1046_A_RAM_TENSIONER_REMOVAL_AND_REPLACEMENT.doc

USNS CHARLES DREW

(T-AKE 10)

UNREP GEAR

N32205-18-R-4252

13 October 2017

ITEM NO. 1046

Category "A"

PHD/NSWC/JDL

RAM TENSIONER REPLACEMENT

1.0

ABSTRACT:

1.1 This work item describes the requirements for the removal/replacement and testing of seven

(7) hydraulic Ram Tensioners. The Contractor will ship the removed Ram Tensioners to the MSC BATS Warehouse in San Diego.

2.0

REFERENCES:

2.1 Operation Technical Manual S9571-A9-MMA-010 Rev-1, Hydraulic Ram Tensioner

2.2 NAVSEA Dwg 6519082 Navy Standard Ram Tensioner.

2.3 NAVSEA Dwg 6651883 Interface Requirements Navy Standard Ram Tensioner

2.4 NAVSEA Dwg 5746880 System Interface Requirements-STREAM Fueling Station

2.5 NAVSEA Dwg 5746882 System Interface Requirements-STREAM Cargo Station

2.6 S9571-AQ-MMA-010 Control, Automatic Ram Sending Unit

3.0

ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity:

3.1.1 Location: 02 Level

Unrep Station No. 1 Model 6519082-1 Unrep Station No. 2 Model 6519082-1 Unrep Station No. 3 Model 6519082-3 Unrep Station No. 4 Model 6519082-2 Unrep Station No. 5 Model 6519082-1 Unrep Station No. 6 Model 6519082-1 Unrep Station No. 8 Model 6519082-1

3.1.2 Quantity: Seven (7) Ram Tensioners.

3.2 Description/Manufacturer's Data:

3.2.1 Ram Tensioner Assembly

Manufacturer: Naval Sea Systems Command

Drawing: NAVSEA 6519082

Model: 120

WIRE ROPE DIAMETER: 1”, 7/8”, 3/4"

3.2.2 Bill of Materials: The following contractor furnished material list is provided for, but not limited to, the accomplishment of this repair. Quantities are considered estimates. The Contractor shall provide the exact quantities and additional material such as miscellaneous pipe fittings, elbows, caps, valves, pipe hangers, weld material, cable hangers, cable tags, busywork, etc., which are not included in the List of Materials, in order to install a fully functional system which meets the requirements of this specification.

PART

PART NO./NSN QTY

REMARKS

BOLT, GRADE 5

MIL-S-1222, Type III

NON FITTED, LENGTH TO BE

1-1/2-6UNC

or EQUVIALENT

DETERMINED BY CONTRACTOR

BOLT, GRADE 5

MIL-S-1222, Type III 28

FITTED, BLANK SIZE AND

1 1/2-6UNC

LENGTH TO BE DETERMINED

BY CONTRACTOR

NUT, LOCK 1-1/2-6UNC

MIL-N-25027

WIRE ROPE GREASE

5 GALLON CANS

MOBILARMA 798

4.0

GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Materials (GFM):

PART

PART NO./NSN QTY

REMARKS

Ram Tensioner

NAVSEA D6519082-

Rams Provided by NSWC PHD Ram Tensioner

NAVSEA D6519082-2

Ram Provided by NSWC PHD

Ram Tensioner

NAVSEA D6519082-3

Ram Provided by NSWC PHD

Fyrquel/

9150-01-113-2047

55 Gal Drum PE Furnish

MIL-H-19457C

3/4" Spanwire

4010-00-142-6341

RL

900 FT

7/8" Spanwire

4010-00-142-6342

RL

900 FT

Terminal End FTG 4030-01-315-4279

WR 3/4"

Terminal End FTG 4030-01-316-4428

WR 7/8"

SCREW, CAP, HEX

MS35307-419/

ACCUMALATOR BRACKET

5305-00-103-2072

NUT, SLFLKG HEX,

MS17829-8C/

ACCUMALATOR BRACKET

CRES

5310-00-565-4287

SCREW, CAP, HEX

MS35307-409/

ARC BRACKET

5305-00-646-7389

WASHER, LOOK,

MS35338-143/

ARC BRACKET

CRES

5310-01-442-4476

PACKING PREFORMED

M83248/2-932/

ACCUMALATOR NIPPLE

5331-01-075-2185

O-RING

M83248/2-224/

ACCUMALATOR INLET PIPING

5330-01-187-7680

4.3 Government Furnished Services (GFS):

4.3.1 Port Hueneme (PH) Representative will provide technical support/guidance during the accomplishment of this work item.

4.3.2 Port Engineer (PE) and PH, will decide if Fyrquel/MIL-H-19457C will be replaced or reused. If replaced PE will order Fryquel, NSN 9150-01-113-2046, 5 gallon can as decided.

4.3.3 Ships force and PH, will decide if highlines and spanwires will be reused or replaced. If highlines or spanwires are replaced ships force will reorder wire as follows. 3/4" spanwire NSN 4010-00-142-6341, 7/8" spanwire NSN 4010-00-142-6342 and 1" highline NSN 4010-01-309-7439 as required. If spanwires are replaced new end fitting will be required, reorder using NSN 3/4 inch 4030-01-315-4279 and 7/8 inch 4030-01-199-5649.

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 subcontractors regardless of tier must comply with the requirements 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 tier are advised to review other work items under this contract, including but not limited to Work Items 011, 013, 014 and 021 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 The Contractor shall provide any excess parts/material to the MSCREP at the completion of this repair.

5.4 The Ram Tensioners must be removed from the ship within 14 days from the start of the availability to ensure their refurbishment is in time for the next T-AKE availability

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0 STATEMENT OF WORK REQUIRED: For each Ram Tensioner

7.1 Arrangement/Outfitting:

7.1.1 After the ram tensioner have been drained, the contractor with ships force assistance shall remove the Spanwire and/or Highline from the ram tensioner. At the completion of the work item the contractor with ships force assistance shall reinstall existing spanwires and highlines or new spanwires or highlines at the direction of ships forces. The spanwires and highline will be slushed with Mobil arma 798 wire rope grease during installation.

7.2 Structural: None Additional

7.3 Mechanical/fluid:

7.3.1 Bleed all air from ram tensioner hydraulic system using air bleed valve sight glass. Bleed all air from ram tensioner accumulator using air dump valve.

Disconnect HP air piping at tail piece union. Tag-out Ram Tensioner H.P. air charging valve.

7.3.2 Drain hydraulic fluid from ram tensioner and overflow reservoir in accordance with chapter 6-41 of ref. 2.1 into clean containers for possible reuse. If fluid is contaminated and cannot be purified shipyard to properly dispose of fluid as

HAZMAT.

NOTE:

Do not mix hydraulic fluid removed from ram tensioner with hydraulic fluid removed from overflow reservoir

CAUTION

WEAR FACE SHIELD, NEOPRENE OR BUTYL RUBBER BOOTS AND GLOVES WHEN CONTACT WITH RAM TENSIONER HYDRAULIC FLUID IS POSSIBLE. IN AN ATMOSPHERE CONTAINING A FINE SPRAY OR MIST OF RAM TENSIONER HYDRAULIC FLUID, FULL FACE PIECE AND CONTINUOUS AIRLINE RESPIRATOR MUST BE WORN.

7.3.4 Remove spanwire/highine from ram tensioner and winch and spool onto a wire rope reel and hold in protected area for reinstallation.

7.3.5 Disconnect HP air inlet line from accumulator. Ensure not to twist piping, if piping is twisted next o-ring in line will need to be rplaced.

7.3.6 Remove securing brackets from accumaltor and HP air line. Sand blast and piant in accordance with and paint. If new brackets are required provide condition found report to MSC representative. New brackets shall be made of stainless steel.

7.3.7 Place a small wooden wedge between Automatic Ram Control (ARC) sending unit wire rope drum and housing to prevent unwinding.

7.3.8 Disconnect and remove sending unit cable clip from ram upper sheave assembly and hold for reinstallation on replacement ram tensioner.

7.3.9 Disconnect Automatic Ram Control sending unit from ram tensioner IAW Ref.

2.6, and hold for reinstallation on replacement ram tensioner.

7.3.10 Remove ram tensioner foundation bolts and remove ram from its foundation IAW

Ref. 2.3 and prepare for shipment.

7.3.11 Clean ram tensioner mounting pads and protect machined surfaces on top of ram tensioner foundation and preserve interior and exterior of foundation as required.

7.3.12 Install replacement ram tensioner in accordance with Chapter 8 of Reference 2.1 and Ref. 2.3.

7.3.13 Ream the four corner bolt holes of each foundation and ram approximately 1 1/2 inch diameter to suit corner bolts and provide and install four fitted hold-down bolts conforming to MIL-S-1222, Type III grade 5 steel, and zinc plated self locking nuts conforming to MIL-N-25027, and 1 ½ inch flat washers. Provide and install remaining 10, 1 1/2 inch diameter bolts and locking nuts. Torque all nuts to

500 ft. lbs. See section 3.2. The numbers for bolts, nuts and washers are for each ram foundation.

7.3.14 Conduct High-Pressure Air Test IAW Chapter 8 of Reference 2.1, if required.

7.3.15 Remove tags from H.P. air system valves and place back into service.

7.3.16 Reinstall Automatic Ram Control sending unit. Install sending unit cable clip on upper sheave assembly of ram tensioner and adjust in accordance with Chapter 8 of reference 2.6

7.3.17 Fill ram tensioner with hydraulic fluid conforming to Fyrquel 220MLT, MIL-H

19457C (SH). Charge ram in accordance with Chapter 8 pera 8-6 of Reference

2.1. Contractor to provide pump to fill ram tensioner.

7.3.18 Install Contractor provided test wire ropes and accomplish special static structural weight test in accordance with reference 2.2 and 2.3. Install test wire rigged as in service, dead-ended to itself around Spanwire/Highline winch drum so as to not apply torque to the drum. Protect drum with wood dunnage.

Note

Verify winch wire rope drum jaw clutch is disengaged

7.3.19 Upon completion of special static structural testing, reconfigure test wire rope toaccomplish rated load operational test. Install test wire rigged as in service with wire dead ended to drum and wire on average lay.

7.3.20 Upon completion of rated load test, remove test wire and install ship’s wire rope and accomplish preoperational test in accordance with Chapter 8 para 8.7.

7.4 Electrical:

7.4.1 Tag out spanwire winch prior to ram tensioner removal.

7.4.2 Energize spanwire winch upon completion of installation to accomplish operational testing of new ram tensioner.

7.4.3 Adjust ARC sending unit switches in accordance with reference 2.6.

7.5 Electronics: None Additional

7.6 Preparation of Drawings: None Additional

7.7 Inspection/Test:

7.7.1 Conduct Post installation inspection as per Ref 2.1 chapter 8 paragraph 8-5.

7.7.2 Conduct High-Pressure Air test IAW Chapter 8 of Reference 2.1. Ensure higline end fitting is connected to a 50,000 lb statically tested attachment point or spanwire end fitting to a 36,000 lb statically tested attachment point. Using the highline or spanwire winch, remove all wire rope slack.Remove accumulator drain plug (figure 7-1, sheet 8, 145) and O-ring (146). Connect a hose to accumulator drain port; place free end of hose in a bucket of water. Verify that replenishing shutoff valve (figure 7-1,sheet 6,86) from fluid storage tank is shut. Shut air bleed (dump) valve (figure 7-1, sheet 2, 161); slowly open charging/air supply valve and apply high pressure air at 2,000 psi to accumulator for 10 minutes.Observe free end of hose. A steady stream of air bubbles indicates an accumulator piston seal leak. An occasional bubble during the test can be ignored.Shut air supply valve and open air dump valve. Apply low-pressure air to accumulator drain to move piston back up in accumulator. Remove low-pressure air and remove and replace piston seal (paragraph 6-7.19.2 through 6-7.19.5).Remove hose and reinstall accumulator drain plug (145) and O-ring (146).Repeat high-pressure air test (steps 1 through 8 above) to verify replacement seal does not leak.

7.7.3 Conduct special structural static test of completed ram tensioner installation by applying 36,000 lb.load for Spanwire, 50,000lb.load for Highline,for 10 minutes to Test wire in as rigged condition withram tensioner piston in secured position.

7.7.4 Conduct rated load operational test with test wire rope by cycling ram 50 cycles at working flask pressure of 1550 psi,for Spanwire, and 1950 psi, for Highline, using the spanwire/highline winch to let the ram piston extend up and haul down.

7.7.5 All test shall be conducted in presence of Govt/PHD rep. Provide completed test memo to ship and Govt/PHD rep. Install test label plate in vicinity of each Ram Tensioner listing test completed, test facility and date.

7.8 Painting:

7.8.1 Apply two overall coats of PPG Ameron 240 or MSC approved equal surface tolerant epoxy primer to a DFT of 10 mils. Apply one overall finish coat of

Amershield paint to a DFT of 4 mils in way of prepared and primed surfaces.

7.8.2 Paint all new and disturbed surfaces to match surrounding areas.

7.9 Marking:

None

7.10 Manufacturers Representative: None.

7.11 Crating and Shipping

7.11.1 Unpack and reuse the crates and shipping materials that the supplied Ram Tensioners were packed in to prepare for shipment and ship to:

MSC BATS Warehouse 9284 Balboa Avenue San Diego, CA 92123 POC: Blake Nam, Tel: 619.553.6053 blake.nam@navy.mil 8.0 GENERAL REQUIREMENTS: None Additional 1046-1