SOW_Markey_Winch_Overhaul.pdf

Title: Repairs to CTD Winch

1. SCOPE:

1.1 Objective: Open, inspect, and overhaul the CTD winch. The winch is a MARKEY Type DESH-

5 serial # 16332-1.

2. REFERENCE DOCUMENTS:

2.1 Technical Manual DS-575-01, MARKEY Type DESH-5 CTD Research Winch

2.2 Steel Structures Painting Council, Surface Preparation Specification No. 10, Near White Blast

Cleaning (SPCC-10).

2.3 NOAA Standard Specification S6300-1, Inspection and Repair of Electric Motors

2.4 NOAA Standard Item S6900; General Requirements for Electrical/Electronic Items

3. GOVERNMENT FURNISHED MATERIAL (GFM):

3.1 One Markey DESH-5 CTD Winch Model # 16332-1

4. GENERAL REQUIREMENTS:

4.1 The contractor shall perform all work in accordance with the requirements of the documents cited in paragraph 2 above.

4.1.1 Winch overhaul shall be performed by or under the direct supervision of the original equipment manufacturer (OEM). The OEM for the brailing winches is:

Markey Machinery Corporation

7266 8th Avenue South, Seattle, WA 98108

PH (206) 622-4697

4.1.2 Accomplish an operational test of the winch to identify any additional repair items.

Submit a written report to the COR detailing additional work.

4.2 Disassemble the winch entirely and provide a comprehensive material inspection of all components of the winch in accordance with reference 2.1, 2.3 and 2.4.

4.2.1 Remove and dispose of all oil from the gear housings. Open and wipe down chain housing.

4.2.2 Chemically and mechanically clean each part free from contamination without causing harm or deterioration. Inspect all parts for damage or wear using references 2.1, 2.3, 2.4 and

2.6 for guidance. Submit a written report to the COR detailing what additional parts/components are required as a result of the inspection.

4.2.3 Handwork each machined sealing, aligning, mating, and gasket surface. Ensure no excessive material is removed causing loss of critical size or alignment.

4.3 Rebuild winch with new bearings, bushings, seals, chains, fasteners and any other mechanical and electrical components and parts identified for repair in 4.1.2 and 4.2

Refurbish brake bands and shims. Paint the winch interior/exterior following the schedule in item 4.6

4.4 Disassemble the motor entirely and provide a comprehensive material inspection of all components of the motor in accordance with reference 2.1, 2.3 and 2.4. Complete the following repairs:

4.4.1 Meggar the windings. Wash, dip and bake the coils.

4.5 Reassemble the electric motor with a new Stearns encoder brake, new motor seals and bearings. Paint the motor interior/exterior following the schedule in item 4.6

4.6 Sandblasting & Painting - Accomplish the requirement of 2.2 and abrasive blast-clean the exterior winch body/components, motor, and interior body/motor painted surfaces.

4.6.1 After sand blasting, apply the following coating system to the exterior winch body:

• Primer: Apply one (1) full coat zinc rich epoxy conforming to MIL-P-24441 Formula 159, INTERNATIONAL INTERZINC 52 or equal,, to the exterior surfaces of the area prepared in 4.4, in accordance with the manufacturer's recommended procedures to a DFT of 2-2 ½ mils.

• Apply one coat of a high build, high solids, low temperature curing, recoatable epoxy build coat (color as selected), INTERNATIONAL INTERTUF 262 or equal, to the exterior surfaces of the area prepared in 4.4 in accordance with the manufacturers recommended procedures to a DFT of 5-6 mils. Measure and record the DFT of the coating system in 5 random locations.

***** CHECKPOINT *****

• Apply one coat of a high build, high solids, low temperature curing, recoatable epoxy build coat (black), INTERNATIONAL INTERTUF 262 or equal, to the exterior surfaces of the area prepared in 4.5, in accordance with the manufacturers recommended procedures to a DFT of 5-6 mils.

• Apply one coat of high solids enamel conforming to MIL-E-24635 (black), INTERNATIONAL INTERLAC 665 or equal, to the exterior surfaces of the area prepared in 4.5, in accordance with the manufacturers recommended procedures to a DFT of 1.5-2 mils. The first coat of enamel shall be applied while the last coat of epoxy is still soft.

4.6.2 Where applicable after sand blasting, apply the following coating system to the winch interior.

• Apply one coat of Zinc Rich Epoxy Primer conforming to MIL-P-24441 Formula 159, INTERNATIONAL INTERZINC 52 or equal, to the interior surfaces of the area prepared in 4.5, in accordance with the manufacturer's recommended procedures to a DFT of 2-2 ½ mils.

• Apply one coat of INTERNATIONAL INTERGARD 264 (WHITE) or equal, to the interior surfaces of the area prepared in 4.5, in accordance with the manufacturer's recommended procedures to a DFT of 5-6 mils.

4.7 Fill the winch gear case with approximately 60 gallons of ISO 150 synthetic EP gear oil Mobil “Mobilgear” SCH-150, # 61078-2 or equal. Lubricate all grease fittings and level-wind in accordance with reference 2.2 with Mobil “Mobilith” SCH 460 #64355-1 or equal.

Lubricate the chain drives with SAE 30 motor oil.

4.8 Winch Testing – Perform a no load shop test of the rebuilt winch to prove satisfactory performance in accordance with reference 2.2. The COR shall be present during the test.

4.9 Touch-up Painting - clean all damaged paint to sound paint or bare metal. Clean all exposed metal free of foreign matter and corrosion. Spot prime all damaged paint or exposed metal. Coat all new or damaged areas with 2 coats of finish paint to match the surrounding area. Epoxy paint must be used over galvanized metal

5. QUALITY ASSURANCE:

5.1 Submit a written report of the results of the testing required by 4.8. The report shall contain the date, time results and names of witnesses. Submit reports for item 4.6.

Reports shall include millage readings taken at 20 locations for each coat of paint.

6. NOTES:

6.1 None