0514_A_PUMP OVERHAUL.doc

USNS Guadalupe

( TAO 200 )

1.0 ABSTRACT

1.1 Provide all labor, material and equipment to overhaul various pumps in in the Pump Room and Engine Room.

2.0 REFERENCES/ENCLOSURES

2.1 References: None

2.2 Enclosures

2.2.1 Military Sealift Fleet Support Command (MSFSC) Standard Work Item for Repetitive Repair Requirements, Item #31, “Motor Driven Pumps Overhauls” (Pages: 4)

3.0 ITEM LOCATION/DESCRIPTION

3.1 Location/Quantity/Description/Manufacturer’s Data:

3.1.1 Location: Machinery Space 4-60-0

Motor Room #1 (4-34-0)

3.1.2 Quantity:

One (1) CFW Pump

Two (2) CPP Hydraulic Pumps

Two (2) Fuel Oil Service Pumps

Two (2) ME Rocker Arm Lube Oil pump

One (1) JP5 Cargo Pump

One (1) DFM Cargo Pump

Two (2) Reduction Gear Lube Oil Pumps

3.1.3 Description/Manufacturer’s Data:

NO.1 CENTRAL FRESH WATER PUMP:

NOMEN...........: PMPCTFGL 7200GPM 43PSI 1180RPM MD VLT

APL.............: M016021585

MANUFACTURER....: TRUARC CO LLC

Location........: 3-87-2 Model Number....: 14-DBVB-16 Serial Number...: 87336

NO.2 CPP HYD PUMP:

NOMEN...........: PMPRTY PWR 225.0GPM 400PSI 1750RPM MD

APL.............: M016161183

MANUFACTURER....: TRUARC CO LLC

Location........: 4-76-2 Model Number....: A3DBCSX-337 Serial Number...: 104733-1

NO.1 AND 2 FUEL OIL SERVICE PUMP:

NOMEN...........: PMPRTY PWR 38GPM 150PSI 1750RPM MD

APL.............: M016161155

MANUFACTURER....: IMO INDUSTRIES INC.

Location........: 4-78-2 Model Number....: G3DHCS-187/SF10855 Serial Number...: 105317-3

NO.2 ME ROCKER ARM LUBE OIL PUMP:

NOMEN...........: PMPRTY PWR 14GPM 25PSI 1150RPM MD

APL.............: M016161156

MANUFACTURER....: IMO INDUSTRIES INC.

Location........: 4-88-0 Model Number....: A3DBS-156/SF10860 Serial Number...: 105350-4

NO.3 CPP HYD PUMP:

NOMEN...........: PMPRTY PWR 225.0GPM 400PSI 1750RPM MD

APL.............: M016161183

MANUFACTURER....: TRUARC CO LLC

Location........: 4-78-1 Model Number....: A3DBCSX-337 Serial Number...: 104736-4

NO.3 JP-5 CARGO PUMP:

NOMEN...........: PUMP CTFGL 3000GPM 430PSI 1750RPM MD

APL.............: M016021658

MANUFACTURER....: WARREN PUMPS INC

Location........: PUMP ROOM Model Number....: 998D3267-M398-21.875 IN Serial Number...:

NO.3 ME ROCKER ARM LUBE OIL PUMP:

NOMEN...........: PMPRTY PWR 14GPM 25PSI 1150RPM MD

APL.............: M016161156

MANUFACTURER....: IMO INDUSTRIES INC.

Location........: 4-88-0 Model Number....: A3DBS-156/SF10860 Serial Number...: 105350-2

NO.4 DFM CARGO PUMP:

NOMEN...........: PUMP,CTFGL 3000GPM 186PSI 1750RPM MD CW

APL.............: M016021659

MANUFACTURER....: WARREN PUMPS INC

Location........: 4-40-2 Model Number....: 998D3267/21.50IN Serial Number...:

PORT REDUCTION GEAR FWD LUBE OIL PUMP:

NOMEN...........: PUMP,ROTARY,SCREW

APL.............: M016161181

MANUFACTURER....: IMO INDUSTRIES INC.

Location........: 4-86-1 Model Number....: 413DBCS-337/S10882 Serial Number...:

STBD REDUCTION GEAR AFT LUBE OIL PUMP:

NOMEN...........: PUMP,ROTARY,SCREW

APL.............: M016161181

MANUFACTURER....: IMO INDUSTRIES INC.

Location........: 4-84-2 Model Number....: 413DBCS-337/S10882 Serial Number...:

3.2 Paint Scheme

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1 Government Furnished Materials

4.1.1 Government will furnish MINOR Repair Kits for PUMPS LISTED in PARA 3.Minor repair Kits consist of Seals and Bearings

4.1.2 Paint as below

4.2 Government Furnished Services

4.2.1 The Government shall provide the services of the Paint Manufacturer’s Technical Representative.

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 regardless of tier must comply with the requirements of all applicable GTR’s.

5.2 The contractor and all subcontractors regardless of tier are advised to review all other work items in this specification 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.

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0 STATEMENT OF WORK REQUIRED

7.1 Contractor is to provide all labor, materials, services and equipment in order to overhaul various Engine Room and Pump Room Pumps detailed in Paragraph 3.1 in accordance with Reference 2.1.1-2.1.X and Enclosure 2.2.1 Section A, B & D for Centrifugal and Rotary Pumps.

7.2 Prior to starting any work ensure that all pertinent systems, valves and Circuit Breakers are isolated, secured and tagged-out in accordance with MSC procedures and Ship’s Force before commencing with this Work Item.

7.2.1 Provide all labor, rigging and materials to disconnect and remove the pump from vessel and transport to contractor overhaul facility.

7.3 Accomplish all work specified in Enclosure 2.2.1 (Section A, B & D) using Reference 2.1.1-2.1.X as guidance.

7.4 Pump Casing exterior, interior and all other components are to be “Grit blasted to near white metal”, SSPC-SP-10. Protect all machined and treaded surfaces during blasting operations. Pump foundation aboard vessel shall be “Power tool cleaned,” SSPC-SP-3, excluding the mating surface of foundation to Pump Feet.

7.4.1 Prime and paint exterior of each pump and pump foundation in accordance with MSC Paint Scheme detailed in Paragraph 3.3.

7.4.2 After blasting casing IAW Enclosure 2.2.1 Section B, apply in an approved manner over the entire interior of the casing, Enecon® METALCLAD CeramAlloy™ CL+ on the Interior of all Salt Water Pumps. Use caution to protect machined surfaces during blasting and Enecon application.

7.5 Build-up and machine to original dimensions the O-ring sealing areas on pump shaft in the areas of the shaft sleeves, seals and rings as necessary.

7.5.1 Weld Build up/tungsten flame spray shaft and machine to manufactures dimensions.

7.6 Bore and bush bearing housings as necessary to the original dimensions.

7.7 Install new brass name tags for each bearing housing noting the bearing type.

7.8 Submit two (2) copies of a written report of the conditions found, along with any additional recommended repairs or parts required, to the Port Engineer within 24 hours of the visual inspections.

7.9 Upon completion of overhaul, conduct a hydrostatic test of pump in the presence of the Chief Engineer and MSCREP. Hydrostatic pressure shall be no more than 45 psi for a period of five (5) minutes.

7.9.1 After successful hydro, provide all labor, rigging and materials to transport pump from the overhaul facility back to the vessel to reinstall in parent location detailed in Paragraph 3.1 in accordance with Reference 2.1.1.

7.10 Conduct an operational test of the pump in conjunction with ship's force for a minimum of four (4) hours. Take and record output pressures and bearing temperatures every 30 minutes under normal load. Adjust all controls and prove new and disturbed joints are free of leaks to the Port Engineer and the Chief Engineer.

8.0 GENERAL REQUIREMENTS: None Additional

Enclosure 2.2.1 (Pages:4)

Military Sealift Fleet Support Command (MSFSC)

Standard Work Item for Repetitive Repair Requirements

Item No. 31

22 March 2010

MOTOR DRIVEN PUMP OVERHAULS

1. ABSTRACT

This standard item provides requirements for the overhaul of motor driven pumps. This item includes UNIVERSAL REQUIREMENTS, which apply to all work covered in this standard work item and menu-type COMPONENT REQUIREMENTS that detail the work required for specific types of motor driven pumps. This standard item will be incorporated into a MSFSC vessel work package by reference.

2. References:

Note: Reference documents include a mix of public and private information. To the maximum extent possible, all reference information is included in the reference folder which is provided with the MSFSC Standard Work Item package. Private documents, such as SOLAS, ASME or SSPC, are not provided but are considered to be common ship repair industry documents which are available through subscription to the publishing organizations.

S6226-JX-MMA-010, Instruction Manual for the Indicator Reverse Method of Pump Shaft Alignment

3. ITEM LOCATION/DESCRIPTION

Locations are as specified in the base item.

4. GOVERNMENT FURNISHED MATERIAL/ EQUIPMENT/ SERVICE: None

5. Notes: None

6. QUALITY ASSURANCE REQUIREMENTS: None

7. STATEMENT OF WORK REQUIRED

A. Universal Requirements

For the pumps designated in the base work item, drain and disconnect pump from piping, motor and foundation. Clean and retain for reinstallation all removed bolting, gauge lines, fittings, etc., in way of removals. Blank all open ended piping with blind flanges, screw caps or plugs as appropriate. Cardboard or sheet metal blanks or wooden plugs shall not be permitted. Remove existing coupling. Transport pump to repair facility. Report to the MSCREP any pipe misalignment and deteriorated or defective foundations.

All replacement parts shall be OEM (original equipment manufacturer's) factory parts. Where factory parts are unavailable, the contractor may fabricate new parts with the approval of the MSCREP. Documentation showing unavailability of OEM parts shall be provided as justification for manufacturing replacement parts.

Prior to installing pump, pump foundation shall be machine scaled and painted with two (2) coats of primer and one (1) finish coat to match existing color scheme. Transport pump to ship. Remove blanks and reconnect piping without transmitting piping strains to pump. Use new gaskets and fasteners. Align and connect pump to drive unit in accordance with manufacturer's requirements. Shaft/coupling alignment shall be accomplished per the guidance provided in the reference document S6226-JX-MMA-010. Fasten pump/motor units to foundation using new fasteners. Examine foundation mounts and if soft foot conditions are found, follow the recommendations provided in the reference document S6226-JX-MMA-010, Section 2-2. Contractor shall be responsible to stone pads, add shims, reposition mounts as necessary to verify solid contact.

Rotate pump by hand and verify freedom of rotation.

B. Centrifugal Pumps

Completely disassemble pump. Bead blast and thoroughly clean the interior and exterior of casings. Protect machined surfaces. Inspect the casings and pump components for wear and defects in the presence of the MSCREP. Provide a condition report to the MSCREP detailing conditions found and recommendations. If interior erosion is found, contractor shall coat pump casing interior surfaces with contractor furnished epoxy ceramic coating. Exterior surfaces of the pump casing shall be coated with GFM epoxy coatings.

Build up worn and eroded areas of pump casing by welding with parent metal and machine to original configuration. Epoxy ceramic coating material applied in an approved manner may be used for low stress areas when authorized by the MSCREP. This material shall not be permitted for potable water or nuclear rated (T-AS vessel) pumps. Inspect pump shaft for distortion, defects, deterioration and conformance to manufacturer's specifications. Straighten shaft to within manufacturer’s provided tolerance. Correct minor irregularities on running surfaces by polishing.

Replace with new all bearings, wearing rings, shaft sleeves, couplings, keys, locks, and nuts to restore the pump to the original design condition. Reassemble pump using new gaskets, packing, seals and grease fittings. If the base work item indicates that mechanical seals are in place on a particular pump, the contractor shall furnish and install a new mechanical seal, of like configuration and service parameters. Hand dress mating and sealing surfaces to remove raised metal. All clearances and tolerances shall be within manufacturer's specifications. Notify the ABS surveyor and the MSCREP for inspection four (4) hours prior to closing of the pump. Dynamically balance the rotating assembly to manufacturer’s specifications in the presence of the MSCREP. Record and provide a written report of "as released" clearances.

Reinstall pump, ensuring proper alignment to both the motor coupling and piping attachments per the guidance provided in the reference document S6226-JX-MMA-010 and operationally test during dock trials to verify proper operation. Ensure unit is properly lubricated before operation. Accomplish a Hot Alignment Check per the guidance provided in the reference document S6226-JX-MMA-010, Section 1-6.

C. Reciprocating Pumps

Disassemble/reassemble pump using following general guidance. Actual procedures shall be those specified in the equipment technical manual.

Disassemble, clean, inspect and reassemble plunger assemblies: remove plunger stuffing box(es) from the fluid cylinder assemblies. Remove plungers. Remove existing stuffing box packing. Clean stuffing box bore and junk rings. Inspect all parts for excessive wear or damage. Clean stuffing box(es) with emory cloth. Clean plungers with steel wool. Provide and install new stuffing box packing. Reassemble using new pins, springs, o-rings, seals and gaskets.

Disassemble, clean, inspect and reassemble the fluid cylinder: Disassemble the fluid cylinder assembly. Remove existing disc valves and seats. Provide and install new disc vales (suction and discharge) and seats. Where reed valves are installed, these shall also be renewed. Replace any missing or damaged dowel pins. Reassemble using new o-rings, seals and gaskets.

Disassemble, clean, inspect and reassemble the pump power end: Remove the plungers and plunger rods. Remove plunger rod seal housings. Inspect plunger rods for damage. Reassemble with new plunger rod o-rings and new seal housing seals. Renew any additional o-rings, seals and gaskets. Remove back cover and back cover gasket from the power frame. Remove the connecting rod end caps. Slide the rod bearing halves from each connecting rod. Clean and inspect the bearing halves for wear and damage. Clean and inspect the crankshaft journals. Clean the sump area of the power frame. Provide and install new connecting rod bearings. Reassemble with new pins, o-rings, seals and gaskets. Refill pump power frame with proper amount of lubricating oil.

D. Rotary Pumps (gear type, vane type, screw, sliding shoe, multiple piston) Disassemble/reassemble pump using following general guidance. Actual procedures shall be those specified in the equipment technical manual.

Disassemble, clean, inspect and reassemble fluid head: remove, clean and inspect cover o-ring, pump seals and rotor nut assembly. Replace cover, rotor nut and rotor hub keys, washers and o-rings upon reassembly. Replace mechanical seal rotating seal seats, shaft o-rings, stop pins and wave springs.

Disassemble, clean, inspect and reassemble gear case: remove gear case oil drain plug. Reinstall for reassembly. Remove gear case cover. Renew cover oil seal upon reassembly. Remove bearing retainers. Press shafts out of gear case for those pumps where shaft removal is recommended in the manufacturer’s tech manual. Inspect pump shaft for distortion, defects, deterioration and conformance to manufacturer's specifications. Straighten shaft to manufacturer’s specifications. Upon reinstallation use new OEM recommended shims to attain proper backface clearance. Remove gear spacers, keys and gears. Inspect gears for wear. Renew keys upon reassembly. Remove front bearing seals. Renew bearing seals upon reassembly. Remove shims and retain for reinstallation. Remove rear oil seals. Renew upon reassembly. Remove bearings. Renew upon reassembly.

Reassemble gear case components with new parts as specified above. In addition, contractor shall provide and renew all additional keys, pins, nuts, lockwashers, lock tabs, o-rings, seals and gaskets not otherwise mentioned. Upon reassembly turn pump by hand to demonstrate proper reassembly. Record and provide a written report of "as released" clearances.

8.0 General Requirements: None

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