0504_A__CRANE_RETESTING_SURVEY_AND_HYDRAULIC_HOSE_REV_-_(6Apr17).docx

USNS CESAR CHAVEZ

(T-AKE 14)

CRANE RETESTING SURVEY & HYDRAULIC HOSE REPLACEMENT(5-YR)_REV – (CESAR CHAVEZ 2017 only)

1.0 ABSTRACT:

1.1 This item describes performing the 5 Year Crane Retesting Survey (as required by ABS), hydraulic hose replacement, and wire rope replacement.

2.0 REFERENCES:

2.1 ABS Guide for Certification of Lifting Appliances, Chapter 2 Guide for Certification of Cranes, Section 7 Surveys.

2.2 T-AKE-1 Class Cargo Crane Recertification Test Procedure; Test No:8390285 Rev/Chg:00

2.3 Tech Manual TG811-BN-MMC-010, Boom Crane, Electro-Hydraulic DWG AMD-1975

2.4 Dwg. No. 573-8391521, Rev. -; Hose List Appleton Crane

2.5 NAVSEA Dwg. No. 803-6397427, Rev. A; Links Radio Frequency, High-Voltage Insulator Link, Cylinder Type.

2.6 Appleton Marine, Inc., Memo FSR-16136-01, dated 06 June, 2011, Recommended Wire Rope Spelter Anchorage Inspection, Lubrication and Preservation Procedure.

2.7 Appleton Marine, Inc., ABS Required – Turntable Bearing Tilt Test Procedure/Log Book

3.0 ITEM LOCATION/QUANTITY/DESCRIPTION:

3.1 Location:

3.1.1 Crane No. 1, 02 Level Frame 32 STBD

3.1.2 Crane No. 2, 02 Level Frame 32 PORT

3.1.3 Crane No. 3, 03 Level Frame 77 STBD

3.1.4 Crane No. 4, 02 Level Frame 77 PORT

3.2 Quantity:

3.2.1 Four (4) each Appleton Marine, Inc., Boom Crane, Electro Hydraulic Model No: EB270-87-47

3.3 Description/Manufacturer’s Data

3.3.1 Manufacturer: Appleton Marine, Inc.

20 rolls DENSO tape or equivalement

48 ea Upper turntable (slewing ring bearing assembly) fasteners YMD-9051.

43 ea Lower turntable (slewing ring bearing assembly) fasteners YMD-9052.

Hoses listed in Ref 2.4 (note – Hoses need NOT be OEM supplied)

3.3.3 Quantities specified in the Bill of Material List are considered estimates. The contractor shall provide the exact quantities and additional material in order to install a fully functional system, which meets the requirements of this specification.

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material (GFM):

a. Crane Wire Ropes (4ea.), YMD-8845.

b. Hydraulic Fluid, Shell Tellus 460, Approximately 220 gallons (crew furnished)

4.3 Government Furnished Services (GFS): None.

5.0 NOTES:

5.1 The Contractor and all Subcontractors, regardless of tier, must consult the General Technical Requirements (GTRs) 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.

5.2 The Contractor and all Subcontractors, regardless of tier, are advised to review the other work items under this contract to determine their effect on the work required under this work item.

5.3 THIS SHIP CONTAINS HIGH VOLTAGE (HV) ELECTRICAL SYSTEMS. THE CONTRACTOR AND SUBCONTRACTORS SHALL OBEY ALL POSTED AND VERBAL INSTRUCTIONS REGARDING SAFETY AND EXCLUSION FROM HIGH VOLTAGE AREAS. AT NO TIME SHALL A CONTRACTOR OR SUBCONTRACTOR APPROACH, WORK ON, OR ENTER A HIGH VOLTAGE AREA WITHOUT PROPER AUTHORIZATION.

5.4 THE T-AKE CLASS ELECTRICAL COLOR CODING DOES NOT FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK, AND WHITE. THE CONTRACTOR SHALL ASSUME ALL ELECTRICAL CABLES ARE HOT UNTIL TESTED OTHERWISE. THE CONTRACTOR SHALL TEST ALL ELECTICAL CABLES TO ENSURE THEY ARE DEAD PRIOR TO WORKING ON THE ITEM.

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 Contractor is to maintain a markup of Reference 2.2 during inspections and testing with shipyard quality assurance department personnel, port engineer, and ship’s force signatures as inspections and tests are accomplished. Contractor is to turn over markup at the completion of testing and inspections.

7.0 STATEMENT OF WORK REQUIRED:

7.1 Isolate and tag out the system. Drain the affected pipingand dispose of affected liquids in accordance with federal, state and local regulations.

7.2 Remove all interferences including deck plates and pipe hangers and other minor items to facilitate repair. Open deck area shall have a safety barrier installed for the safety of the ships crew.

7.3 Hydraulic Hose Replacement:

7.3.1 Contractor to pressure wash all cranes to remove exterior contaminants to facilitate the inspection and replacement of all hydraulic hoses and fittings.

7.3.2 Contractor to replace all of the hydraulic hoses on all of the cranes, with the exception of the extend boom cylinder hoses (these hoses are housed within cable tracks inside the boom structure and cannot be replaced without complete removal and disassembly of the booms).

7.3.3 All hose fittings to be Denso taped (or equal product) after operational test.

7.3.4 Provide Mill Test Reports (MTRs), Certificate of Compliance, Certification of Heat Treatment and Hydrostatic Test Reports for all replacement hydraulic hoses and fittings to the MSCREP.

7.3.5 Replace 15 square ft of crane cab insulation as required.

7.3.6 Provide and upload latest version of software for each crane PLC.

7.4 Wire Rope Replacement.

7.4.1 Replace cargo crane wire rope on cranes 1 thru 4 in accordance with reference 2.1 and 2.3.

7.4.2 New wire shall be greased in accordance with OEM recommendations. Only approved lubricants shall be used.

7.4.3 Lubricate all sheaves, pins, slew rings and boom luff cylinder fittings. Clean and lubricate luff cylinder rod with light coat of oil. Drain & refill swing drive with 5 gallons of 90 weight gear oil. S/F to provide grease and oil.

7.5 Perform a 5 Year Crane Retesting Survey in accordance with Ref 2.1 and 2.2

7.5.1 Inspection

a. Perform a visual inspection of each crane structure for deformation, excessive wear, corrosion, damage or fractures. The attending ABS Surveyor shall witness the inspection.

b. Perform a visual examination of all crane hooks for deformation, excessive wear or fractures.

c. Perform non-destructive testing (NDT), Dye Penetrant Testing (PT) or Magnetic Particle Testing (MT) of all crane hooks for fractures. The attending ABS Surveyor shall witness testing.

d. Perform all required testing and inspection of all crane hook insulator links as per the Manufacturer’s recommendations and Reference 2.5, submit findings via CFR.

e. Perform a visual external examination and operational test of all crane machinery including prime mover, clutches, brakes; hoisting, slewing and luffing machinery.

f. Perform a visual inspection of wire rope including end attachments. Refer to reference 2.6 for wire rope Speltor anchorage inspection. The attending ABS Surveyor shall witness inspection.

g. Prior to installation of new wire, inspect all sheaves, and pins, submit findings via CFR.

h. Examine turn table (slewing ring bearing assembly) for slack bolts, damaged bearings and deformation or fractured weldments. Any bolt removed must be replaced with new bolt.

i. Perform a torque check of 25% of upper and lower turntable (slew ring bearing assembly) bolts on each crane. Submit findings via CFR..

j. Remove 25% of the turn table (slewing ring) bearing assembly bolts (number of bolts in total for all 4 cranes is 48 upper and 43 lower), conduct NDT, discard upon completion, submit findings via CFR.

k. Conduct torque test of all turntable bearing (slewing ring assembly) bolts to 2500 ft. lbs in an alternating pattern approximately 180 degree’s apart to ensure proper pre-tension.

l. Provide Mill Test Reports (MTRs), Certificate of Compliance, and Certification of Heat Treatment for all replacement slew ring bearing bolts to the MSCREP.

7.5.2 Functional Testing

a. Perform functional tests on each crane including main and auxiliary load hoisting and lowering, boom raising and lowering, slewing (swinging), safety protective (fail-safe) and limiting devices and load and boom angle or radius indicators. Inspect all fittings for leakage and repair.

7.5.3 Rocking (Tilt) Testing

a. Perform a Rocking (Tilt) Test on each crane in accordance with reference 2.7. Rocking (Tilt) Test shall be performed prior to proof load testing. The attending ABS Surveyor shall witness test.

b. If the results of the Rocking (Tilt) Test indicate bearing wear in excess of the Manufacturer’s recommendation, submit findings via CFR.

c. The results of the Rocking (Tilt) Tests are to be recorded in the Register of Lifting Appliances.

7.5.4 Grease Sampling

a. A grease sample shall be taken from each slewing bearing assembly and analyzed for contaminants, and metal particles. The attending ABS Surveyor shall review the analysis report.

b. If the analysis of the grease sample indicates bearing wear or contamination in excess of the Manufacturer’s recommendation, submit findings via CFR.

7.5.5 Load Testing and Examination

a. Perform load testing and examination of each crane in accordance with references 2.1 and 2.2.

b. Provide a “certified” weight (12,500 kg (27,560 lbs) Maximum Capacity) to be used for crane load testing. Provide transportation of the weight tank to and from the ship. Provide all necessary slings, rigging and equipment required to load, unload and transport weight tank.

c. Provide a dynamometer or load cell to be installed in test weight rigging. Certification of calibration shall be prominently displayed on dynamometer or load cell. Certificate of calibration to be provided to the MSCREP prior to load testing.

7.5.6 Post-Load Testing Inspection

a. Perform a thorough examination of each crane, together with all critical accessories, upon completion of load (proof) testing, to determine if any part has been damaged or permanently deformed as a result of load testing. Examination to include the following items:

i. Crane Structural Components

ii. Foundations

iii. Sheaves and Rope Guides

iv. Wire Ropes (including end connections)

v. Hoist machinery, brakes and clutches

vi. Hooks

vii. Slewing assembly and bolting arrangements

b. Perform a volumetric NDT of all critical butt welds in the crane pedestals, including any transition pieces between the pedestal and crane slew ring.

c. NDT critical fillet welds in the pedestal and transition pieces.

7.6 Mechanical/Fluids:

7.6.1 Hydraulic System Inspection

a. Open, clean, and inspect all hydraulic sumps.

b. Hydraulic fluids to be drained and temporarily stored in clean containers for re-use.

c. Hydraulic fluid samples to be taken from each sump and analyzed for contaminants. The attending ABS Surveyor shall review the analysis report.

d. Upon completion of inspection and repairs, Contractor to ensure that the system has been closed, all reservoir/sumps have been filled utilizing a minimum of a 10 micron filter, with the Manufacturer’s recommended type of hydraulic fluid (Shell Tellus 460) and a system test shall be performed.

7.7 Electrical: None Additional.

7.8 Electronics: None Additional.

7.9 Preparation of Drawings/Documents:

7.9.1 Complete reference 2.2 Test Data Sheets. Provide completed test data sheets to Port Engineer and Chief Engineer.

7.9.2 Service Report: Provide a final report, in electronic format, of results, conditions found, discrepancies corrected, and recommendations for any process improvements noted during performance of this work item. Provide report to the Port Engineer and Chief Engineer upon completion. Report shall include drawing of bolt location for bolts changed out.

7.9.3 All reports and data sheets shall be submitted in hard copy and electronic copy (PDF).

7.9.4 Inspection/Test:

a. All Mill Test Reports (MTRs), Certificate of Compliance, Certification of Heat Treatment and Hydrostatic Test Reports for all replacement bolts, hydraulic hoses, fittings and miscellaneous parts to be provided to the MSCREP.

b. Attending ABS Surveyor shall witness all inspections and testing as required.

c. Contractor is to maintain a markup of Reference 2.2 during inspections and testing with shipyard quality assurance department personnel, port engineer, and ship’s force signatures as inspections and tests are accomplished. Contractor is to turn over markup at the completion of testing and inspections.

7.10 Painting: None Additional

7.11 Marking:

7.11.1 Each new hydraulic hose shall have a stainless steel tag affixed to hose with hydro date, hydro pressure and part number information clearly stamped into tag.

7.12 Manufacturer’s Representative:

7.12.1 Provide the services of a qualified technical representative of Appleton Marine, Inc., to assist with the 5 Year Crane Retesting Survey (as required by ABS), hydraulic hose replacement, and wire rope replacement.

Appleton Marine, Inc.

3030 E. Pershing St.

Appleton, WI 54911-8671 (920)738-5432

8.0 GENERAL REQUIREMENTS: None Additional.

504A-1