BT-MMC-010, Operation and Maintenance for Heat Exchanger (Alfa Laval), "A", "M", "P" and "V" Series Units

g: S9311-B9-TRS-020 Rev 1, FFG-7 Class Series 149 Diesel Engines

h: 301-8328931 Rev B, 1600 KW Gen-Set Alignment, Drawing

Awarded contract N5005420P0277 to unknown vendor for unknown amount on 2020-09-04.