0219_A_Main_Reduction_Gears_Inspection_REV-1.doc

USS MT WHITNEY

(LCC 20)

MACHINERY, MAIN PROPULSION

RFP NO. N32205-16-R-4601

Amend 004, 01 APR 2016 ITEM NO 0219 Category “A”Amend 004 MSC/N74/RHA

MAIN REDUCTION GEARS INSPECTION (ABS)

1.0

ABSTRACT

1.1 This item describes the requirements to accomplish inspection and repairs of the Main Reduction Gears (MRG).

2.0 REFERENCES/ENCLOSURES:

2.1 NAVSEA 0942-LP-004-8010, Technical Manual Main Reduction Gears

2.2 NAVSEA Drawings: 2492020_A, Lifting Gear, MN RED Gear

3.0

ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity: Main Reduction Gears (MRG), Engine Room Compartment (8-86-0-E).

3.2 Item Description/Manufacturer’s Data:

3.2.1 Quantity (One), Main Reduction Gear Set, Mfr.

22,000 Shaft Horse Power, APL 691300148, Serial number 178935, GEK 3454, PN MD111A2

3.2.2 Double reduction, double helical, articulated-type reduction gear

4.0

GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Material (GFM):

4.1.1 Paint – as required

4.1.2 (ALOP) Drive shaft seal - Garlock Klozure #63 x 904.

4.2 Government Furnished Technical representative:

4.2.1 None

5.0

NOTES

5.1 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 of all applicable GTR’s including but not limited to GTR’s 1 through 7, 22, 23, 24, 27 28 and 29.

5.2 The contractor and all subcontractors regardless of their tier are advised to review other specification items under this contract to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

5.3 USS Mount Whitney is known to have a considerable amount of asbestos. Additionally, it is known that the coating systems may contain lead. The contractor should expect this condition and factor in removal and remediation time requirements into the overall planning schedule. Costs associated with unexpected hazardous waste remediation and removal shall be attributed to Work Item 023, rather than to the individual work items. Wastes removed in the course of work package accomplishment shall be removed from the ship, handled and disposed of in accordance with Work Item 023 of this work package, but the costs of disposal is to be covered in this item. Contractor shall be responsible to follow all international, national and US Federal regulations in the containment and removal of these wastes as encountered.

5.4 The contractor is expected to use best management practice to identify and dispose of all hazardous waste. Every effort shall be made to minimize the disturbance, removal and handling of hazardous wastes in the accomplishment of the work package. Accomplish work in this item in conjunction with all other dry-dock items in these specifications.

5.5 This work item shall be coordinated with Work Items 0202, 0203, 0309 and 0310.

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0

STATEMENT OF WORK REQUIRED

7.1 Arrangement/Outfitting:

None

7.2 Structural: None

7.3 Mechanical/Fluids:

7.3.1 Make all necessary connections to remove and dispose of the lube oil from the MRG Lube oil sump.

7.3.2 MRG lube oil sump:

7.3.2.1 Open MRG lube oil sump covers and wipe clean with lint-free rags. Remove any loose rust or debris using soft brushes and scrapers. While cleaning, protect all open gears from contamination by loose rust and debris. Inspect sump internals for cleanliness and submit a report to MSCREP.

7.3.2.2 Reinstall all sump covers. Chief Engineer will be the last person exiting the sump. Closure shall take place immediately, using new gaskets.

7.3.3 Remove all interferences in way of Main Reduction Gear (MRG) casing covers in preparation for lifting, removal and storage.

7.3.3.1 Disassemble and remove MRG casing covers to the extent necessary to accomplish inspections described in para 7.3.4, under the guidance of the Original Equipment Manufacturer (OEM) representative and in accordance with Reference 2.1.

7.3.3.2 Casing covers shall be stored in safe and acceptable manner to the MSCREP. Contractor shall take all necessary precautions to prevent the entry of debris, dirt, and foreign matter from entering the confines of the MRG while open and during the lifting/closing process.

7.3.3.3 Inspections are to be accomplished in the presence of ABS and MSCREP.

7.3.4 Using Reference 2.1, accomplish the following inspections and repairs:

7.3.4.1 Check gear tooth contact between high-speed pinions to first reduction gears, first reduction pinions to second reduction gears and second reduction gears to the bull gear. Inspect gear teeth for damage, unusual wear patterns and raised metal.

7.3.4.2 Opened and provide a dimensional inspection of the Low Pressure (LP), Second Reduction Pinion (2RP) aft and fwd bearings. Provide report to MSCREP.

7.3.4.3 In coordination with WI 0909, once the stern tube shaft has been removed, check the line shaft thrust clearances, open/inspect and re-shim the thrust bearing if required as per OEM direction, reassemble, re-check clearance again, open & inspect, re-shim. Design Thrust Clearance is 0.025 – 0.045”. Maximum thrust clearance is 0.045” greater than design.

7.3.4.4 Disassemble, clean and inspect HP and LP High Speed (HS) couplings. Check axial float, backlash, and lift between the coupling sleeves and distance piece. Provide report to MSCREP.

7.3.4.5 Check the alignment between the HP and LP turbines and the Main Reduction Gear. Provide report to MSCREP.

7.3.4.6 Disassemble, clean and inspect the HP and LP intermediate couplings. Check axial float, backlash, and lift between the coupling sleeves and hub. Provide report to MSCREP.

7.3.4.7 Remove and replace the Attached Lube oil Pump (ALOP) Drive shaft seal - Garlock Klozure #63 x 904, (GFM provided in para 4.1.2)

7.3.4.8 Remove and refurbish the ALOP drive shaft seal fit area, final outside dimension (OD) of the shaft in the seal area shall be 1.747 – 1.753”, with a 32 RMS surface finish.

7.3.4.9 Check alignment, realign and dowel the ALOP Drive end cover to establish proper alignment of the seal to the drive shaft.

7.3.4.10 Using contractor provided borescope, inspect LP turbine last stage ahead and astern buckets, and any other accessible stages. Provide report to MSCREP.

7.3.4.11 Inspect the connection between the HP Head and the forward bearing bracket to ensure that the Coking problem has not returned. See excerpt from HP Bolting Data drawing below. Detail “H” shows bolting between HP Head and Bearing Bracket.

7.3.5 Reassemble casing covers upon completion of work and inspection by MSC Technical Representative. During the re-installation process the MSC technical representative and contractor furnished OEM shall witness and oversee the fit of MRG casing mating sealing surfaces. Fit is to be witnessed by the Chief Engineer, Port Engineer, and ABS Surveyor.

7.3.6 Contractor shall provide assistance to the ship’s force to accomplish a Hot Oil Flush of the MRG Lube Oil System. Hot oil flush shall be accomplished using ship’s lube oil pumps and purifier, circulated thru the entire system using 100 micron mesh nylon bags installed in the strainer baskets. Flush shall include all piping, bearings and spray nozzles and shall run for a minimum 48 hours,

7.4 Electrical: None

7.5 Electronics: None

7.6 Preparation of Drawings/Documentation:

7.6.1 As described within work item.

7.7 Inspection/Test:

7.7.1 Ship force will operationally test Main Reduction Gear during dock and sea trials.

7.8 Painting 7.8.1 Clean, prepare, prime and paint to match all new and disturbed surfaces disturbed during lifting and re-installation of turbines IAW ship’s paint schedule.

7.9 Marking: None

7.10 Manufacturer’s Representative:

7.10.1 Contractor shall provide an authorized Original Equipment Manufacturer (OEM) to perform Quality Assurance oversight for the disassembly, initial open and inspect, shop inspections, reassembly and tests of the equipment performed by the Contractor. Final acceptance of work will be performed by the designated OEM and MSCREP. One source for an OEM is as follows:

Mr. Joe Vail, or Mr. Richard Neary Sr. Field Engineers US Gov't, Marine & Industrial: Gears, Turbines and

Motors, GE Energy Management Industrial Solutions

Cell: +1 207-650-6818

Fax: +1 207-226-2091 Email: joseph.vail@ge.com Email: Richard.Neary@ge.com

8.0 GENERAL REQUIREMENTS:

8.1 None additional

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