31298300 SPECS.pdf

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1.0 INTRODUCTION

I.I PURPOSE

This document establishes the performance, design, development, and test requirements for the HMB 90 Motor.

1.2 SCOPE

The vendor shall provide the resources necessary to design, manufacture, test, deliver, and support the subject hydraulic motor in accordance with this document.

2.0 APPLICABLE DOCUMENTS

2.1 GOVERNMENT DOCUMENTS

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The following documents of the issue in effect on the date specified in SEA WOLF Appendix B form a part of the requirements to the extent specified herein. Copies of listed federal and military standards, specifications, and handbooks are available through the DOD Single Stock Point, Commanding Officer U.S. Naval Publications and Forms Center (Attn: NPFC 1032), 5801 Tabor Avenue, Philadelphia, PA 19120.

Specifications:

MIL-F-24704

MIL-H-6083

MIL-I-24137

MIL-L-17672

MIL-M-24784

MIL-P-15024

MIL-P-16789

MIL-P-17869

MIL-S-704-2

MIL-S-901

MIL-S-8660

MIL-T-24388

QQ-C-320

VV-P-236

Flanges, Four Bolt Square, Hydraulic, General Specification for

Hydraulic Fluid, Petroleum Base, for Preservation and Operation

Iron Castings, Nodular Graphitic and Nodular Graphitic

Hydraulic Fluid, Petroleum, Inhibited

Manuals, Technical; General Acquisition and Development Requirements

Plates, Tags, and Bands for Identification of Equipment, General Specification for

Pumps; Packaging of

Pumps and Motors, Power, Oil Hydraulic

Structurebome Vibratory Acceleration Measurements and Acceptance Criteria of Shipboard Equipment

Shock Tests, H.J. Shipboard Machinery, Equipment, and Systems, Requirements for

Silicone Compound, NATO Code Number S-736

Thermocouple and Resistance Temperature Detector Assemblies, General Specification for

Chromium Plating

Petrolatum, Technical

4/02/01 r

Standards:

DOD-D-1000

MIL-STD-167-1

MIL-STD-271

MIL-STD-278

MIL-STD-438

Handbook

MIL-HDBK-695

SEA WOLF Appendix B

2.2 REFERENCES

Drawings, Engineering and Associated Lists

Mechanical Vibrations of Shipboard Equipment Requirements for Nondestructive Testing Methods

Welding and Casting Standard

Schedule of Piping, Valves, Fittings and Associated Piping Components for Submarine Service

Rubber Products: Recommended Shelf Life Technical Requirements for Design and Construction

a. MacTaggart Scott Interface Control Drawing P05773701, Winch Motor Interface Control Drawing, Version 3, dated September 23, 2000

b. EB Comments to MTS !CD P05773701, dated November 14, 2000.

c. EB Comments to MTS !CD P05773701, dated November 16, 2000.

3.0 REQUIREMENTS

3.1 ENVIRONMENT

3. I.I Mounting: The motor mounting shall be capable of carrying the weight of the motor and the fasteners sized to withstand shock loading described in paragraph 3 .1.3.

3.1.2 Ambient: The motor shall operate over an ambient temperature range of +28° F to +85° F (submerged, rated performance) and 0° F to 150° F (in air, short-term maintenance).

3.1.3 Shock: The motor shall be capable of passing a Wetted-Surface Hi-Shock Test in accordance with MIL-S-901 for Grade B equipment. The motor shall meet Grade B requirements while subjected to 51 "G" half-elastic shock input and motor hold-down fasteners shall be sized to meet full-elastic values (i.e., 102 "G"). If hardships exist in meeting full-elastic inputs, the vendor shall address the hardships on a case by case basis with the buyer. There is a 9500 lbs. mass located mid-way along the shaft length, which shall be taken into consideration during shock. The motor shaft shall be designed to half-elastic input except in the threaded portion, which shall be designed for full elastic input. The vendor shall demonstrate conformance with the above requirements by either testing, extension from a similar motor, or analysis per their recommendation and subject to the buyers approval.

3.1.4 Vibration: The motor shall meet the vibration requirements of MIL-STD-167-1, Type 1, over a frequency range of 4 to 25 Hz.

3.1.5 Operational Environment: The motors are required to meet the following severe operational environment requirements:

a. Corrosion resistant materials and/or measures are necessary due to constant immersion in seawater.

b. Mechanical joints exposed to seawater shall have double seals with a leak-off piping connection between the two seals.

c. The motor shall be designed to withstand an external pressure of 1300 PSI.

3.2 PERFORMANCE

3.2.1 Operating Torque: The motor shall supply the following torques:

Minimum Operating Torque:

Static Breakaway Torque:

114,777 ft-lbs. with 2000 PSI at 0.54 RPM 129,124 ft-lbs. with 2250 PSI

3.2.2 Static Load: The motor shall be designed such that a maximum static shaft torque of 359,450 ft lbs., a uniformly distributed load of 9,500 lbs. over the entire length of the shaft, and an overhung load of 174,590 lbs. at the end of the shaft will not cause permanent deformation to any motor component.

3.2.3 Design Life: The motor shall be designed for a thirty-year life. Shaft seal design shall be designed to allow for replacement under restricted maintenance space. The shaft seal design shall be designed for a minimum of a ten-year life. The motor will be operated approximately 1250 revolutions per year at normal operating speed with approximately a third occurring with the external side of the shaft seal exposed to air and the remaining exposed to seawater. In addition the motor will be subjected to one emergency deployment per year where the motor will freewheel for ten seconds at 60 RPM.

3.2.4

3.2.5

Hydraulic Design Pressures:

a. Maximum System Pressure:

b. Maximum System Return Pressure

c. Hydrostatic Supply Port Test Pressure:

d. Hydrostatic Return Port Test Pressure:

e. Hydrostatic Brake Port Test Pressure:

f. Maximum Case Drain Pressure

g. Hydrostatic Case Drain Port Test Pressure

H:;tdraulic Com12onent Reguirements:

3000PSI

205 PSI

4500PSI

4500PSI

4500PSI

375 PSI

506 PSI

a. Hydraulic motors shall be in accordance with MIL-P-17869

b. Cast iron, except for nodular iron in accordance with MIL-I-24137, shall not be used in construction of motors or other hydraulic components unless otherwise approved by the purchaser.

c. Cadmium plating or zinc coating shall not be used in construction of the motors.

d. All chrome plating shall be in accordance with QQ-C-320.

e. Hydraulic service seals shall be in accordance with the requirements of Appendix B - SSN21CL, Technical Requirements for Design and Construction.

f. Silicone greases identified by MIL-S-8660 shall not be used in the assembly of hydraulic components. For difficult assemblies that require seals to be held in place by the lubricant, a light application of petroleum jelly conforming to VV-P-236 should be used.

3.2.5.1 Hydraulic Fluid: The motor shall operate with hydraulic fluid in accordance with MIL-L-17672 (Military Symbol 2075 TH).

3.2.5.2 Hydraulic Connections: Ports shall be designed to meet the requirements of paragraph 3.1.5. Ports shall be permanently marked and located in accordance with References (a), (b), and (c).

Hydraulic connections shall be in accordance with MIL-STD-438 external hydraulic piping requirements.

3.2.6 Acoustic Characteristics: The motor shall be designed such that the noise levels produced under normal operating conditions are minimized to available technology. The purchaser shall be notified of cost and schedule impacts due to acoustic designs of the motor.

3.2.7 Functional Improvements: The following considerations shall be implemented for improved performance:

a. Shall use a design with maximum number of pistons similar to previously designed motors to allow for better load distribution

3.3 DESIGN

3.3.1 General: Where requirements are not specified, design of the motor shall be in accordance with existing similar motor designs and submitted to the purchaser for approval.

3.3.2 Motor Configuration: The motor shall be a single displacement motor and designed with piston return springs to allow the winch motor to function as a hydraulic pump when back driven. The motor shall be capable of freewheeling at motor speed of 60 RPM with a case pressure of 75 PSI above Cl and C2 ports with a maximum drag of 650 to 1950 ft-lbs. In addition, during a casualty the motor shall be capable of freewheeling at a speed of 141 RPM with a case pressure of 190 PSI above Cl and C2 ports.

3.3.3 Output Shaft: See References (a), (b), and (c).

3.3.4 Integral Brake: The motor shall be equipped with a hydraulically controlled, oil-immersed, spring applied fail-safe internal brake which will apply full brake torque in the event of loss of hydraulic pressure. The brake shall have, after 40 drag cycles, a minimum static brake torque of 108,000 ft lbs, drag torque (dynamic brake torque) of 63,000 ft-lbs, and thermal capacity of 2,784,000 ft-lbs over a 10 seconds time period.

The brake shall be designed to function 40 drag brake cycles (minimum) without requiring maintenance. A drag brake cycle is a dynamic brake operation in which a constant dynamic braking torque of 63,000 ft-lbs is applied for seven revolutions of the motor shaft over a period of 10 seconds. The brake shall be designed to operate with a flow of 3.5 GPM. Note that the shipboard torque requirement is 48,000 ft-lbs.

Brake oil shall be in accordance with section 3.2.5.1 and shall be sealed within the brake unit to prevent contamination of the motor case oil. The brake shall be supplied with a temperature sensing device for monitoring oil temperature in accordance with MIL-T-24388. See References (a), (b), and (c) for mounting location of the temperature-sensing device. The fittings shall be of a receptacle type that will mate with a 5-contact plug. A pressure cap shall be provided to seal any extra receptacles.

3.3.5 Mounting Surface: See References (a), (b), and (c).

3.3.6 Weight Control: The motor shall not exceed 16,500-lbs. dry weight without approval from the purchaser. If weight grows beyond specified limit then the seller shall notify the purchaser immediately upon knowledge of this information. Wet weight shall include the weight of the oil, which is approximately 88.0 gallons.

3.3.7 Envelope: See References (a), (b), and (c).

3.3.8 Lifting and Handling: See References (a), (b), and (c).

3.3.9 Leakage: The motor shall have an internal leakage (supply/return port to case) over the life of the motor that does not exceed the flow loss in Figure 1. Motor leakage during freewheeling shall not exceed 1.0 GPM throughout the life of the motor.

3.4 CONSTRUCTION AND WORKMANSHIP

3.4.1 Materials: Materials, in general, shall be suitable for a marine atmosphere and compatible with the requirements of Appendix B - SSN21CL, Technical Requirements for Design and Construction.

3.4.2 Toxic Products and Formulations: Hazardous materials shall be restricted in use in accordance with the requirements of Appendix B - SSN21CL, Technical Requirements for Design and Construction.

3.4.3 Mercury: The use of mercury shall be restricted in use in accordance with the requirements of Appendix B - SSN21CL, Technical Requirements for Design and Construction.

3.4.4 Asbestos: The use of asbestos shall be restricted in use in accordance with the requirements of Appendix B - SSN21CL, Technical Requirements for Design and Construction.

3.4.5 Lubricants: Lubricants shall be selected in accordance with Appendix B- SSN21CL, Technical Requirements for Design and Construction.

3.4.6 Threaded Fasteners: All threaded fasteners external to the motor shall comply with Appendix B - SSN21CL, Technical Requirements for Design and Construction. Threads for fasteners external to the motor shall be unified national series.

3.4.7 Plating: Plating of fasteners shall comply with Appendix B - SSN21CL, Technical Requirements for Design and Construction and the applicable material specification.

3.4.8 Coatings: Coating shall comply with Appendix B - SSN21CL, Technical Requirements for Design and Construction and the applicable material specification.

3.4.9 Workmanship: Workmanship shall comply with Appendix B - SSN21CL, Technical Requirements for Design and Construction.

3.5 NAMEPLATES/PROCUCT MARKINGS

Identification plates shall be provided in accordance with MIL-P-15024. Identification plate material shall be suitable for withstanding their environmental conditions.

3.6 DOCUMENTATION

3.6.1 Drawings:

-1

16.00 14.00 ij: 12.00 "u; 10.00 � 8.00 s: 6.00 � 4.00

2.00 0.00

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TOTAL FLOW LOSS (90.0 Liter)

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TEMPERATURE (F)

Figure 1

-750 PSI

-1000 PSI

1250 PSI

-1500 PSI

-1750 PSI

-2000 PSI

-2250 PSI

-2500 PSI

-2750 PSI

3000 PSI

3250 PSI

a. Vendor furnished outline drawing shall be in accordance with Military Specification DOD-D- 1000, Level 1 and paragraphs 3.6.3 & 3.6.4. In addition, a shock note shall be included in accordance with Section 3.3 ofMIL-S-901.

b. Vendor furnished Interface Control Drawing (!CD) shall be prepared depicting physical and functional interface requirements and maintenance envelopes which includes all pull space requirements.

3.6.2 Technical Manual: The vendor shall develop a technical manual in accordance with MIL-M- 24784.

3.6.3 Installation Instructions: Vendor furnished drawings referenced to this paragraph shall include installation instructions.

3.6.4 Maintenance Requirements: Vendor furnished drawings referenced to this paragraph shall include all maintenance requirements.

3.7 MANTAINABILITY

The hydraulic motors shall be designed for ease of maintenance. Maintainability considerations shall include but not limited to the following:

a. Parts standardization and interchangeability

b. Ease of replacement of wear items

c. Disassembly/Assembly techniques

4.0 QUALITY ASSURANCE PROVISIONS

4.1 GENERAL

Unless otherwise specified, the vendor is responsible for the performance of all inspection requirements as specified herein. The vendor may use any facility acceptable to the purchaser.

The purchaser reserves the right to perform any of the inspection set forth where it is deemed necessary to assure supplies and services conform to the prescribed requirements.

4.2 FABRICATION ASSURANCE

4.2.l Welding Procedures: Weld procedures shall comply with MIL-STD-278. Welding procedures shall be submitted to the purchaser for approval prior to any welding and within thirty days upon the vendor's receipt of the order.

4.2.2 Castings: All castings shall be inspected in accordance with MIL-STD-278.

4.2.3 Nondestructive Test Procedures: Nondestructive test procedures shall comply with MIL-STD-271 unless otherwise specified and be performed in accordance with written procedures approved by the purchaser. The procedures shall be submined to the purchaser within thirty days upon the vendor's receipt of the order.

4.2.4 Heat Treatment Procedures: Heat treatment procedures required to meet specific requirements contained here in, such as post-weld heat treatment, shall be performed in accordance with written procedures approved by the purchaser. Heat treatments performed to certify material to a specification, such as ASTM B148, and those performed due vendor generated requirements are not required to be submitted for approval. Submitted procedures shall be high level such that the purchaser can determine that specified requirements are being met. The procedures shall be submitted to the purchaser within thirty days upon the vendor's receipt of the order.

4.3 FIRST ARTICLE TESTING

The first article comp9nents furnished to the purchaser shall undergo inspection and tests as specified in paragraphs 4.3. I through 4.3.8. Prior to testing, a qualification test procedure shall be prepared by the vendor and approved by the purchaser. The qualification test procedure shall be sent to the purchaser for approval 60 days prior to commencement of testing. The vendor shall notify the purchaser twenty days prior to the commencing of testing. Results of the tests shall be submitted to the purchaser for approval in accordance with paragraph 4.5.

4.3.1 Visual and Dimensional Inspection: All components shall be visually and dimensionally examined by the vendor prior to assembly to determine conformance with the requirements of approved drawings. A visual examination of the final assembly for quality conformance shall be performed to verify conformance with the outline drawing and !CD and to discover any visually detectable defects.

4.3.2 Qualification Test: The motor shall be subjected to all tests required by MIL-P-17869, except 4.10.9, 4.10.15 through 4.10.16. In addition, the motor brake shall be subjected to a qualification test to prove ability of the design to meet the requirements described in paragraph 3.3.4. Where a similar, existing design has been subjected to the required qualification tests, the vendor may submit those test reports and approvals to the purchaser for approval as having met the requirements for the test.

4.3.3 Functional Test: Functional testing shall be performed such that mechanical and volumetric efficiency data for operation from O to 3000 PSI and O RPM to maximum motor speed can be obtained in graphical format as required by MIL-P-17869.

4.3.4 Hydrostatic Tests: The motor shall be subjected to hydrostatic pressure tests in accordance with section 3.2.4.

4.3.5 Brake Test: A test is required to prove the ability of the design to meet the requirements of paragraph 3.3.4.

4.3.6 Acoustic Testing: Not applicable.

4.3.7 Shock Testing: See paragraph 3.2.3.

4.3.8 External Pressure Testing: The motor shall be subjected to external pressure tests with the motor running in accordance with the following:

Pressure (PSI)

Cycles

IO

IO

IO

The seal leakage shall be monitored during the test with a permissible leakage of 5cc during any IO cycles of running time.

The motor shall then be hydrostatically tested to 1000 PSI external pressure for 48 hours for strength, porosity, and seal leakage. Upon completion of the tests, the hydraulic motor, including all shafts and seals, shall be thoroughly inspected for signs of degradation, excessive wear, and water contamination.

4.4 PRODUCTION TESTING

All production unit s shall undergo production tests as specified in paragraphs 4.4. l through 4.4.6.

Prior to testing, an Acceptance Test Procedure {ATP) shall be prepared by the vendor and approved by the purchaser. The ATP shall be sent to the purchaser for approval 60 days prior to the commencement of testing.

4.4.1 Functional Test: Functionality testing shall be performed such that mechanical and volumetric efficiency data for operation from O to 3000 PSI artd O RPM to maximum motor speed can be obtained in graphical format as required by MJL.P-17869.

4.4.2 H;ydrostatjc Tests: The motors shall be subjected to hydrostatic pressure tests in accordance with paragraph 3 .2.4.

4.4.3 Freewheeling Testing: The motors shall be subjected to a functional test to ensure that the motor meets the normal operation freewheeling requirements of paragraph 3 .3 .2 and freewheeling leakage requirement of3.3.9.

4.4.4 External Pressure Testing: The motor shall be subjected to external pressure tests with the motor running in accordance with the following:

Pressure (PSI)

Cycles

IO

The seal leakage shall be monitored during the test with a permissible leakage of 5cc during any IO cycles of running time.

The motor shall then be hydrostatically tested to 1000-PSI external pressure for 5 hours for strength, porosity, and seal leakage.

4.4.5 Brake Test: The motor shall be subjected to a test that verifies the dynamic release pressure required to meet the shipboard requirements in paragraph 3.3.4.

4.4.6 Acoustic Testing: The motor shall be subjected to acoustic testing in accordance with MIL-STD- 740-2 for information only. The motor shall be tested over the minimum and maidmum speed ranges and load ranges specified in paragraph 3.2.l.

4.5 TEST DOCUMENTATION

Test reports shall be developed to reflect all test fmdings. It shall include detailed descriptions of any damage or malfunction incurred, at what stage of the test it occurred, and what corrective action taken. In event of a failure, the purchaser shall be notified immediately prior to the vendor performing failure analysis and/or corrective action and a FRACAS report shall be filled out by the vendor and supplied to the purchaser. Photographs of physical damage shall be included and all test reports shall include data pertaining to fluid type, cleanliness, and temperature at the time of the test. Recommendations shall be given as to what corrective measures, if any, should be taken. Test reports shall be submitted to the purchaser for approval within fourteen days upon completion of the test. If a failure occurs, the purchaser reserves the right to demand an additional test to assure compliance with the functional requirements.

ned.williams Highlight

The vendor shall notify the purchaser twenty days prior to stan of the tests to permit witnessing of test by the purchaser.

5.0 PREPERA TION FOR DELIVERY

5.1 BASIC REQUIREMEt.ITS

The motors, repair parts, drawings, procedures, reports, and technical manuals shall be preserved, packaged, and marked for shipment and immediate use. Methods and materials shall be as specified in MIL-P-16789.

5.2 INTERNAL PRESERVATION

Internal preservation shall be by the use of hydraulic equipment preservative oil conforming to MIL-H-6083. This oil shall be thoroughly worked into the motor by operating for short intervals.

The oil shall be drained and all openings sealed and locked in a manner specified for flange bolts and nuts in MIL-P-16789 prior to shipment. Internal protection afforded by using preservative conforming to MIL-H-6083 shall be limited to one year. The motors shall be conspicuously labeled on the unit package and shipping container to indicate date of preservation.

Care shall be taken to prevent entry of contamination into the motor during the preservation process and handling.

5.3 MARKlNG

Interior packages and shipping containers shall be marked in accordance with MIL-STD-129.

5.4 CERTIFICATION OF SHELF LIFE

The vendor shall provide certification that all o-rings, gaskets, packings, and other elastomeric products used in the equipment furnished are installed prior to expiration of their shelf life as defined by MIL-HDBK-695.

6.0 DELIVERABLES

6.1 HMB 90 MOTORS

6.2 OUTL!h'E DRAWINGS (First Timi: Only Unless Otherwise Requested)

In accordance with paragraph 3.6.1.

6.3 INTERFACE CONTROL DRAWINGS (First Time Only Unless Otherwise Requested)

In accordance with paragraph 3.6.1.

6.4 TECHNICAL MANUALS (First Time Only Unless Otherwise Requested)

In accordance with paragraph 3.6.2.

6.5 MANUFACTURING PROCEDURES (First Time Only Unless Otherwise Requested)

In accordance with paragraph 4.2.

6.6 TEST PROCEDURES (First Time Only Unless Otherwise Requested)

In accordance with paragraphs 4.3 and 4.4.

6.7 TEST REPORTS

In accordance withs paragraph 4.5.

6.8 CERTIFICATION OF �HELF LIFE

In accordance with paragraph 5.4.