Attachment_2_-_Spec-225WLB_Red_Gear_Flush.pdf

2411_JPH_0518_225B

WORK ITEM 1: Main Reduction Gear, Flush

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to clean and flush the reduction gear, to recover from foreign material contamination and restore the system to an operational state until comprehensive disassembly and bearing renewals can occur. Reduction gear is a Philadelphia Gear

Model # 96DHCMG-CP.

1.2 Government-furnished property.

None

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 225-WLB 243-001, Rev B; PROPULSION SHAFTING

ARRANGEMENT

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 3523-241-A&B, 225 WLB MIB, VOL 5, SWBS 241, GEAR, REDUCTION, MMC PN 241-01-01

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

OTHER REFERENCES

A-A-59323, Rev -; CLOTHS, CLEANING, LOW-LINT , 6/30/99

MIL-PRF-9000, Rev H; Lubricating Oil, Shipboard Internal Combustion Engine, High Output

Diesel, 9/16/87

Naval Ships' Technical Manual, Chapter 241, Propulsion Reduction Gears, Couplings, Clutches, and Associated Components

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of an OEM authorized/ licensed Tech Rep for the Philadelphia Gear Corporation to accomplish the following on site:

Provide manufacturer's proprietary system/ equipment information, software, and tools.

Assist with and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, cleaning, flushing, reassembly, operational testing, gear tooth contact checks and sea trials of the Cutter’s Reduction Gear.

3.1.2.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their résumé.

3.1.2.2 Submit the name and résumé of the Tech Rep to the COR at the Arrival Conference.

3.1.2.3 Submit a copy of the Tech Rep’s résumé and a list of references to the to the COR at the Arrival

Conference.

3.1.3 Protective measures. The Contractor shall furnish and install all protective coverings to seal off and protect all non-affected vessel's components, equipment, and spaces near the work area against contamination during the performance of work. Upon completion of work, the Contractor shall remove all installed protective measures, inspect for the presence of contamination, and return all contaminated equipment, components, and spaces to original condition of cleanliness.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec

0000, paragraph 3.3.5 (Interferences).

NOTE

Should the related Optional Item “Main Reduction Gear, Additional

Disassembly Efforts”, the same Tech rep will work both related Items. Only bid for the share of Tech Rep work in this item (Optional item share of work will be bid in that item).

3.1.5 Other general information.

3.1.5.1 The concerned work area is MMR, Main Reduction Gear 96DHCMG-CP Philadelphia Gear

Corporation. Refer to CG Tech Pub 3523-241 for arrangement and details.

3.1.5.2 At the end of each working day and during periods when the work on the reduction gears has ceased, the reduction gears and open piping shall be wrapped with plastic sheeting and taped closed to exclude dirt and moisture.

3.1.5.3 All disconnected lube oil piping and hoses shall be blanked or capped immediately after opening to prevent dirt or foreign particle intrusion.

3.1.5.4 All parts (including piping, hoses, fittings etc.) shall be thoroughly cleaned prior to reassembly of the reduction gear.

3.2 Reduction Gear security, production precautions, and contamination control.

3.2.1 The Contractor shall propose, implement, and employ effective physical security and contamination control measures concurrent with opening, inspecting, and repairing reduction gears.

3.2.2 Entry into the red gear and thrust bearing or the lubrication system shall be made only with the knowledge and approval of the cutter's Engineer Officer or his designated representative and only after written concurrence with contractor's procedures and methods used to exclude contamination.

3.2.3 Plug, cap, cover, or erect barriers as necessary to preclude dirt contamination and foreign object damage, as each part of the reduction gear and thrust bearing system is disconnected or otherwise disturbed to facilitate inspection. Coordinate and sequence work to prevent conflicting operations that may result in loose materials and tools being used over an open gear. Coordinate and sequence work to eliminate dust, debris, and dirt-generating processes like grinding, sanding, slag chipping, while any part of the gear box is open for inspection or repair.

3.2.4 Only workers with clean clothing and tools will be permitted to work around the reduction gear's open case. Worker's pockets must be empty, and all jewelry, watches, and loose personal effects shall be removed, to prevent items from inadvertently falling into the gear casing.

3.2.5 All tools shall be safeguarded from dropping into the open reduction gear case by securing with lanyards attached to a fixture or the worker.

3.2.6 No material, tools, parts, shall be placed or stored on any catwalks, staging, ledges or any other location above the level of the open reduction gear casing within a ten foot radius.

3.2.7 All lifting equipment; chain blocks, rope, nylon slings, wire rope slings, and any other equipment shall be washed clean prior to use to prevent dirt or paint chips from falling into the open reduction gear casing.

3.2.8 All disconnected lube oil piping shall be blanked immediately after opening to prevent dirt or foreign particle intrusion.

3.2.9 All parts shall be thoroughly cleaned prior to reassembly of the reduction gear.

3.2.10 Observe and implement all the precautions detailed in CG Tech Pub 3253, for opening and protecting parts, equipment, and personnel. Note in particular the following:

3.2.10.1 Avoid damage to all joint surfaces. Prevent the forming of burrs or ridges that will result in oil leakage. Protect joint flanges with clean canvas and wooden blanks or visyquene.

3.2.10.2 Mark or tag parts to aid in correct reassembly. Place these parts in clean containers for temporary storage. Match mark parts as necessary where indexed relationships between parts exist for proper fit or operation of the equipment.

3.2.10.3 Treat thermometers and sight flow indicators, when removed, with care and blank exposed pipe and flange ends to prevent contamination. Sections of oil supply and drain piping should be removed from the-immediate area to prevent damage, bending or other casualty which may hinder proper reassembly.

3.2.10.4 Protect all pipe openings with clean, canvas covered tapered wooden plugs, caps , or bolted blanks. Do not use rags or waste for this application.

3.2.10.5 Covers, end covers and other portions of the housing, when removed, must be placed and supported to fully protect the flange joints. Support heavy parts on wooden blocks or inverted, whichever is easier and allows the better protection in the available space. Pinions and gears, if removed should be supported on clean wooden blocks and must be covered with clean canvas.

3.2.10.6 Wire cables, hooks or shackles must not be used adjacent to gear and pinion teeth or journal surfaces. Shaft areas, adjacent to-journal surfaces which may be used for sling locations, should be protected with sheet lead of soft copper chafing gear.

3.2.10.7 Protect the exposed surfaces of all precision and running parts, particularly gear teeth, shaft journals, and sleeve bearing surfaces. Cover precision and running parts to prevent contamination and impact damage.

3.4 Reduction gear cleaning and hot oil flush

3.4.1 Remove following components for disassembly, inspection, hand cleaning, reporting, reassembly and testing:

Electric Pump

Gear Driven Pump

Cooler

Amot Valve

Relief valves

Duplex Filter Housing

Short hoses and piping

3.4.2 Jumper exterior piping and hoses together to perform hot oil flush (using AW46).

3.4.2.1 Flushing rig shall have flow rate up to 120 GPM and a relief valve that ensures maximum system pressure is not exceeded.

3.4.2.2 Install muslin bags in lubrication system per NSTM Chapter 241, section 3.2.2.3 (NSTM excerpt pasted below).

241-3.2.2.3 Large amounts of foreign particles may enter into and contaminate the lube oil whenever MRG casing covers or bearing caps are lifted for maintenance, inspection, or repair; and during extended system shutdowns. If contamination is present, install temporary muslin or nylon filter bags (NSTM Chapter 262 ) in the strainer baskets until those particles that would normally pass through the strainer are removed from the system and the bags are free from debris. Ships using filters may be able to replace the filters with temporary strainer baskets and muslin or nylon bags. When the bags are clean, remove the strainer and muslin bag assembly and reinstall the filters. Even though filters may provide a higher level of filtration, strainer bags are preferred for inspection for foreign material.

3.4.2.3 Flush until lint free muslin filter bag is clean and approved by Coast Guard and Technical

Representative.

3.4.2.4 Repeat the cycle until filters remain clean and Technical Representative concurs flushing is adequate.

3.4.2.5 Contractor may use an in-line particle counter or oil sampling method to monitor progress of flushing.

3.4.3 Ships force to manually rotate reduction gear during flushing

3.4.4 After flushing has been completed wash down the gear casing with hot oil.

3.4.5 Using contractor flushing unit and contractor stand by pump circulate hot oil through the gear box through the reduction gear inlets until suction gear strainers are clean and approved by the Coast Guard and Technical Representative.

3.4.6 Restore jumpered connections and restore the lube oil system.

3.4.7 Refill system with Contractor furnished oil.

NOTE

The final filling only will be from US Coast Guard supplied oil. All other oil, solvents, flushing medium shall be supplied by Contractor. Process any new oil added to the system through a non-bypass filter assembly prior to its introduction into the reduction gears. Filter assembly shall utilize new clean disposable filter elements with a minimum Beta 10 = 75 ratio rating. Do not exceed filter assembly and/or element flow ratings or pressure ratings (both maximum collapse as well as delta across) during filling.

3.4.8 Final Lube Oil Flush - Conduct the final lube oil flush in accordance with instructions given in

NSTM Chapter 262, Section 3.8.3.2 and the guidance given below.

NOTE

All jumpers will have been removed and all components restored to operation for this flush. Perform the final flush after cleaning of the lube oil cooler.

3.4.8.1 Operate system with electric driven pump for one hour. Ships force to manually rotate reduction gear during this operation.

3.4.8.2 During lube oil flushing, open gear case inspection covers and verify lube oil spray pattern on gear teeth. Verify spray pattern in the presence of the Technical Representative and the Coast Guard

Inspector.

3.4.8.3 If clean, drain system and dispose of oil in accordance with all applicable local, state, and federal laws and regulations.

3.4.9 Refill with new oil and operate system.

3.4 Post repair/post flush operational testing and gear tooth contact check.

3.4.1 Remove gear inspection covers and clean the gear teeth.

3.4.2 Apply prussian blue dye to the gear teeth in accordance with NSTM 241 at locations approved by the Coast Guard Inspector and the Technical Representative. At a minimum, apply dye to each of the high speed gears and the low speed pinions.

3.4.3 Jack over the reduction gear. Open the inspection covers and verify proper gear tooth contact.

Verify Gear tooth contact in the presence of the Technical Representative and the Coast Guard Inspector.

3.4.4 Reinstall gear inspection covers.

3.4.5 Move the shaft fore and aft 3 times, measuring the movement of the gears with a dial indicator or other suitable device. Submit a CFR with nominal axial play and the existing axial play.

3.4.6 The Contractor shall attend while the Coast Guard Inspector operates the lube oil system and turns the reduction gear with the Main Diesel Engine during a dockside test.

3.4.7 Run the unit for ½ hour in normal direction of rotation with no load. Observe and record load and percentage of tooth contact.

3.4.8 Run the unit for one hour in normal direction of rotation with 30% rated load (or load recommended by the Technical Representative). Observe and record load and percentage of tooth contact.

3.4.8.1 A good contact under 30% load will be centered along the pitchline covering the entire uncrowned length of the gear tooth (50-60% of total gear face width) and spread up at least 50% of the profile. The 30% load contact pattern should be equal to or greater than the no load contact pattern check.

3.5 Sea trial.

3.5.1 After successful dock trials, the Cutter will get underway for sea trials. The Cutter will be operated up to full power both ahead and astern with the MDE and MGT. Full power trial shall be a minimum of two hours after the propulsion system is in a stable condition.

3.5.2 Submit a condition found report at the end of seal trials. The CFR, (including photos and sketches) of the conditions found and any recommended repairs shall be delivered to the CG Inspector in accordance with the General Requirements. Any repairs necessary to restore the operational integrity of the reduction gears may be negotiated as a contract change.

3.5.3 Conduct a sea trial to verify reduction gear operations. The Contractor Representatives and

Technical Representative must attend entire sea trial. For estimating purposes, the sea trial will take approximately 1 day at sea.

3.5.4 During sea trials, ship's force will monitor bearing temperature and oil flow to the reduction gears.

3.5.5 During the sea trial the Technical Representative will inspect the gear tooth contact after trials at

50% power and again after trials at 100% power.

3.5.6 After returning from sea trial, in the presence of the Technical Representative and the Coast Guard

Inspector, open the gear case inspection covers and check the gear tooth contact patterns. Note any indications of unusual contact or wear. Submit a CFR with the inspection results.

3.5.6.1 After completion of final inspections, provide and install new flange spray shields at all lube oil connections that were disturbed during this work.

3.7 Technical Representative continuing inspection by crew guidance and instruction.

3.7.1 As stated earlier the Coast Guard, intends on operating the Cutter (reduction gear) in a normal continuous manner until a thorough overhaul can occur with long lead time parts in hand. Subsequently, the Coast Guard requires specific inspections and guidance from Technical representative regarding the prudent steps to take to monitor and prevent catastrophic failure or cascading severe damage.

3.7.2 Technical Representative shall both in on-scene training of crew and in final written report, advise/train/instruct on the “what, where, how” details to monitor the safe operation of the reduction gear.

3.8 Upon completion of all inspections and tests, take an oil sample and sent it out for analyses and submit a CFR with results.

4. NOTES

This section is not applicable to this work item.