Scope_of_Work.doc

56201_JAH_12/16/2016_420

WORK ITEM 1: Steering System and Hydraulic Power Assembly, Inspection and Service

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to inspect the steering gear and clean the hydraulic power assembly for the port and starboard steering actuators. The Contractor shall also install QTY (4) Freydenbo control valves and renew the couplings on the 1A, 1B, and 2A pumps.

1.2 Government-furnished property.

($/UNIT)

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing 420-WAGB 561-501, Rev A, General Arrangement Steering Gear Parts List

Coast Guard Drawing 420-WAGB 561-502, Rev A, General Arrangement Steering Gear

Coast Guard Drawing 420-WAGB 561-503, Rev C, HPU Reservoir Assembly Parts List

Coast Guard Drawing 420-WAGB 561-504, Rev E, Rudder Actuator Assy

Coast Guard Drawing 420-WAGB 561-505, Rev E, Rudder Actuator Assy Parts List

Coast Guard Drawing 420-WAGB 561-507, Rev A, Head Tank Assembly Parts List

Coast Guard Drawing 420-WAGB 561-508, Rev B, Head Tank Assembly

Coast Guard Drawing 420-WAGB 561-509, Rev B, Hydraulic Schematic

Coast Guard Drawing 420-WAGB 561-510, Rev A, Control Valve Assembly Pump Unit Pe 2 1/2" & 3"

Coast Guard Publications

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

Surface Forces Logistics Center Standard Specification 3041 (SFLC Std Spec 3041), 2014, Shipboard Electrical Cable Test

Surface Forces Logistics Center Standard Specification 3042 (SFLC Std Spec 3042), 2014, Shipboard Electrical Cable Removal, Relocation, Splice, Repair, And Installation

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

Coast Guard Technical Publication (TP) 5217, 01-NOV-03, S9561-D4-MMC-010 - Steering Gear, Electro-Hydraulic

Other References

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.1 (SSPC-SP 1), 2004, Solvent Cleaning

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 3), 2004, Power Tool Cleaning

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Tech Rep. The Contractor shall provide the services of qualified Tech Rep, who is familiar with the steering actuators, to accomplish the following tasks – on site:

· Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system.

· Assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system.

· Perform all actual repair work on the actuator.

3.1.2.1 The Contractor shall ensure that the Tech Rep is a certified representative of CS Controls.

3.1.2.2 The Contractor shall submit the name of the Tech Rep to the COR at the Arrival Conference.

3.1.3 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, 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 Receipt of Government Furnished Material (GFM). Receive the GFM listed above. Open and inventory all parts in the presence of the Coast Guard Inspector. Submit a CFR. Note any missing parts.

3.2 Background Information.

The work in this specification item is to perform an annual inspection of the steering gear, install new control valve assemblies and hydraulic pump grommets. Additional work to accomplish with the annual inspection is also specified in the paragraphs below.

3.3 Steering Actuator Inspections. The contractor shall assist the OEM Tech rep in performing the inspections listed below:

3.3.1 Conduct the monthly, annual, and bi-annual surveys of both the port and starboard steering actuators listed in Section 3.2 of the Tech Pub. These tests include:

Monthly checks:

· Test the steering modes from all steering stations for both the normal and emergency conditions.

· Visually check the pump units and filter assemblies.

· Check the oil level in the oil reservoir.

Annual Survey:

· Visually check all components in the control and machinery subsystem.

· Test operate the switches and contactors associated with the system. Megger the hydraulic pump electric motors on each of the hydraulic steering pumps.

· Locally start the pump units directly from each motor controller.

· Identify defective components to be replaced.

· Manually operate the pump solenoids to obtain rudder travel.

Bi-Annual Survey:

· Visually check the couplings and seals on the hydraulic pump shafts.

· Test the setting of the relief valves.

· Test the rotor vane seals for leakage.

· Readjust the relief valves to original setting pressure upon completion of seal leakage rate testing.

3.3.2 Record the leakage rate of the port steering actuator unit and the starboard steering actuator unit for further comparison.

3.3.3 Time the swing rates on each of the rudders. Swing the rudder from hard over to 5 degrees before hard over and measure the amount of time each rudder stock takes to complete the rudder swing.

3.3.3.1 Cycle the rudders from 35 degrees left rudder to 30 degrees right rudder. Measure and record the amount of time it takes the rudders to complete the cycle.

3.3.3.2 Cycle the rudders from 35 degrees right rudder to 30 degrees left rudder. Measure and record the amount of time it takes the rudders to complete the cycle.

3.3.4 Visually inspect the port and starboard steering units during testing. Note any evidence of excessive leakage from valves or pumps. Note any evidence of operation that doesn’t appear smooth or appears unusual.

3.3.5 Steering Actuator Inspection Results. Submit a CIR documenting the results of the steering inspections listed above. Ensure that the report contains the rudder seal leakage rate and the swing time on each rudder stock. This information will be used in evaluating the steering actuators for additional repairs if required.

3.4 Hydraulic power units. Each steering actuator assembly is served by a separate hydraulic power unit assembly. Each hydraulic power unit assembly consists of two (2) separate hydraulic power units mounted to a common base. Each hydraulic power unit has a separate 625 gallon hydraulic fluid tank, for a total of 1250 gallons of hydraulic fluid in each of the two (2) hydraulic power unit assemblies serving the port and starboard steering actuators.

NOTE

Testing shows that the hydraulic fluid is not satisfactory for re-use.

3.4.1 Drain all hydraulic oil from each of Hydraulic Fluid Tanks and Hydraulic Power Assembly and dispose of the oil in accordance with Federal and local regulations.

3.4.1.1 Hydraulic fluid renewal. After work completion, verify that the tanks are clean and free from moisture and contamination prior to filling the tanks with new hydraulic oil.

3.4.2 Open access covers on each hydraulic fluid tank on each hydraulic power pack assembly. Clean and wipe down the interior of each tank with lint free cloths.

3.4.3 Remove, clean, and inspect the suction strainer assembly on each hydraulic oil tank.

3.4.4 Inspect the interior of each tank for cleanliness.

3.4.5 Reinstall the suction strainer assembly in each tank.

3.4.6 Close up the hydraulic tanks upon completion of other work. Provide and install new gaskets on each tank inspection cover.

3.4.7 Install new return filter assemblies on each hydraulic power pack assembly.

3.4.7.1 Using the filters listed below, renew each of the return filter elements on the hydraulic power pack assemblies.

TABLE 3.4.7.1 Hydraulic Filters

3.4.8 Upon completion of other work return the hydraulic fluid to the Steering system. Use a filter rig assembly with a 30 micron filter to return the hydraulic fluid to the tank.

3.5 Additional work. The contractor shall perform the additional work listed below during the course of the steering system groom:

3.5.1 Steering pump motor coupling renewals: The Contractor shall perform the following work:

3.5.1.1 Electrically and mechanically disconnect the No. 1A, No. 1 B, and No. 2A steering gear electric motors from the hydraulic power units. Disconnect the motors and set them aside.

3.5.1.2 Install new pump to motor couplings on each of the three electric pump/motor combinations.

3.5.1.3 Reinstall and reconnect each of the electric motors.

3.5.1.4 Verify that the pumps and motors rotate in the correct direction during acceptance testing.

3.5.2 Control valve renewals. The Contractor shall perform the following work:

3.5.2.1 Disconnect each of the four (4) hydraulic control valves on the hydraulic power units. There are two (2) control valves for each hydraulic power unit.

3.5.2.2 Install the new GFM control valves. Provide and install new gaskets and fasteners at each location.

3.5.2.3 Box up the old control valves and turn them over to the Coast Guard Inspector for disposition.

3.5.3 Adjust relief and safety valve settings. The Contractor shall perform the following work:

3.5.3.1 Following guidance in Section 5-2.1 of the technical manual, adjust and set each of the HPU relief valves to lift at 675 psig.

3.5.3.2 Following guidance in Section 5-2.3 of the technical manual, set the overhauling relief valves on each hydraulic actuator to 1875 psig.

3.5.3.3 Using a contractor furnished hydrostatic test pump assembly, follow guidance in Section 5-2.2 of the technical manual to set the rudder actuator safety valves on each rudder actuator assembly. Set the rudder actuator safety valves at 1860 psig.

3.5.3.4 Fabricate and install new metal label plates on each relief valve which was tested. Engrave the set pressure, test date, and test facility who performed the testing on each label plate.

3.6 Acceptance Testing.

3.6.1 Rudder Actuator Performance Check. Following guidance in para 4-2.3 of the technical manual, test operate each rudder actuator to determine if the actuator is leaking internally.

3.6.2 Rudder Testing. Conduct the following tests of the rudder and steering system.

3.6.2.1 Verify that the rudders swing from hard over to hard over with no indications of chattering or binding and appear smooth during operation.

3.6.2.1.1 Cycle the rudders from 35 degrees left rudder to 30 degrees right rudder. Measure and record the amount of time it takes the rudders to complete the cycle.

3.6.2.1.2 Cycle the rudders from 35 degrees right rudder to 30 degrees left rudder. Measure and record the amount of time it takes the rudders to complete the cycle.

3.6.3 Submit a CFR with the rudder swing times to the Coast Guard Inspector.

3.6.4 Test Performance. All acceptance tests shall be performed in the presence of the Coast Guard Inspector. Provide a written report to the Coast Guard Inspector of all test results within one week of test completion.

3.7 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed exterior and interior surfaces to match existing adjacent surfaces, in accordance with COMDTINST M10360.3, Appendix A (Cutter and Boat Exterior Painting Systems) and Appendix B (Cutter and Boat Interior Painting Systems), respectively, and as applicable. Abide by all touch-up requirements outlined in SFLC Std Spec 0000, Appendix A (Requirements for Preservation of Ship Structures).

4. NOTES

This section is not applicable to this work item.