EPF class HEF Pump Overhaul_DTC.docx

ABSTRACT

The purpose of this item is to inspect and overhaul of the Edwards Pentair Model 80-440 HEF pumps.

REFERENCES/ENCLOSURES

References

1.1.1 Tech Manual S9555-FE-MMC-01-03, High Expansion Foam (HEF) Fire Fighting Components Model 630

1.1.2 MSC.1/Circ. 1432, 31 May 2012, Revised Guidelines for the Maintenance and Inspection of Fire Protection Systems and Appliances (Available Commercially)

1.2 Enclosures

1.2.1 Edwards Pentair gear pump repair parts index found in reference 2.1.1

2.0 ITEM LOCATION/DESCRIPTION

2.1 Location/Quantity

2.1.1 Location: Contractors Facility

2.1.2 Quantity

8: Edwards Model 80-440 Rotary Gear Pump, 65 (+/- 5) gpm at 175 psi

1. Newport: S/N 17-2522046

2. Trenton: S/N 10-1916792-3

3. Carson City: S/N 13-2318525

4. Point Loma: S/N 22-2625995

5. Point Loma: S/N 22-2626001

6. Apalachicola: S/N 18-2526896

7. Apalachicola: S/N 18-2526895

8. Apalachicola: S/N 23-2633851-1

2.2 Item Description

2.2.1 HEF firefighting pump, Original Equipment Manufacturer (OEM) Edwards Pentair.

3.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE

3.1 Government Furnished Equipment (GFE):

3.1.1 Eight (8) Edwards Pentair 80-440 High Expansion Foam Pumps.

3.2 Government Furnished Material (GFM)

3.3 Government Furnished Service (GFS): None

3.4 Government Furnished Information (GFI): None

4.0 NOTES

4.1 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, 24, 28, and 29.

4.2 Performance Period:

4.3 Technical Point of Contact (TPOC):

Melissa Gooch

(757) 917-0579 Melissa.a.gooch2.civ@us.navy.mil

5.0 QUALITY ASSURANCE REQUIREMENTS:

5.1 All material shall be certified by OEM Rep.

5.2 Care should be given to not damage any components through the execution of work stated in paragraph 7.0.

5.3 Any Request for Deviations (RFD) to accomplish paragraph 7.0 shall be submitted to TPOC in writing via CFR to be evaluated for approval.

6.0 STATEMENT OF WORK REQUIRED

6.1 Contractor shall provide all tools, labor, materials, and service to conduct OEM Factory Refurbishment of Edward Pentair HEF Pumps captured in paragraph 3.0. This shall include disassembling, cleaning, inspecting, overhauling, re-assemble, balance and testing the ship’s HEF pumps identified in paragraph 3.0 using References 2.1.1 - 2.1.2 and Enclosure 2.1.1 for guidance.

6.2 Accomplish disassembly, clean, inspect, overhaul, assemble, balance, and test in accordance with USCG, IMO, SOLAS, and the Manufacturer’s requirements.

6.3 For guidance disassembly procedure includes the following:

6.3.1 Remove four machine screws, four nuts, timing gear cover and cover gasket. Discard gasket.

6.3.2 Remove idler timing gear locknut

6.3.3 Fabricate timing gear puller plate.

6.3.4 Install timing gear puller plate with two 5/16 NC x 1-3/4-in. Grade 8 cap screws on idler timing gear. Using jaw-type puller, pull on the gear puller plate to remove idler timing gear. Repeat procedure for drive timing gear

6.3.5 Remove Woodruff key from drive shaft.

6.3.6 Remove four machine screws, four nuts, front cover, and cover gasket. Discard gasket.

6.3.7 Remove front cover seal from front cover. Discard seal.

6.3.8 Remove four setscrews from two endcases.

6.3.9 Remove four bearing adjusting nuts from each endcases.

6.3.10 Remove 8 caps screws, 2 nuts, and ten washers from timing gear endcase.

6.3.11 Using jaw-like puller, remove timing gear endcase and pump body gasket. Discard gasket.

6.3.12 Remove 8 cap screw, 2 nuts, and 10 washers from timing gear endcase.

6.3.13 Using jaw-type puller, remove drive endcase and pump body gasket. Discard gasket.

6.3.14 Using hammer and hardwood block, tap pump drive shaft to remove idler and drive rotor assemblies and two liners.

6.3.15 Using hammer and hardwood block, remove other two liners from pump body.

6.3.16 Remove four studs from pump body.

6.3.17 Using hammer and brass drift, remove four ball bearings and four grease seals from two endcases.

6.3.18 Using hammer and brass drift, remove four lip seals from two endcases.

6.3.19 Remove two grease fittings from two endcases.

6.3.20 Remove grease fittings from timing gear cover.

6.4 Cleaning:

6.4.1 Use dry cleaning solvent to clean parts. Do not use gasoline for cleaning parts.

6.4.2 After soaking parts in dry cleaning solvent, deposits may be washed away by flushing or spraying. Where necessary, use soft-bristled, non-metallic brush moistened in solvent.

6.4.3 Except for bearings, dry parts using filtered, compressed air after cleaning.

6.4.4 Unless otherwise noted, do not use metal scrapers, wire brushes, abrasive wheels, or compounds when cleaning parts.

6.4.5 Place ball or roller bearings in basket and suspend in container of dry cleaning solvent overnight. If necessary, use soft bristled brush to remove caked grease and chips. Avoid rotating bearing before solid particles are removed to prevent damaging balls and races. After cleaning, dry bearings with low pressure compressed air.

6.4.6 Check all passages and cavities for cleanliness and freedom from foreign material. Use wire brush or pressurized spray gun and dry cleaning solvent to clean individual passages.

6.4.7 Buff bearing adjusting nut threads with a wire brush.

6.5 Inspection:

6.5.1 Check the rotor assemblies and liners are free of radical scoring and heat damage. Usually indicated by blue discoloration.

6.5.2 Check all surfaces in contact with gaskets, packings, seals for nicks, burrs, or scratches that may damage new parts during assembly.

6.5.3 Visually check castings or weldments for cracks.

6.5.4 Check bearings for rusted or pitted balls, races, or cage. Check balls and races for brinelling, abrasions, and discoloration. Excluding defects that may cause bearing binding or misalignment, nicks or gouges outside race load areas are not cause for rejection. Bearings shall be rejected for cuts or grooves parallel to ball or roller rotation, or for fatigue pits.

6.5.5 Check all screw, nuts, fittings, and tapped holes for distortion and for stripped or corroded threads.

6.5.6 Submit a condition found report to the MSCREP with all discrepancies once inspection has been completed.

6.6 Repair and Replacement:

6.6.1 Using fine file or 220 grit emery cloth, remove nicks, burrs, or scratches from surface in contact with gaskets, packings, or seals.

6.6.2 Using 220 grit emery cloth, remove any buildup on endcase counterbore surfaces and inside diameter of pump bod.

6.6.3 Using 220 grit emery cloth or flat file, deburr all edges of pump parts, especially the end covers and endcases.

6.6.4 Repair of cracked castings and weldments is not authorized. Replace all cracked or damaged parts with OEM parts.

6.6.5 Replace all damaged screws, nuts, and fittings. Repair minor damage to tapped holes with same size tap. Do not change size or thread type. Replace all self-locking fasteners.

NOTE: Take special care to keep gasket surfaces flat and smoothly finished to prevent leakage.

6.7 Assembly General Practice:

6.7.1 Provide and replace all bearings, seals, o-rings, and gaskets with new. All components shall be the same as existing.

6.7.2 Remove any protective coatings from new parts.

6.7.3 Lubricate bearings with same type of lubricant normally used in pump or as directed in specific repair procedure.

6.7.4 Lubricate lip of oil seals with lubricant specified in procedure. Install oil seals, with lip facing out, by applying an even force to outer edge of seal. Recommend using an arbor press to seat seals.

6.7.5 Coat both sides of gaskets with high-tack spray. Be sure all old gaskets and sealants are removed from parts before installing new ones.

6.7.6 Hand-thread cap screws into parts until snug, then tighten in crisscross pattern to final torque. Install all cap screws, nuts, and fasteners using anti-seize compound unless otherwise indicated in specific procedure.

6.8 Assembly Procedure for Rotors and liners:

6.8.1 Install four studs in pump body using red Loctite. Remove all traces of red Loctite after installing studs.

6.8.2 Install two liners in pump body. Make sure liner suction hole faces pump body suction port.

NOTE: Do not rotate rotor assemblies until bearings have been installed and adjusted. Damage to rotors and liners may occur.

6.8.3 Install idler rotor assembly in pump body and into liner. Make sure threaded end of rotor shaft is away from drive end of pump.

6.8.4 Install drive rotor assembly in pump body and into liner. Make sure drive rotor shaft is in correct position and short end of rotor shaft is away from drive end of pump.

6.8.5 Install second set of liners in pump body. Make sure suction holes face pump body suction port.

6.9 Assembly Procedure Install Seals:

6.9.1 Lightly coat ores and outside diameter of four seals with red Loctite.

NOTE: Do not use excessive force when installing seals. This could damage the seals, causing them to leak. Use approved tools only.

6.9.2 Install four lip seals in bores of two endcases. Press seals all the way to the bottom of the bore. Recommend using an arbor press to seat the seals.

6.9.3 Pre-lubricate four grease seals in the two endcases with sealing lip facing towards counterbore in endcase.

NOTE: Lip seals have two lips on one side and one lip on the other side. The side with two lips must face toward pump body.

6.10 Assembly Procedure Install Endcase:

6.10.1 Install new pump body gasket to each side of the body.

6.10.2 Install large flat washer and nut on one of the studs on timing-gear end of pump body. The outside diameter of the washer must overlap the liners to prevent the liners and rotors from being displaced during installation of the drive endcase. Make sure liners are protruding at least 0.2 in. from the body before running the nut and washer up against liners.

6.10.3 Check that seals have been installed in endcases before proceeding with endcase installation.

NOTE: Make sure liners fit into counterbore on endcase, and that the can be fully seated into the endcase counterbore without using excessive force. Damage to endcases and liners could occur.

6.10.4 Starting with the drive end, carefully install endcase over idler and drive motor assemblies. Use caution not to damage seals.

6.10.5 Install eight cap screws, ten washers, and two nuts and tighten finger-tight.

6.10.6 Remove large washer and nut from timing-gear end of pump body.

6.10.7 Carefully install other endcase over idler and drive rotor assemblies. Use caution not to damage seals.

6.10.8 Install eight cap screws, ten washers, and two nuts and tighten finger-tight.

6.11 Assembly Procedure Install Bearings:

6.11.1 Pack four ball bearings with approved grease.

NOTE: Support ends of shaft axially with a jaw puller on the endcase when installing ball bearings to avoid damaging lines and rotors. The jaw puller should be used on the shaft end opposite the end where the bearing is being installed. Use a shaft protector to avoid damaging shaft center.

6.11.2 Using a bearing seating sleeve, install two ball bearings on both ends of idler and drive rotor assemblies. Make sure ball bearings are seated on shoulders of shafts with loading grooves facing center of pump.

6.11.3 Using crisscross patter, tighten 16 cap screws to 12 to 25 lbs-ft.

6.11.4 Using crisscross pattern, tighten four nuts to 8 to 10 lbs-ft.

6.12 Assembly Procedure Adjust Rotor Clearance

6.12.1 Install four bearing adjustment nuts on two endcases, leaving about 1/2-turn short of bearing contact.

6.12.2 On idler rotor assembly tighten one bearing adjusting nut until rotor contacts liner. Install dial indicator on opposite end of shaft and zero indicator.

6.12.3 Loosen previously tightened bearing adjusting nut. Tighten opposing bearing adjusting nut until rotor contacts the other liner and note reading. This is the total clearance.

6.12.4 Loosen adjusting nut tightened in step c and tighten opposing nut until dial indicator reading is half the total clearance reading obtained in step c.

6.12.5 Slowly tighten adjusting nut opposing adjusting nut tightened during step d until slight opposite dial indicator needle movement is observed. Do not overtighten.

NOTE: Do no overtighten bearing adjusting nut setscrews. Excessive bearing preload may result, causing bearing damage.

6.12.6 Tighten the set screws enough to secure the bearing adjusting nuts in endcase.

6.12.7 Repeat steps b through f for drive rotor assembly bearings.

6.13 Assembly Procedure Install Timing Gears

6.13.1 Using a lapping compound, lap taper idler timing gear to idler rotor shaft, then clean both surfaces with a clean rag and dry cleaning solvent.

NOTE: To avoid injury, always use suitable protective gear. The timing gear is hot!

6.13.2 Preheat drive timing gear to 450°F and install with Woodruff key on drive shaft. Position gear about 0.175 to 0.200 inch from face of endcase. Recommend using shims for accurate positioning.

6.13.3 Cool drive timing gear with compressed air. Do not quench gear with liquid.

6.13.4 After drive timing gear has cooled to ambient temperature, insert piece of 0.003 to 0.006 in. shim stock between rotors from the discharge port for lash adjustment. Shim should feed into pump between rotors when drive rotor is turned in normal direction of rotation.

6.13.5 Install idler timing gear on idler shaft. Remove all lash between timing gears in direction of rotation by turning idler timing gear until gear meshes fully with drive timing gear.

6.13.6 After all lash has been removed, hold idler timing in place while seating gear by lightly tapping it with a bearing seating sleeve.

6.13.7 Apply anti-seize compound to timing gear locknut threads and install locknut on idler shaft. Wedge a piece of nylon or rawhide between rotors to prevent rotation, and tighten locknut to 90 lbs-ft.

6.13.8 Remove shim stock and rotate drive rotor in direction of rotation. The drive rotor should rotate idler rotor freely with no contact between rotors.

6.14 Assembly Procedure Install End Covers:

6.14.1 Apply light coat of approved grease to rubber surface of new front cover seal.

6.14.2 Install front cover seal in front cover with seal lips pointed toward inside of cover. Recommend using an arbor press to seat the seal.

6.14.3 Apply light coat of approved grease to front cover gasket surface and install new gasket, front cover, four machine screws, and four nuts. Tighten machine screws to 12 to 15 lbs-ft.

6.14.4 Fill timing gear cover with about three ½-in. beads of approved grease around inside perimeter of cover.

6.14.5 Apply light coat of approved grease to timing gear cover sealing surface and install new gasket, timing gear cover, four machine screws, and four nuts. Tighten machine screws to 12 to 15 lbs-ft.

6.15 Assembly Procedure Lubricate Bearings:

6.15.1 If removed, install two grease fittings in each endcase and two grease fittings in timing gear cover.

6.15.2 Using grease gun, lubricate pump bearings with approved grease through endcase grease fittings. Usually five to six pumps is sufficient when bearings have been previously packed.

6.16 Pump Testing:

6.16.1 Perform hydrostatic pressure testing on all overhauled pumps in accordance with OEM Rep recommendations, reference 2.1.2, NSTM 503, and ABS Part 4. The minimum test pressure will be no less than 150% times the normal operating pressure. Testing shall be done in the presence of ABS in efforts to gain certification.

6.17 Upon completion of refurbishment, package each HEF pump individually for long-term storage and international shipment. Packaging shall have labeling identifying Requisition, Nomenclature of part (including rotation identified), Part Number. Serial numbers shall be listed and issued to the government for tracking purposes. Provide certification and inspection documents validating overhaul/refurbishment of all parts to the government.

6.18 HEF pumps shall be shipped back to the government facility upon completion. For proposal purposes, assume shipment shall be to MSC W143 Warehouse Facility located at MSC W143 Warehouse 1968 Gilbert Street DWY 10 Norfolk, VA 23511

6.19 Reports

6.19.1 When inspection, service and testing reveal any deficiency a condition report is to be submitted to the OMT REP with recommended repairs and parts required. Submit one electronic copy in Portable Document Format (PDF).

6.19.2 Upon completion of all inspections, refurbishment and tests, prepare and submit the results.. The report is to be typewritten documenting the examination of the system and final “as released” conditions. Submit one electronic copy in Portable Document Format (PDF) to TPOC.

6.19.3 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.

6.20 Painting/Lagging

6.20.1 Mechanically clean, prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces.

6.21 Manufacturer’s Representative

6.21.1 Provide the services of OEM authorized field service representatives to inspect and test the ship’s high expansion foam pump. Persons performing overhaul of pumps are to be certified and recognized as an authorized specialist by ABS.

6.21.2 Companies and persons performing overhaul of pumps are to have available the appropriate servicing manuals, correct tools, recharging materials, lubricants, and manufacturer’s replacement parts.

6.21.3 This work item requires maintenance and repair actions to be performed on an MSC ship critical safety item. Only original equipment manufacturer (OEM) authorized technical field service providers 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.

6.21.4 Known POC for OEM Support

Hiller Systems 1242 Executive Blvd Chesapeake, VA 23320 POC: Jason Woolard Office (757)549-9123 Email: jwoolard@hillercompanies.com Fire Lion Global 14707 NE 13th Court, Suite B100 Vancouver, WA 98685 POC: Aaron Johnson Office: (360) 574-9068 Email: aaron@firelionglobal.com

6.21.5 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.

Preparation of Drawings Provide electronic copies of all revised and/or updated technical documentation including drawings, technical manuals, service bulletins, parts lists, certification and test data associated with the work performed or parts supplied to the OMT REP.

GENERAL REQUIREMENTS: None additional

T-EPF CLASS HEF PUMP OVERHAUL

0XXX - 14

ENCLOSURE 2.2.1 EDWARDS GEAR PUMP REPAIR PARTS INDEX

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