SOW_PROSERVE_CRANE_TECHNICIAN_REV_A.docx

USNS PECOS

T-AO 197

PROVIDE PROSERV BRIDGE CRANE TECHNICIAN AND REPAIR PARTS

1.0 ABSTRACT

1.1 The intent of this work item is to provide an OEM crane technician to supervise the overhaul the main engine bridge cranes and recertify same. Also, to provide the repair parts listed in para. 4.2.

2.0 REFERENCES/ENCLOSURES

2.1 References

2.1.1 Manufacturer’s Instruction Manual No. TG812-AB-MMC-010; Engine Room Bridge Crane.

2.2 Enclosures: None

3.0 ITEM LOCATION/QUANTITY/DESCRIPTION

3.1 Location: Kingdome of Bahrain (visa can be obtained on line)

3.2 Period of Performance: 3/29 -04/15/2016

3.3 Quantity

3.3.1 Two (2) each Bridge Crane, Port and Stbd Main Engine Bridge Crane

3.4 Description: Anchor Crane and Hoist Co. R&M D325F22T, 156566UFI, 5 Ton

4.0 GOVERNMENT/CONTRACTOR FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Government Furnished Services:

4.1.1 The government will provide mechanics and machine shop services to assist the crane technician.

4.2 Contractor OEM Furnished Material:

ELECTRICAL PARTS

8945 WIRE HOIST ROPE-3/8" 6X37-EIPS-IWRC 130FT

5.0 NOTES

5.1 Cordon off and post appropriate warning signs for local work areas during active testing operations.

6.0 QUALITY ASSURANCE REQUIRED: None Additional

7.0 STATEMENT OF WORK REQUIRED

7.1 Provide an OEM crane technician to supervise the reconditioning of three (3) each per crane, motor/brake assemblies in accordance with Enclosure 2.2.1, section A & B.

7.1.1 Prior to starting any work “Lock out/Tag out” Crane Hoist/Trolley/Bridge motor. In conjunction with Ship’s Force, ensure all pertinent systems and Circuit Breakers are isolated, secured, locked out or tagged-out.

7.1.2 Disconnect and remove motor from vessel, transport to shop.

7.2 Disassemble motor/brake assembly and overhaul each in accordance with Enclosure 2.1.1, section A&B.

7.2.1 Layout all motor components for checkpoint inspection in the presence of the MSCREP and Chief Electrician.

7.2.1.1 Submit Condition Report to MSCREP detailing initial condition of motor and any recommended repairs.

7.2.2 Local facilities will bake motor windings and rotor to remove all moisture. The windings then shall be impregnated with Class “F” or “FE” insulating varnish and baked in accordance with IEEE Standard 45.

7.2.3 In addition to work detailed in Paragraph 2.2.1 technician is to supervise the following:

7.2.3.1 Weld buildup/tungsten flame spray worn shaft areas and machine to manufacturer’s design criteria detailed in Reference 2.1.1

7.2.3.2 Bore and bush drive and non-drive end bell bearing bores to manufacturer's design criteria.

7.2.4 Motor/Brake casing exterior, pecker head, end bells 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. Motor foundation aboard vessel shall be “Power tool cleaned,” SSPC-SP-3, excluding the mating surface of foundation to Motor Feet.

7.2.4.1 Prime and paint in accordance with MSC Paint Scheme or as original.

7.2.5 Conduct a dynamic balance of the rotor assembly in the presence of the MSCREP, Chief Electrician and ABS. Assembly shall be within specifications detailed in Enclosure 2.2.1.

7.2.6 Technician to supervise the reassembly of each motor/brake assembly using GFM outlined in Paragraph 4.1 and conduct a shop test in the presence of the MSCREP. During this time amp, voltage across phases, RPM, vibration and temperature readings are to be recorded in five (5) minute interval for a period of fifteen (15) minutes.

7.2.6.1 After successful shop test convey motor from contractors overhaul facility shop to vessel and install in parent location.

7.2.7 Conduct an operational under normal conditions for a period of one (1) hour in the presence of the MSCREP. During this time amp, voltage across phases, RPM, vibration and temperature readings are to be recorded in fifteen (15) minute interval.

7.3 With the assistance of ship’s force ensure that all pertinent electrical systems and circuit breakers have been properly secured and “Tagged Out” IAW MSC procedures before commencing with this work item.

7.4 Technician shall supervise the removal the Wire Rope, Lower Block and Hook Assembly, Bridge Reducer, Trolley Reducer, and hoist electric brake using Reference 2.1.1 as guidance.

7.4.1 Technician shall supervise the overhaul of all components in local shop.

7.4.2 Disassemble all pieces of equipment and clean using Manufactures’ approve cleaning solvents.

7.4.3 Submit in a condition report to MSCREP detailing any discrepancies and recommend repairs.

7.5 Reassemble all components using GFM detailed in Paragraph 4.1. Transport from shop to ship and install in their parent location.

7.6 Conduct a visual inspection and operational test of the Stbd Bridge Crane described in Paragraph 3.2.1.

7.6.1 Remove parts as necessary to reinstall GFM parts listed in Paragraph 4.1.

7.6.2 Adjust, set and test all safety shutdown mechanisms and limit switches.

7.6.3 Clean and re-grease all lubrication points as described in Reference 2.1.1 & Enclosure 2.2.1.

7.6.4 Technician shall supervise installation of wire rope.

7.6.5 Conduct a 150% capacity Weight Test of the Crane in the presence of Chief Engineer, MSCREP and the Local ABS Surveyor.

7.6.6 Provide crane recertification certificate, dated and signed by the OEM crane technician.

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. 19 22 March 2010

MOTOR AND VENTILATION FAN REPAIRS

1. ABSTRACT

This standard item provides requirements for repairs to motors and ventilation fans. 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 motors and vent fans. This standard item will be incorporated into a MSFSC vessel work package by reference, and the base item in the work package will indicate which menu-type COMPONENT items are to be accomplished.

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.

IEEE Std 45-2002, Recommended Practice for Electrical Installations on Ships

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:

Contractors and/or subcontractors used to accomplish ventilation cleaning requirements as specified in this standard work item shall be certified under the auspices of reference 2.1.

7. STATEMENT OF WORK REQUIRED

A. Universal Requirements

In conjunction with ship’s force, electrically tag out motors and vent fans as designated in the base work item. Disconnect units and rig from the ship to the shop.

Upon completion of all repairs and satisfactory inspection by the MSCREP, convey the units back to the ship and reinstall. Motor alignments shall be in accordance with the equipment tech manual.

Perform the following electrical tests (AC Service) and record results:

Motors rated not more than 250v or 0.5 hp 900 900 except those listed below

Bracket fan motors 600

Motors rated not more than 35v 500 500

Direct Current Hi-Pot Test:

Et = 1.6(2E + 1000)

Locked Rotor Test.

Perform the following electrical tests (DC Service) and record results:

Motors rated not more than 250v or 0.5 hp 900 900 except those listed below

Bracket fan motors 600 600

Motors rated not more than 35v 500 500

Direct Current Hi-Pot Test:

Et = 1.6(2E + 1000)

Bar to Bar Test.

All surfaces of the fan and fan housing or motor frame exterior shall be grit blasted to bare metal. Apply one (1) coat primer and one (1) finish coat to match surrounding areas for units located within the interior of the ship. Units exposed to weather deck areas shall receive two coats of primer and one finish coat.

Dynamically balance the rotor and the fan or motor as a unit. Final balance weight adjustments shall be made. The MSCREP shall witness final balancing. Final unbalance shall not exceed the manufacturer's specifications for a new unit or, in the absence of this, value determined by:

a) For speeds in excess of 1000 RPM;

b) For speeds between 150 and 1000 RPM:

c) For speed below 150 RPM:

Unbalance (ounce inches) = 0.177 x wt of rotor & fan (lbs.)

Dress all bearing housings to accept new bearings.

Install new bearings and grease seals as original and lubricate. Renew internal leads and connections as required. Completely reassemble the motor. Renew assembly hardware and gaskets on covers, inspection plates, and between the external connection box and frame.

Perform the following shop test and prove all work satisfactory to the MSCREP: Perform a 500 volt megger insulation and continuity test on all windings. Record results. Measure and record air gaps. Inspect shaft for freedom of rotation. Turn by hand at least three turns. Measure resistance value of each winding temperature detector using a low voltage ohmmeter. Test equipment at operating speed(s) for a minimum of 15 minutes. Measure and record voltage and current.

Test under actual operating conditions for minimum of one hour after temperatures stabilize. Record current, voltage, speed and frame and bearing temperature rise at 15 minute intervals. Clean, prime and paint all new and disturbed areas to match the surroundings.

: None

B. Recondition Squirrel Cage (AC Service) Motors and Vent Fans

Completely disassemble the motor or fan, thoroughly clean and examine all parts. Protect machined surfaces. Inspect the armature for defective bars.

Inspect and dimensionally measure end bells, frame, shaft, sleeve, bearings, keyways, and running surfaces for wear, eccentricity, and other defects. Record as found readings.

Additional repairs deemed necessary by the MSCREP shall be the subject of a change order.

Bake windings and rotor to remove all moisture. The windings shall then be impregnated with Class F insulating varnish and baked IAW latest IEEE STD 45 regulations.

603-2