P45340_Spar_SOW.doc

2411_JPH_1019_225B

WORK ITEM 1: Main Reduction Gear, Repairs

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform repairs and flush of Reduction Gear. Damage has been discovered in the vicinity of the turning gear and generator pinion. Repairs shall be made and the entire reduction gear drained, cleaned, flushed, and restored so that the system is fully operational upon the completion of this specification. Reduction gear is a Philadelphia Gear Model # 96DHCMG-CP.

1.2 Government-furnished property.

($/UNIT)

9,949

*Government-loaned property, which shall 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.

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, repair, modification, calibration, and reassembly of the equipment/system.

3.1.2.1 When required, 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).

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.

3.1.5.5 Conduct all hotwork in accordance with SFLC Std Spec 0740.

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.

3.3 Reduction gear repairs, renewals, and inspections.(All part numbers in paragraph 3.6 refer to drawing 01070-0353 of TAB 241-B, CG Tech Pub 3523) .

3.3.1 The Contractor shall remove all interferences in way of the reduction gear's disassembly, repair and reassembly activity and shall restore all affected equipment to the normal operating condition upon completion of the reduction gear repair.

3.3.2 Repair the damaged forward bearing bore.

3.3.2.1 The bearings supporting the Turning Gear/Generator Pinion have failed. The forward bearing’s failure is known to also have damaged the bearing housing bore. In line machining is required to carefully open up the bore so that a sleeve can be installed.

3.3.2.1.1 Contractor shall in accordance with OEM Tech Rep’s detailed guidance in place machine the damaged bore to an oversized dimension and fabricate a sleeve to bring the bore size back to specifications. Bore dimensions, sleeve sizing and material shall be to tolerances and specifications provided by the OEM Tech Rep. Submit a CFR with OEM Tech Reps procedures, dimensions, surface finishes, material specifications, required QA, and any other pertinent details for USCG’s records.

3.3.2.1.2 While Turning Gear/Generator Pinion is out to facilitate bore repairs and bearing renewals inspect the bearing journals for any damage from possible inner bearing race spinning. Submit a CFR with any negative findings and recommended repair actions.

3.3.2.1.2 Measure and inspect the aft support bearing’s bore to ensure it too has not suffered damage or otherwise out of tolerance. Submit a CFR if repairs are recommended.

3.3.2.1.3 Reinstall the Turning Gear/Generator Pinion into the reduction with new GFE Bearings (Bearing Part numbers are 31000-1795 cone fwd, 31000-1796 cup fwd. 31000-2224 cone aft, 31000-2223 cup aft).

3.3.2.1.4 Under Tech Rep’s guidance and instructions perform any final adjustments and/or shimming, tooth contacts, etc. to ensure Turning Gear/Generator Pinion’s position is optimal.

3.3.3 Renew turning gear mounting adapter.

3.3.3.1 Remove turning gear (in coordination with other work) from being mounted to reduction gear to allow renewal of turning gear adapter. A new GFP adapter (Tech Pub 3523’s DWG 01070-0353 Item 308, P/N 35000-0202). Renew turning gear adapter with Tech Rep’s guidance.

3.3.3.2 Under Tech Rep’s guidance reinstall the Turning Gear into the reduction.

3.3.3.3 Under Tech Rep’s guidance and instructions perform any final adjustments and/or shimming, tooth contact checks, etc. to ensure Turning Gear’s position is optimal.

3.3.4 Replace filter assembly with upgraded GFP assembly.

3.3.4.1 USCG has partnered with a filter company to manufacturer to provide a direct bolt in replacement filter assembly. New filters are designed with improved filtering capabilities, sample port, and gauges.

3.3.4.2 Remove existing filters and install direct replacement GFP filter assembly.

3.3.4.3 During subsequent flushing and operational testing inspect for and fix any joint leaks.

3.3.5 Seal Renewals.

3.3.5.1 Seals have been recently renewed. Renew any damaged, disturbed, or suspect seals (that may hold or contain debris). For purpose of bid all reduction gear seals can be assumed to require renewal. Renewal may involve additional disassembly (beyond bearing renewals). The exact details for performance are not being offered, because this is a performance specification whereby the Technical Representative and Technical documentation together exist to perform the work scope.

3.3.5.2 Technical Representative shall determine the timing of these seal renewals in regards to other scheduled work.

3.3.5.3 Seals shall not be cut and glued and/or vulcanized without USCG concurrence. Split seal options (vs. intact one piece seals) shall also not be installed without USCG concurrence. Submit such request in a CFR with justification. It is acknowledged that split seals may reduce disassembly efforts, regardless of that Contractor’s bid shall be for one-piece seals and the associated effort required to install.

3.3.5.4 The following Table lists the contingency seals offered as GFE. Identify in CFR any missing seals or gaskets from the Table, so they may be added to Table for future versions of this specification.

NOTE

For purpose of bid Contractor shall assume only the two oil seals, listed in line Item 19 below are known to be mandatory renewal. Additional seals beyond those may be subject to a contract change.

TABLE 1 – LIST OF GFE SEALS

3.4 Reduction gear flushing

3.4.1 The sump will be in a drained condition at start of work.

3.4.2 Flushing Oil Rinse and circulation.

3.4.2.1 The case and internals should be thoroughly rinsed with flushing oil (approved by tech rep/manufacturer ) under pressure through the upper pinion area and the 4 inspection ports.

3.4.2.2 Disconnect all piping where it enters the casing (smaller flexible lines etc.) and run the flushing oil through the lines until they are clean.

3.4.2.2 Assume 150 gallons of flushing fluid will be required.

3.4.2.3 At conclusion of the rinse reduction gear shall be closed up.

3.4.2.4 Circulation of flushing fluid with attached pumps shall also occur under Tech Rep’s instructions including use of a pipe vibrator.

3.4.2.5 Check all spray nozzles for flow during and after completion of flushing.

3.4.2.6 Heat flushing oil to 140 deg F.

3.4.2.7 At conclusion of flushing fluid’s use it shall be drained and disposed of in accordance with all applicable local, state, and federal laws, and regulations.

3.4.2.8 Manually hand clean sump and head tank with lint free rags to remove contamination and residue.

3.5 Reduction gear refilling and final system flush (using installed pumps).

3.5.1 Renew with Government provided the reduction gears lube oil (130 gallons). Oil is MIL-PRF-17331, Symbol MS 2190 TEP.

3.5.1.1 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.

3.5.1.2 Non-bypass filter assemblies utilizing MIL-F-24702/1-B10-75 filter elements have been found to meet the above requirements. They are designed for low pressure applications and are inexpensive, have a rated flow of 30 GPM per element, and are commonly available. NSN is 4330-00-229-4147 for these elements.

NOTE

Schroeder Industries and Parker Hannifin Corporation are known manufacturer’s of MIL-F-24702/1-B10-75 filter elements as identified in the qualified products list (QPL).

3.5.2 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.

3.5.3 Remove the tags from the electrical L/O pump, energize it and use it to flush the red gear system until muslin bags remain clean (no less than 30 minutes).

3.5.4 After using muslin bags, install normal clean system filters and run L/O pump for 1 hour (or longer depending on Technical Representative’s guidance). At conclusion of run, remove inspect and clean filters in accordance with procedure 4.4.4 titled, “ Clean Oil Filter on Reduction Gears” of CG Tech Pub 3523-241.

3.5.5 Clean the oil filter, in accordance with procedure 4.4.4 titled, “ Clean Oil Filter on Reduction Gears” of CG Tech Pub 3523-241

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

3.5.7 Check all spray nozzles for flow during and after completion of flushing.

3.5.8 Use a pipe vibrator on lube oil piping as directed by Tech Rep during the flush to further promote dislodging of all potential debris.

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

3.6.1 Remove gear inspection covers and clean the gear teeth.

3.6.2 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.

3.6.3 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.

3.6.4 Inspect for and clean up any minor tooth scoring.

3.6.5 Reinstall gear inspection covers.

3.6.6 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.

3.6.7 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.

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

3.6.9 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.

3.6.9.1 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.

3.7 Sea trial.

3.7.1 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 MDEs. Full power trial shall be a minimum of two hours after the propulsion system is in a stable condition.

3.7.2 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.

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

3.7.4 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.

3.7.5 During the sea trial the Technical Representative will assist the ship’s force take and record thrust bearing clearances (the underway method).

3.7.6 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.

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

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

4. NOTES

This section is not applicable to this work item.