01003_A_Saddle_Winch_and_Saddle_Foundation_Refurbishment-Arctic_1.doc

USNS ARCTIC

T-AOE 8

UNREP GEAR

N32205-18-R-4256

6 JUNE, 2018

ITEM NO. 1003

CATEGORY “A”

PHD/NSWC/KCS

SADDLE WINCH AND SADDLE WINCH FOUNDATION REFURBISHMENT

1.0

ABSTRACT:

1.1 This item describes the removal of the saddle winches and refurbishment of the foundation and preservation of the area behind the winches.

2.0

REFERENCES:

2.1 Winch, Saddle, Navy Standard Three Speed/Two Speed, MK1 MOD 1 SG813-B6-TRS-010 (to be provided by Port Hueneme Representative)

2.2 Winch, Saddle, Navy Standard Three Speed/Two Speed, MK1 MOD 0 SG813-B6-MMA-010 (aboard ship)

2.3 NAVSEA DWG. 5210545, Standard Painting Procedures for UNREP Equipment

2.4 NAVSEA DWG. 4847452, Saddle Winch Interface NOTE: The Interface drawing 4847452 references Gen Specs S9AA0-AA-SPN-010/GEN SPEC. This reference document is cancelled and replaced by General Specifications for Overhaul of Surface Ships S9AA0-AB-GOS-010/GSO.

2.5 NAVSEA DWG. 4847460, Base Weldment

2.6 NAVSEA DWG. 4847459, Base Machining

2.7 General Specification for Overhaul Paragraph 075b.13

3.0

ITEM LOCATION/DESCRIPTION:

3.1

LOCATION/QUANTITY

3.1.1 Location: Fueling at Sea Station 10, Saddle winches No. 1, 2 and 3

3.1.2 Quantity: Three (3) winches.

3.2

ITEM DESCRIPTION/MANUFACTURER'S DATA:

MFR: Lake Shore Inc.

DWG:80064-4847457

DWG: 4847470

MODEL THREE SPEED/TWO SPEED MK 1 MOD 0

AMPS: 34/38/34

VOLTAGE: 440AC

MFR: Louis Allis

Dwg 15A00406-0000

Model Three Speed/ Two Speed

MK 1 MOD 0

4.0

GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Materials (GFM):

4.3 Government Furnished Services (GFS):

4.3.1 Port Hueneme representative will provide technical support/guidance during the accomplishment of this work item.

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 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, 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 Contractor Furnished Materials (CFM):

Electrical wire Water tight connector

5.3.1 Contractor to manufacture twelve (12) body bound fitted bolts and nuts of grade 5 materials for the saddle winch foundation bed. These fitted bolts are to be used on four corners of the foundation. Four (4) fitted bolts will be used for each saddle winch.

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional

7.0

STATEMENT OF WORK REQUIRED:

7.1 Arrangement/Outfitting:

7.1.1 Contractor with Ship’s Force assistance will lower hoses as needed on deck or as per Ship’s Force instruction. Remove saddle wire and place in a suitable container for storage off ship until completion of item. Install suitable line as rigged to facilitate reinstallation.

7.1.2 Upon completion of work item, the contractor with Ship’s Force assistance will reinstall the saddle whip wire back onto the winch drum. Ensure to apply Mobil Arma 798 grease during reinstallation. Contractor will also help Ship’s Force in the reinstallation of the hoses.

7.2 Structural:

Note:

Removal of the foundation bolts shall be accomplished with care, using wrenches, hydraulic jacks, and torches as required. Care is to be taken so as not to damage the winch foundation or winch bed. Use of torches shall be limited as localized heating of winch foundation degrades strength of steel. Contractor shall consult with MSC Representative prior to use of torches. Care is to be taken to protect deck, winch and foundation coating systems from heat damage using sheet metal and fire cloth. Some bolts may need to be drilled out.

7.2.1 After removal of the saddle winch, remove electric motor and wire rope drum. Cover motor and drum opening in order to protect the gear box from Ultra High Pressure (UHP) water blasting. Port Hueneme representative shall inspect prior to any water blasting. UHP saddle winch and king post foundation to SSPC-SP10, additionally some areas will require power tool cleaning to SSPC-SP11. After metal repair has been completed and inspected by Port Hueneme Representative, preserve prime and paint the area on the backside of the saddle winch and kingpost foundations. For bidding purposes; estimate for each saddle winch, crop out each saddle winch foundation frame in two different areas that are 3” by 26” with 3/8” ASTM A36 or equivalent steel. Clad weld a 3” by 3” area in three different areas and double a 3” by 12” area utilizing 3/8” ASTM A36 steel or equivalent in one area.

7.2.2 Using References 2.4, 2.5, and 2.6, inspect winch foundation/base for excessive metal loss. If structural metal loss is greater than 50%, clean and prep loss areas and repair with a welded doubler plate or crop out and repair. Do not crop out steel in any load bearing portion of the gearbox. If there is less than 50% material loss, clad weld to build loss areas to be within designed specifications, and grind to smooth finish, taking care not to damage winch feet.

7.3 Mechanical/Fluids:

7.3.1 Shipyard to drain and dispose saddle winch gearbox oil (gearbox capacity is approximately 10 gallons).

7.3.2 Rig suitable lifting slings around saddle winch assembly. Connect lifting slings to hoisting equipment. The saddle winch assembly weighs approximately 4,570 lbs.

NOTE: Mark parent location of the winch for reinstallation.

7.3.3 Remove winch from foundation and convey to shop. Clean by degreasing all saddle winch assembly parts.

7.3.4 Sandblast/ UHP blast saddle winch and foundation and surrounding area to bare metal with emphasis under side of frame. Some area will have to be mechanically clean to SSPC-SP-11. Port Engineer/Port Hueneme rep will inspect prior to painting.

7.3.5 Remove wire rope guard, mark wire rope guard for reinstallation. Shipyard provide new fasteners for reinstallation.

7.3.6 Remove drum shaft end cover and drum shaft gear end cover, using reference 2.1 for guidance.

CAUTION

IF WIRE ROPE DRUM IS NOT SUPPORTED PRIOR TO REMOVING GEAR CASE COVER IT COULD DAMAGE EQUIPMENT AND PERSONNEL.

7.3.7 Support wire rope drum using a suitable lifting device.

7.3.8 Remove gearbox case cover; mark cover for reinstallation. Retain fasteners for reinstallation.

7.3.9 Remove winch drum shaft gear assembly from saddle winch gearbox.

7.3.10 Transport winch drum shaft assembly from ship to shop, protect drum shaft and low speed gear from damage during transportation to shop. Cover open end of saddle winch gear box on king post to keep foreign material out.

7.3.8 Remove outer bearing, wire rope drum, seal and inner bearing from shaft, discard old seal and bearing. Inspect drum shaft and low speed gear for damage. Submitted inspection report to MSC representative. If required clean shaft seal area and refurbish/rechrome as required in accordance with reference 2.2

7.3.11 Install GFM oil seal, bearings on drum shaft in reverse order it was disassemble. (Bearings are a press fit.)

7.3.12 Install winch drum shaft assembly, using reference 2.1 for guidance.

7.3.13 Reassemble gear box using new GFM materials provided.

NOTE:

1.

HIGH SPEED PINION GEAR (END OF THE ELECTRIC MOTOR) TO HIGH SPEED GEAR BACKLASH IS .004” TO .007”.

2.

LOW SPEED PINION GEAR TO LOW SPEED GEAR BACKLASH IS .005” TO .008”.

7.3.14 Electric Motor: Overhaul in accordance with Ref. 2.2.

7.3.15 Using reference 2.1, paragraph 4.1 and reference 2.3, paragraph 6-8 for guidance, overhaul magnetic brake.

WARNING:

The field housing (with armature and coil) weighs approximately 160 pounds. Use suitable hoisting equipment to support the housing during removal to prevent injury to personnel or damage to equipment. Tension must be released off spring before disassembling the brake.

7.3.16 Reassemble the brake assembly, using new brake linings, rivets and fasteners.

7.3.17 Reinstall magnetic brake on electric motor using reference 2.1, paragraph 9.4 for guidance. Use anti-size compound on all pins and pivot areas.

7.3.18 Reinstall electric motor/brake assembly on winch bed and carefully guide high-speed pinion into proper contact with low speed pinion.

7.3.19 Adjust/position electric motor to provide 0.004 – 0.007 backlash (both gears) across entire face. Use reference 2.1 paragraph 4.2.b for guidance. Install electric motor dowel pins on diagonally opposing mounting feet.

7.3.20 Reinstall electric motor mounting capscrews.

7.3.21 Reinstall gasket and cover on gear case. Tighten cap screws to 18 foot pounds.

7.3.22 Paint saddle winch and saddle winch foundation and surrounding area in accordance with reference 2.4.

7.3.23 Using Reference 2.1, 2.4 and 2.7 for guidance, provide and install new replacement non fitted and fitted bolts, self-locking nuts and flat washers at Stations 10. Bolts are to be installed using Molykote P-37 anti-seize on all threaded fasteners.

7.3.24 Fitted bolts: Ream the saddle winch corner holes for fitted bolts to Fit Tolerances for 1/2 to 1-1/8 Nominal Size bolt (Maximum Clearance +.0005, Maximum Interference -.0010). Fitted bolts will require freezing in liquid nitrogen prior to installing, if liquid nitrogen is not available dry ice may be used as alternative, ensure the bolts have been chilled to 0 deg F prior to insertion. NOTE: Fitted bolt holes will be inspected by Port Hueneme representative for acceptance before shipyard measures and manufactures the new bolts. Bolt holes shall be marked and measurements shall be recorded. All bolts will be Grade 5, installed with flat washers and self-locking nuts using Molykote P-37 anti-seize on all threaded fasteners. Non-fitted bolts shall be torqued to 260-300 foot pounds and fitted bolts torqued to 400-440 foot pounds in the presence of the MSC Representative.

7.3.25 Fill gearbox with CFM gear oil approximately 10 gallons per sump SHELL OMALA 150. Shipyard will provide new oil.

7.3.26 Replace gear box cover gaskets. Tighten cap screws to 18 foot pounds.

7.4 Electrical:

Checkpoint:

Label and protect all leads. Provide MSC Representative with a copy of wiring disconnect sheet for each winch.

7.4.1 Disconnect and tag all electrical leads to saddle winch main electric motor and magnetic brake assembly.

7.4.2 Ring-out all electrical leads to motor control panel and provide report to MSC Representative. Remove electrical motor junction box with winch. Power tool clean junction boxes and tap out all wire connector holes. Preserved inside and outside of junction boxes also use belzona on junction boxes for any holes.

7.4.3 Connect electrical leads to main electric motor and magnetic brake assembly in accordance with disconnect sheet. Manufacture and install new junction box cover gasket and install four (4) new CFM provided stainless steel fasteners for junction box. And coated with anti-seize compound.

7.4.4 Remove tag and energize saddle winch main circuit breaker.

7.5 Electronics: None additional

7.6 Preparation of Drawings/Documentation: None additional

7.7 Inspection/Test:

7.7.1 Conduct an 8,000-pound static test on saddle winch to verify new foundation bolts will hold 200% of winch rated load. Test shall be conducted with test wire rigged through normal ships rigging and shall be held for 10 minutes without brake slippage, damage or deformation to components tested.

7.7.2 Test to be performed shall be witness by MSC Representative.

7.8 Painting:

7.8.1 Prepare, prime and finish paint the winch bed and disturbed surfaces to match surrounding areas in accordance with Reference 2.3. Apply and extra top coat underneath the winch bed on both the winch and kingpost. Shipyard will provide the paint.

7.9 Marking:

7.9.1 Mark all components to identify exact location for inspection and reinstallation.

7.10 Manufacturer’s Representative: None

8.0 GENERAL REQUIREMENTS: None additional

1003-1