SOW - Stbd Layshaft Alignment 2020.pdf

SCOPE OF WORK

STARBOARD LAYSHAFT ALIGNMENT

PR&C 0111-4261

REFERENCE DRAWINGS

MF-M8-l (47537); Arrangement of Drag Winches MF-M8-3 (47538); Sectional Arrangement through Drum Shafts & Layshaft MF-M8-6 (47541); Arrangement of Brake & Clutch Controls

MF-M8-9 (47544); Ball Joint Drums MF-M8-10 (47545); Shafts and Couplings MF-M8-11 (47546); Gears & Pinions MF-M8-12 (47547); Bearings for Drag Winches MF-M8-13 (47548); Fulcrum Wheels, Etc.

MF-M8-14 (47549); Clutch Bands MF-M8-15 (47550); Brake Bands MF-M8-16 (47551); Detail of Brake and Clutch Controls MF-M8-24 (47559); Arrangement of High Speed Clutch

INTENT

The intent of this scope of work is to install two layshaft bearings on the stbd draghead layshaft, and align the starboard side layshaft bearings, layshaft, drum bearings and drum shafts.

HISTORY

The starboard and port layshafts and drum shafts were aligned using a laser alignment procedure. The starboard final alignment report from 06 March 2020 is attached. The port final alignment report from 05 February 2020 is attached. However, during testing, two bearings wiped on 11 March and another two on 14 April.

HEALTH

The contractor shall provide all necessary PPE to the personnel working on the McFARLAND. All contractor employees are required to wear face masks at all times while working on the vessel. All contractor employees shall be required to have their temperatures taken prior to being allowed onboard the vessel.

Any contractor employee who has symptoms of COVID-19 or has a temperature of 100F or above will not be allowed on the vessel. Other than being required to operate equipment, the crew will be isolated from the contractor during the performance of this work.

Due to COVID-19 concerns, the use of vessel tools and equipment to perform any work listed herein is prohibited.

SAFETY

Coordinate with the crew and the COR, and ensure the electrical systems and hydraulic systems are disconnected, secured, and tagged-out.

There are multiple hydraulic piping lines and hydraulic valves that run either along the deck, winch foundations, and the bulkheads. Extreme care and caution shall be taken not to damage the hydraulic piping.

Clean and gas-free for Hot Work, both forward and aft, starboard and port, winch rooms.

Provide a marine chemist gas-free certificate prior to any hot work.

Any rotation of the winch equipment will be done by the crew, and coordinated with the

COR.

GOVERNMENT FURNISHED MATERIAL

Layshaft bearings (47547–A); Qty: 2 each. Finished weight 300#; 6.505” ID Drum pawl, pin, and spring; Qty: 1 each.

SCOPE OF WORK

The contractor shall provide all necessary labor, material, services (including rigging), parts, tools, material and equipment to perform and complete the work in accordance with the following specifications. The Government will provide forklift and crane service as required.

The starboard winches are located on the starboard side, in the upper levels of the voids, outboard of the hopper. The dragarm winch extends from approximately Frame 49 to Frame 87 (approximately 75 feet), and contains equipment servicing the trunnion elbow, ball joint, and draghead.

Starboard Alignment

The Contractor will rig the two GFM bearings into the stbd aft winch room. Install the bearings with existing liner and chocks.

Using laser alignment, verify the alignment of the entire starboard layshaft (from trunnion to draghead), and the three drum shafts, using the attached alignment report from 06 March as reference. Verify the parallel and angular alignment of layshaft to drum shafts (both vertically and horizontally). This procedure may require the removal of existing bearings caps.

To perform the laser alignment, cut a “window” in the watertight bulkhead between the forward and aft winch rooms. Upon completion of all work, re-weld the “window” and perform a “soap and blow” test to verify watertight integrity.

For any bearing cap that is removed or exposed, wing clearance readings shall be taken upon removal and again prior to reinstallation of the bearing cap. Provide a report of readings.

Align the trunnion, ball joint, and draghead layshaft bearings, and drum bearings to be no less than 0.005” (max 0.009”) clearance to the shafts. Bearing alignment shall be such that the shafts rest at the bottom of the bearing, and all clearance is at the top of the bearing. The contractor will verify clearance using feeler gages or crush readings to ensure clearance at the top.

All bearings needing alignment will be done with Contractor provide stainless steel shims. Existing tack welds from chocks of bearings needing alignment will need to be removed and re-welded.

Align the layshaft from the trunnion winch to the draghead winch, including the gearbox and motor. Align the three drum shafts to the layshaft, maintaining the parallel and angular alignment of layshaft to drum shafts (both vertically and horizontally). The horizontal parallel distance between the layshaft and the drum shaft centerline s is 44.666”.

Clean and degrease the pinion and bull gears on all winches, and blue-hit the gears to determine contact area. Align the drum shafts and gear to the pinion gear to achieve maximum gear efficiency (95% is optimal).

Final torque of the bearing foundation bolts shall be 800 ft-lbs. Final torque of the bearing cap bolts shall be 400 ft-lbs. Install the bearing caps with the existing liners and laminated shims (P/N 47547-E and F). To prevent wiping the grease during rotation, the bearing shims and liners shall be installed away from the centerline of the bearing during installation.

On the three winches, adjust both brake band and clutch band Set Screws to allow 1/8” clearance when disengaged. The crew will engage and disengage the brake and clutch as necessary to perform this task.

Adjust the reinstalled items. While the crew is performing an intermediate operational test and monitoring bearing temperatures, make running adjustments to the brake and clutch bands required for proper operation. This intermediate operational test may run for up to two hours and during this time, the crew will also freewheel and clutch in the winches while monitoring bearing temperatures.

Once aligned and intermediate testing is complete, tack weld in two locations, the wedge chocks at any affected bearings. Install shim to achieve contact between the welded chock, the existing chock, and the bearing base.

After intermediate testing and prior to final operational testing, the crew will require a full day to reeve dragarm wires on the ball joint winch and draghead winch. The contractor will allow a day for the crew to reeve the wires. While the crew is performing the final operational test of raising and lowering the dragarm while pierside and monitoring bearing temperatures, make running adjustments to the brake and clutch bands required for proper operation.

Starboard Ball Joint Winch

Install the sectional gear guard on the ball joint winch.

Starboard Draghead Winch

Install both low speed and high speed clutch sleeve collars. Install clutch linkages, and make 1/8” adjustment as shown on Drawing MF-M8-24 (47559). After 1/8” adjustment, adjust Set Screws to make contact with links to prevent further movement.

On low speed clutch, weld slotted extension brackets to extend the clutch lever over the clutch sleeve collar pins. See existing installation on port ball joint, but final design shall be coordinated with the COR.

Connect the gearbox coupling flange to the draghead layshaft using new Contractor provided gasket and existing hardware.

Install the brake band and brake band spring angle support and spring. Adjust as necessary during installation and final adjustments.

Install the clutch guard, coupling guards on the layshaft, and sectional gear guards on the winch gears. Weld the support angle from the high speed clutch sectional gear guard to the overhead fleeting sheave side plate.

Install the overhead ductwork in the stbd aft winch room. Ductwork shall not rest on gear guards. This ductwork is already removed and resting on the deck.

Install the drum pawl, pin and spring on the draghead drum.

Winch Rooms

Install a handrail support bracket for the coupling guard in the stbd aft winch room, and attach the coupling guard to the new support bracket. See existing port aft handrail coupling guard for templating.

In the port and starboard winch rooms, cut the overhang of the stainless steel shims

(existing or new shims) on all three winches, pedestal mounted bearings, both gearboxes, and both motors, to prevent accidental injuries due to sharp edges.

In the port and starboard winch rooms, verify torque values on existing bearing cap or foundation bolts, 20 per side (40 total), to be selected randomly by the COR. Contractor’s equipment for this verification shall be rated for up to 1000 ft-lbs.

Clean both starboard winch room decks, winch foundations, and machinery, of all debris, grease and dirt. For the starboard winch rooms, wipe and clean with degreaser all the winch room bulkhead sheathing from the doghouse entrance to the far end of the winch room.

Prepare and paint all disturbed areas with gray paint to match surroundings.

Port Alignment Verification

Using laser alignment, verify the alignment of the entire port layshaft (from trunnion to draghead), and the three drum shafts, using the attached alignment report from 05 Feb 2020 as reference. Verify the parallel and angular alignment of layshaft to drum shafts (both vertically and horizontally). This procedure may require the removal of existing bearings caps.

To perform the laser alignment verification, cut a “window” in the watertight bulkhead between the forward and aft winch rooms. Upon completion of the alignment verification, re-weld the “window” and perform a “soap and blow” test to verify watertight integrity.

For any bearing cap that is removed or exposed, wing clearance readings shall be taken upon removal and again prior to reinstallation of the bearing cap. Provide a report of readings.

PERIOD OF PERFORMANCE

The contract work is expected to begin on/about 07 May 2020. All work listed above shall be completed within 14 calendar days after award of contract, unless extended by a Contract Modification.

SITE VISIT

A vessel site visit for interested contractors is scheduled for 01May 2020, at 1000 hrs at Fort Mifflin Project Office.

PLACE OF PERFORMANCE

All work shall be performed at:

Department of the Army U.S. Army Corps of Engineers, Philadelphia Fort Mifflin Project Office 6400 Hog Island Road Philadelphia, PA. 19153

BIDDING

The Contractor shall submit one quote, with two separate line items for the work listed above, with the breakdown as follows:

Line Item #1: All work for Starboard Alignment, Starboard Ball Joint Winch, Starboard Draghead Winch, and Winch Rooms

QTY UNIT AMOUNT

1 Job $________________

Line Item #2: All work for Port Alignment Verification

QTY UNIT AMOUNT

1 Job $________________

NET AMOUNT: $_________________________

(Sum of Line Items #1 and #2)