Tech Ref 1 - USS NEW YORK TM EATP 15-0005 _C (1).pdf

PDF 2 MB Posted Jun 16, 2020

Attached to: USS New York - Main Propulsion Diesel Engine Clutch Assembly
Solicitation number: N5400420Q0130
Issued by: Department of the Navy Naval Sea Systems Command

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Attachment 1 - SOW - Clutch Assembly.pdf	PDF	Jun 16, 2020

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EATP 15-0005, Rev C

LIST OF EFFECTIVE PAGES

SHT NO. REV

NO.

SHT NO. REV

NO.

SHT NO. REV

NO.

SHT NO. REV

NO.

Approval Page C Encl 1 pp. 1 of 3 C

Revision Page C Encl 2 pp. 1 to ____ C

LOEP C Encl 3 pp. 1 to ____ C

4 C Encl 4 pp. 1 of 7 C

5 C Encl 5 pp. 1 of 7 C

6 C Encl 6 pp. 1 to ____ C

7 C Encl 7 pp. 1 to ____ C

8 C Encl 8 pp. 1 to ____ C

9 C

10 C

11 C

12 C

13 C

14 C

15 C

16 C

17 C

18 C

19 C

20 C

21 C

1. PURPOSE/GENERAL INFORMATION

1.1. PURPOSE

1.1.1. The purpose of this Engineering Approved Technical Procedure (EATP) is to provide direction for the inspection of the friction shoes and quill shaft clutch bearing in the clutch assembly for Main Propulsion Diesel Engine (MPDE).

1.1.2. Based on the requirements of the invoking work item circle the applicable MPDE to MRG clutch assembly.

1A 1B 2A 2B

1.2. GENERAL INFORMATION

1.2.1. This EATP is required to be physically at the work site whenever work under its direction is performed.

For multiple worksites, the EATP may be copied; however, all signatures and data will be recorded on the ‘master’ EATP. This can be accomplished by transferring the appropriate ‘master’ forms from the ‘master’ EATP to the working copy, capturing signatures as work occurs at ‘other’ worksite(s), then transferring the appropriate forms back to the ‘master’ EATP when complete.

1.2.1.1. Work Authorization Form (WAF) and Tag Out requirements shall be accomplished and maintained in accordance with Reference A and the invoking work item / contract.

1.2.2. As each procedural step in the EATP is commenced, the step number will be circled. Upon completion of the step, an “X” will be marked through the circled step and initial by the tradesman / craftsman. The first set of initials used by an individual will also include a printed name for traceability purposes. Signatures must be made by individuals who have performed the work or who have personally observed that the work is complete. This process also applies to work accomplished in Enclosures.

1.2.2.1. If at any time a step, test or inspection cannot be accomplished as specified, the tradesman / craftsman doing the work must stop work and notify his / her supervisor immediately. Contractor supervisory personnel will immediately notify the SUPERVISOR of the issue by verbal means and resolve the matter with the Government Technical Matter Expert (TME). Resume work only after being directed, in writing, by the SUPERVISOR. This may be accomplished as a pen and ink note in the EATP if the change is not contractual and does not alter the original scope of work.

1.2.2.2. Any NONCONFORMING conditions found during the execution of this EATP will require immediate documentation by those involved in performing or overseeing the work. The NONCONFORMING condition must be immediately submitted to the Local Technical Authority (Regional Maintenance Center (RMC) Chief Engineer) or their signatories (RMC Deputy Chief Engineers) for review and further direction before continuation of work affected by the NONCONFORMING condition.

1.2.3. For each procedural step in this EATP that requires data to be recorded, required signature sign-offs will be on an enclosure Objective Quality Evidence (OQE) Form or along the signature line. Fleet Maintenance Activities (FMAs) and other activities required to record OQE on JFMM (Reference B) data forms may do so, providing those forms are also attached to and submitted with this EATP upon completion. When supplemental OQE forms are attached to this EATP, the LOEP shall be updated to reflect the incorporation.

If JFFM forms are used to collect OQE, the executing activity must ensure that ALL of the data listed on the attached EATP provided forms is collected.

1.2.3.1. Wherever OQE is recorded, each applicable page shall contain the vessel name and component name(s) that the data represents.

1.2.4. For each procedural step in this EATP that does not require data to be recorded, required signature sign-offs will be captured on signature lines in the procedure indicating that this step has been completed satisfactorily. In instances where the work is not contracted, the Fleet Maintenance Activity (FMA) Shop Lead will sign for the work accomplishment.

1.2.5. Procedural steps for individual components shall be followed sequentially unless otherwise allowed or directed by the Technical Matter Expert (TME). Multiple individual components may be worked in parallel if the progression of this EATP is not disrupted by doing so and the TME concurs.

1.2.6. For contracted work (non-FMA), the (RMC) Technical Matter Expert (TME) has the authority to add steps or omit steps deemed “Not Applicable” in accomplishing the repair actions based on conditions found throughout the repair process. Steps added or omitted may be accomplished as pen and ink notes in the EATP if the change is not contractual in nature and does not alter the original scope of work. This will prevent delay in accomplishing the task in a timely and efficient manner. If the change alters the original scope of work, it shall be handled via the Condition Found Report / Request for Contractual Change (CFR / RCC) process.

1.2.6.1. Pen and ink changes can be made by the Project Support Engineer (PSE) or TME for minor administrative changes that do not change the scope and / or intent of the EATP. Changes of this nature include typographical / editorial errors, amplifying / additional information to clarify a step, or a change in the sequence of step. Pen and ink changes shall be accomplished by drawing a single line through the portion to be changed, and entering the necessary change adjacent to the portion. The PSE or TME making the change will print their name, initial and date.

1.2.6.2. Formal revisions require a review and approval using the same process as the original review and approval. Formal revisions are required if the scope of work changes, boundary of work changes, test requirements change, change in material that will result in a change to the requirements, or any process change in how the work is to be performed that has not been previously defined by this EATP.

1.2.6.3. Rework, which is an unplanned repetition of a step or a series of steps, must be documented and annotated on the LOEP. When the need for rework is identified and a rework addendum is required, the craftsman must stop work and notify the Shop Supervisor who will need to obtain approval / concurrence from the Government TME, Government Project Support Engineer (PSE), or designated Government Engineering Department Representative as designated by the RMC CHENG. A rework addendum may be documented through an Engineering Service Request (ESR) detailing the steps or process to be repeated.

1.2.6.4. When this EATP is implemented by FMAs or other activities required to perform changes in accordance with the JFMM (Reference B), all changes shall be accomplished in accordance with Volume V, Part I, Chapter 2 of Reference B.

1.2.7. Government Notification (G) will be made in accordance with Reference A, 009-04 and as agreed upon with the SUPERVISOR.

1.2.8. It is the Government’s responsibility for a TME to attend 100 percent of the (G) checkpoints contained in the EATP unless the QA form authorizes a Ship Building Specialist (SBS). Work progression on individual components and reassembly of equipment shall not proceed to the next procedural work steps without first completing applicable (G) checkpoints. The TME shall be cognizant of and support the work schedule so as to not delay production and is responsible to notify the Naval Supervising Authority (NSA) Project Manager (PM) immediately if he / she cannot attend a scheduled checkpoint.

1.2.9. Refer to the invoking Work Item for any associated EATP, Process Control Procedure (PCP) or any other non-controlled work that is not covered by this EATP. The Work Items are used as the sequencing document for the accomplishment of any non-EATP related work.

1.2.10. Incremental Certification Points (ICP): ICP are critical junctures in the EATP where the Shipbuilding Specialist (SBS) or Technical Matter Expert (TME) and Contractor (KTR) Quality Assurance (QA) perform pre-certification of OQE. Pre-certification is verification that all data has been properly recorded and all signature blocks in the OQE Forms are signed by the checkpoint participants. Ideally, ICP’s would coincide with I & G check points where all the participants including the government representatives are present.

1.2.11. Retain and verify all serviceable fasteners are satisfactory for re-use in accordance with Reference A, 009-84.

1.2.12. All exposed piping surfaces shall be visually free of grease, oil, flux, scale, dirt, loose particles and any other contamination foreign to the base metal. Light rust inside exhaust manifold components system component surfaces, caused by short time exposure to the atmosphere is permitted.

1.2.13. All paragraphs identified with a (D) represent required report submittals.

1.3. PRECAUTIONS

1.3.1. Foreign Material Exclusion and system cleanliness will be maintained in accordance with Reference A, 009-06 and 009-24. Enclosure 3 is used to document Foreign Material Exclusion (FME) in accordance with Reference A, 009-24 requirements. This process will require more than one page, and is annotated to allow manual page number entry. Upon completion, the actual number of pages will be entered in the LOEP and the Blank / Plug Log will be inserted as Enclosure 3.

1.3.2. Each individual is responsible for his / her own safety. Personnel must wear the proper eye, ear, skin and respiratory protection when using compressed air, power tools, or cleaning solvents.

1.3.2.1. Only Ship’s Force (S/F) shall operate shipboard equipment.

1.3.2.2. Immediately shut down equipment if abnormal noise, vibration, or other unusual conditions occur.

DO NOT operate the equipment until the unusual condition has been corrected.

1.3.3. Observe all notes, cautions, warnings and safety precautions invoked in the References. All notes, cautions and warnings contained within this EATP shall be followed and are contractually binding.

1.4. PREREQUISITES AND INITIAL CONDITIONS

1.4.1. A Readiness to Start (RTS) meeting will be scheduled in accordance with Enclosure 1 prior to the start of this EATP. The purpose of the RTS briefing is to ensure that all documents are complete, materials are on-hand, initial conditions are set, and that all parties involved in the work are fully prepared to execute and certify the work to be performed.

1.4.2. In support of the Naval Supervising Authority’s (NSA) Readiness to Start (RTS) Brief, the Prime Contractor Representative will ensure that all materials identified in Paragraph 1.7 are on hand or on order, all procedures to be used are ready, the work is properly authorized to begin, all tools (including special test equipment, if required), and that all contractor personnel (and subcontractors) involved in the work are fully prepared to execute and certify the work to be performed.

1.4.3. LMA shall ensure all tools or equipment used in the performance of this work package, which requires periodic calibration, shall be verified as being in current calibration in accordance with Reference A (Standard Items). All applicable calibration data shall be recorded as required on OQE forms. The LMA shall ensure that the most current revision of this and all associated EATPs are being used. If the most recent revision has not been invoked contractually, the intended revision shall be discussed and agreed to by the SUPERVISOR / TME prior to the RTS Brief.

1.4.4. Regional Maintenance Center Technical Matter Expert (TME). Provide technical assistance and perform inspections and verification as required by this EATP.

1.4.5. Regional Maintenance Center Project Support Engineer (PSE): Perform tasks as required by this EATP.

The PSE may serve as a Signatory Assistant TME for (G) Checkpoints with expressed TME authorization on a case by case basis. Authorization must be granted for each instance when checkpoints are called out.

1.4.6. Regional Maintenance Center Shipbuilding Specialist (SBS): Perform inspection and verification as required by this EATP. SBSs may serve as a Signatory Assistant TMEs for (G) Checkpoints with expressed TME authorization on a case by case basis. Authorization must be granted for each instance when checkpoints are called out.

1.4.7. Ships Force (SF): Perform tasks as required by this EATP. SF must be knowledgeable about the system, as designated by SF CHENG.

1.4.8. Original Equipment Manufacturer (OEM): Provide technical assistance as required by this EATP.

1.4.9. The Shop Foreman/Assistant Foreman/Lead Persons shall have a minimum of five (5) years’ experience in the field of marine repair.

1.4.10. All assigned technicians / mechanics shall have a minimum of three (3) years’ experience in the field of marine repair. Personnel with less than the above experience shall receive briefings and shall be permitted to participate in the repair process, provided they are under the immediate supervision of a qualified technician/mechanic.

1.5. PERSONNEL QUALIFICATIONS

1.5.1. All first class grade outside machinists performing work on this procedure shall be experienced in the following:

1.5.1.1. Working on Main Reduction Gear (MRG) Systems.

1.5.1.2. Proper methods of verifying and recording Objective Quality Evidence.

1.5.2. The first class grade marine outside machinists may be assisted in the execution of this procedure by second class, third class, and handyperson rated outside machinists.

1.5.3. Specialist grade rated outside machinists, first line machinist supervisory lead personnel, the Machine Shop Assistant Superintendent, and the Machine Shop Superintendent shall be capable of providing all oversight and guidance needed by the first class grade marine outside machinists. The overall responsibility for all non-electrical production work rests with the Machine Shop Superintendent.

1.5.4. In addition to the qualification requirements listed above in Paragraph 1.5.1, all personnel who conduct work under the EATP must participate in a pre-work briefing, which ensures they are thoroughly familiar with the work direction, applicable safety precautions, documentation requirements and overall guidance provided by the EATP. This briefing will be repeated as necessary to accommodate new personnel assignments and when dictated by supervisor judgment. Attendance at this briefing will be documented on Enclosure 2.

1.5.5. When directed by the invoking work item, accomplish the requirements of Reference A, 009-90; Technical Representative. If 009-90 is not invoked in the Work Item the OEM (Q) will be lined out as required.

1.6. HAZARDOUS MATERIAL

1.6.1. Hazardous material is required in the performance of this EATP. Detailed information on material characteristics and considerations in handling can be found on the Material Safety Data Sheets available at the work site.

1.6.2. The following measures will be taken to minimize the volume of hazardous waste generated by this EATP.

1.6.2.1. Steps will be taken to minimize the threat of spillage of toxic or hazardous waste.

1.6.2.2. All waste material (hazardous or otherwise) used in the performance of this EATP shall be disposed of in accordance with the invoking contract per local, state and federal regulations.

1.7. MATERIAL

1.7.1. The following material table is a general list of material required to accomplish this EATP. It is the responsibility of the executing activity to determine the exact material (consumables, parts, tools) requirements to accomplish this EATP based on the requirements of this EATP and the invoking work item. Where allowed, if equivalent materials are used, the specifics of the replacement materials shall be recorded below on the material table.

QTY

REQ.

REF NO.

NAME OF PART

FIGURE NO.

PART NO.

1 Per OEM Clutch Bearing NA 31000-0453 1 Per OEM Bearing Pin NA 50078-0710 1 Per OEM Bearing Retainer Plate NA 50085-3118 6 Per OEM Bearing Retainer Bolts – drilled for lockwire NA 33000-0307 1 Per OEM Inner Spacer NA 50316-0091 1 Per OEM Outer Spacer NA 50316-0092 1 Per OEM Grease Seal, Standard NA 36000-1055 1 Per OEM Grease Seal, Oversized NA 36001-1106 1 Per OEM Seal Repair Sleeve NA 50316-0093 4 Per OEM Air Manifold Plate Retaining Bolts NA 33000-0307

28 Per OEM Friction Assembly’s NA 512321

2 Per OEM Air Tube w/ Valves, ¾-16 UNF Threads 90#, 42CV1200 NA 413771

AR NA Permatex Type 2 NA NA 1 Per Rowland Dist. Air Manifold Hub NA 510819 8 Per Rowland Dist. Rubber Washer NA 412324-04

80 Per Rowland Dist. ¾-10 Stop Nut NA 000110X0090 24 Per Rowland Dist. ¾-10NC-2X3LG Gr. 8 NA 000197X0715 24 Per Rowland Dist. ¾-10NC-2X3.5LG Gr. 8 NA 000197X0717 8 Per Rowland Dist. ¾-10NC-2X3.25LG Gr. 8 NA 000197X0716

24 Per Rowland Dist. ¾-10NC-2X2.5LG SHCS Gr. 8 NA 000030X0713 8 Per Rowland Dist. ½-13NC-2X.75LG NA 000001X0405 8 Per Rowland Dist. ½” Lockwasher NA 000068X0015 2 Per Rowland Dist. Torque Bar Kit, 14PCS 302115 70# 146500BQ 2 Per Rowland Dist. Spring Kit, 14 PCS 301908 146500AR 8 McMaster Carr 1”ODx1.75LGx3/4-10 SSHCS 91259A133 4 McMaster Carr 1”ODx2LGx3/4-10 SSHCS 91259A134 8 McMaster Carr 1”ODx2.5LGx3/4-10 SSHCS 91259A136 1 Philadelphia Gear Bearing Retainer Plate 50085-3118 4 Per Rowland Dist. Pipe Plug 000153X0354 4 Per Rowland Dist. 90 Degree Elbow 0000153X0802 4 Per Rowland Dist. Hex Head Screws 412274-12 1 Per Rowland Dist. Grease Fitting (Amelite) 1607B / 00145X0004 1 Per Rowland Dist. Relief Fitting (Amelite) 4720 / 000145X0030 4 Per Rowland Dist. Straight Fitting (Lenz) A100-12-10/000153X801 4 Per Rowland Dist. 90 Degree Fitting (Lenz) A400-12-10/000153X800

AR NA Loctite 271 NA NA AR NA Bearing Grease NA DOD-G-24508 AR NA Molykote GN, or equivalent NA NA AR NA Solvent, PD-680 type III, or equivalent NA NA AR NA 0.041 inch Stainless Steel Lockwire NA 304L SS ANNEALED 1 N/A Cortec VpCi-329 N/A N/A

1.8. PLANNERS NOTES FOR CONTRACTED WORK

1.8.1. The following Cat II NAVSEA Standard Items are referenced in this EATP and should be invoked in the invoking work item for contracted work. If not invoked in the invoking work item they can be lined out.

Item Number Title

009-90 Technical Representative: provide

1.8.2. The invoking work item should specify which equipment gets worked. The intent of this EATP is that the procedure will be accomplished in its entirety. If this EATP is not planned for accomplishment in its entirety, the specific work intended shall be called out directly in the invoking work item. If additional equipment repairs or replacements are required outside of the scope of this EATP, they will be invoked via the CFR / RCC process. If the TME decides that portions of this EATP are not necessary, items may be de-scoped through the CFR/ RCC process during work execution.

1.8.3. The invoking work item shall include an “INTERMEDIATE CERTIFICATION”. The completed EATP, up to Paragraph 3.8, to include all required enclosures, will be provided to the Government a minimum of 72 hours prior to the scheduled start of Paragraph 4. This will allow adequate time for the Government to accomplish a review of the complete document. Any identified technical discrepancies will require correction prior to the start of Paragraph 4.

1.8.4. The invoking work item shall include Level of Effort (LOE) which will be required for the contractor to provide Ship Force and TME support when accomplishing “safe to start” checks and Performance Test.

LOE man-day and material amounts will be determined by the Maintenance Team.

1.8.5. Consult the applicable TME branch to determine 009-90 (OEM Technical Representative; provide) requirements. When determined to be necessary, 009-90 shall be included in the invoking work item.

1.8.6. All References identified within the References section of this EATP should also be included as References in the invoking work item. Reference A is required for contracted work only.

1.8.7. Reference D is an OEM Proprietary drawing and procedure requiring 009-90 to be invoked for contracted work.

1.8.8. Enclosure 5 is an OEM procedure which contains additional required checkpoints.

1.8.9. The invoking work item shall identify what parts will be replaced with new.

1.8.10. This work affects both Main Propulsion Diesel Engines (MPDEs) associated with the Reduction Gear.

Once work commences, no diesel engines shall be operated until all clutch work in Paragraph 3 has been fully completed.

2. ENCLOSURES / ADDENDUMS

ENCL. ENCLOSURE DESCRIPTION

1 Ready to Start Brief 2 Prebrief Form

3 FME Log

4 MRG Clutch OQE Collection

5 Clutch Drum Repair Procedure

6 Incremental Certification Point, Paragraph 3.7.2

Vibration analysis

8 Pier-side testing

9 Performance testing

PC# QTY DESCRIPTION PC# QTY DESCRIPTION

7-3,1 2 Rotorseal Assembly 1” R.H. (Consists of 1 thru 15)

27 8 Hex Head Screw 3/4 - 10 NC - 2 x 2.75

2 8 Drive Screw 28 24 Hex Head Screw 3/4 - 10 NC - 2 x 3 3 1 Spacer 29 2 Socket Head Screw 3/4 x 2.00 4 1 Spacer 30 4 Socket Head Shield Screw 5/8 x 1.75 5 1 Dual Element Manifold Assembly (Consists of 13 thru 32) 31 4 Socket Head Screw 3/4 x 2.50

6 1 Hub and Drum Sub-Assembly (Consists of 33 thru 36)

32 1 Dual Element and Adapter Plate Sub- Assembly

7 8 1.500 Lockwasher 33 1 Hub 8 48 Stop Nut 34 1 Drum 9 1 Grease Fitting 35 36 Hex Head Screw 1² - 8NC x 3 10 1 Relief Fitting 36 36 Safety Wiring Clip 11 1 Hose Assembly 37 28 Friction Shoe Assembly (Consists of 38 thru

41) 12 1 Straight Thd 90° Elbow 38 280 Stop Nut 13 4 Air Tube 39 28 Friction Block Lining 14 1 Rotorseal Adapter 40 28 Backing Plate 15 1 Air Manifold Plate 41 280 Flat Head Machine Screw 16 1 Air Manifold Hub 42 28 Release Spring 17 24 Hex Nut 3/4 43 28 Torque Bar 18 4 Flat Washer 44 2 Tube 19 4 Lockwasher 45 1 Rim 20 8 Lockwasher 46 Deleted 21 4 Stop Nut 47 8 Snap Ring 22 4 Stop Nut 48 4 90° Elbow 23 2 Stop Nut 49 2 Tubing 24 4 90° Male Elbow 50 24 Hex Socket Screw 25 4 Male Connector 51 24 Locknut 26 4 Hex Head Screw 1/2 - 13 NC - 2 x 1.25

Figure 1 – Dual Clutch Assembly (Derived from Reference C, Figure 7-3)

3. PROCEDURE

3.1. READINESS TO START

(Q)(G) “READINESS TO START / START OF PROCEDURE”

3.1.1. Ready to Start (RTS) brief conducted and a signed copy of the RTS with minutes has been attached to the EATP as Enclosure 1.

(V) Contractor Signature Contractor Printed Name Contractor Badge# Date/Time

(Q) OEM Signature OEM Printed Name Date/Time

(G) NSA PM Signature NSA PM Printed Name Date/Time

3.2. PRE-OPENING CLEANLINESS

(Q)(G) “PRE-OPENING CLEANLINESS”

3.2.1. Prior to starting ensure no foreign material exists on adjacent surfaces that could contaminate the internal areas upon disassembly of components in compliance with Reference A, 009-24. By signing below, the Contractor, OEM and SUPERVISOR agree that all work has been properly completed

(G) SUPERVISOR Signature SUPERVISOR Printed Name Date/Time

(Q)(G) “CLUTCH AIR MANIFOLD PLATE TIR”

3.3. Measure the total indicator runout (TIR) alignment of the clutch air manifold plate and air manifold hub using the illustrations in Reference C for guidance. Max Run-out allowable 0.005” TIR. Document the results and sign for this checkpoint on Enclosure 4.

NOTE: USE OF CAUTION TAGS MAY BE UTILIZED FOR ROTATION OF CLUTCH DURING

DISASSEMBLY. DANGER TAGS SHALL BE ADDED UPON COMPLETION OF DISASSEMBL

3.4. VERIFY MRG CONDITION

3.4.1. Secure and tag out lubricating oil system.

3.4.2. Secure and tag out main engines.

3.4.3. Secure and tag out turning gear.

3.4.4. Secure and tag out clutch/brake air supply and Turn clutch control manual override valve (V8 or V11) on clutch control panel (CCP) to DISENGAGE position and tag OUT OF SERVICE.

3.4.5. Shift shaft lock to ENGAGED position and tag OUT OF SERVICE.

Q)(G) “VERIFY MRG CONDITION & PREREQUISITES”

3.4.6. Verify conditions noted in Paragraphs 3.4.1 through 3.4.5. By signing below, Contractor, OEM and SUPERVISOR agree that subject paragraphs have been properly completed.

3.5. REMOVAL

NOTE: TAG/LABEL ALL COMPONENTS PRIOR TO AND DURING REMOVAL TO ENSURE

REINSTALLATION IN EXACT LOCATION AS REMOVED.

NOTE: NO INTERNAL FME PLUGS ARE TO BE UTILIZED ON SYSTEM OR COMPONENTS.

NOTE: ALL NUMBERS BELOW REFERENCE THE CORRESPONDING PART SHOWN IN FIGURE 1.

(Q)(G) “VERIFY POSITION MEASUREMENTS”

3.5.1. Take relative position measurements in accordance with Reference C from the aft end of the quill shaft to the end of the pinion. Take additional relative position measurements on the forward end from the quill shaft to the geislinger coupling. These readings will provide reference points for reinstallation. Document the results and sign for this checkpoint on Enclosure 4.

(V)(Q) “MATCH MARK CLUTCH COMPONENTS”

3.5.2. Match mark manifold plate, side plates, and inboard and outboard rims prior to disassembly.

(D) 3.5.3. Disassemble clutch assembly in accordance with Reference C, Section 6-10.1.1, steps f through n.

Figure 2 – Quill Shaft Clutch Bearing Measurements

(Q)(G) “QUILL SHAFT CLUTCH BEARING MEASURMENTS”

(D) 3.5.4. Disassemble clutch assembly in accordance with Reference C, Section 6-10.1.1, steps o through t. Inspect the quill shaft clutch bearing using the illustrations in Figure 2 and Reference D. Measure and record as found clutch bearing race OD and thickness measurements and bearing hub dimensions. Note any damage found to the shaft, clutch bearing, bearing hub, grease seal, or any existing repair sleeves. Document the results and sign for this checkpoint on Enclosure 4. Submit results to SUPERVISOR.

(V)(Q) “CLEAN COMPONENTS”

3.5.5. Accomplish cleaning of the clutch components, using Reference C, Section 6-10.1.2. If any components are found to be deteriorated or damaged beyond repair, notify the SUPERVISOR immediately.

3.6. INSPECTION

(D)

3.6.1. Inspect the actuating tubes for abnormal conditions, cracks or deterioration indicated by air bubbles or ply separation in accordance with the criteria of Reference C, Table 6-7 Submit results to SUPERVISOR.

(Q)(G) “FRICTION SHOE, TORQUE BARS & SPRINGS AND CLUTCH RIM INSPECTION”

3.6.2. Measure the thickness of each friction shoe and inspect for abnormal conditions using Reference C, Table 6-7 (Criteria: greater than 3/8”). If friction shoes are found to be within tolerance, the TME may determine that replacement is not necessary. Visually inspect torque bars and springs as well as torque bar holes in the clutch rims using the criteria in the OEM drawing. Document the results and sign for this checkpoint on Enclosure 4.

3.6.3. Accomplish the requirements of 009-32 Table 5 line 2 of Reference A for FWD and AFT rims.

(Q)(G) “CLUTCH DRUM FLATNESS MEASUREMENTS”

3.6.4. Measure the Clutch drum for Flatness. Measure positions at 30° angled increments around the drum circumference (total of 360° - 12 measurements). All position measurements must be a maximum allowable deviation of 0.015”. Document the results and sign for this checkpoint on Enclosure 4.

(D) 3.6.5. Submit a report to the SUPERVISOR containing results of para 3.6.4.

3.6.6. Disassemble clutch drum in accordance with Reference C, Section 6-10.1.1, steps v through z.

3.7. EQUIPMENT REPAIR

3.7.1. Accomplish the requirements of Enclosure 5 for Clutch Drum repairs

(Q)(G) “INCREMENTAL CERTIFICATION POINT”

3.7.2. Verify the proper completion of Paragraphs 3.3. through 3.7.1. and review the reports submitted in 3.5.3, 3.5.4, 3.6.1 and 3.6.5 and Enclosure 4. By signing below, Contractor, OEM and SUPERVISOR agree that subject paragraphs have been properly completed. Attach / insert the reports submitted in 3.5.3, 3.5.4, 3.6.1 and 3.6.5 as Enclosure 6.

3.8. ASSEMBLY

NOTE: ALL FASTENERS SHALL BE TORQUED IN ACCORDANCE WITH REFERENCE E UNLESS A

SPECIFIC TORQUE IS LISTED BELOW.

NOTE: ALL NUMBERS BELOW REFERENCE THE CORRESPONDING PART SHOWN IN FIGURE 1.

3.8.1. Replace clutch drum working in reverse order of Reference C steps 6.10.1.1.v thru 6.10.1.1.z.

(V)(Q) “TORQUE CLUTCH DRUM TO QUILL SHAFT HUB SCREWS”

3.8.1.1. Noting the match-marks, reinstall and torque 36 hex head screws holding clutch drum to quill shaft hub to 680 ft-lbs wet (MIL-G-24508 grease).

3.8.1.1.1. Lockwire the clutch drum to hub hex head screws in accordance with Reference C using Reference E for guidance.

3.8.1.2. Reassemble clutch working in reverse order of Reference C steps 6.10.1.1.o. thru 6.10.1.1.t.

(V)(Q) “TORQUE CLUTCH RIM BOLTS”

3.8.1.3. Final torque all clutch rim bolts to 309 ft-lbs (dry).

3.8.2. Accomplish clutch bearing setting procedure in accordance with Reference D and the below steps. Record all required OQE and measurements on Enclosure 4.

3.8.2.1. Final assembly of the clutch bearing hub shall be built on deck. Utilize bolts and fender washers to hold bearing seals and spacers in place while assembling hub on quill shaft.

(Q)(G) “NEW PILOT BEARING MEASUREMENTS”

3.8.2.2. Using New Pilot bearing #31000-0453, set the bearing retainer on a level surface with the quill shaft facing surface up. Measure the width of the bearing inner ring to +/-0.001” accuracy and record. Then set the bearing in place on the retainer plate and measure and record the distance from the top of the inner ring to the face of the retainer plate to within +/-0.001” accuracy. Subtract the bearing width from the depth to the facing surface on the retainer plate. If the inner surface of the retainer plate is elevated above the outer surface, label this measurement “B”. If the inner surface of the retainer plate is below the outer surface, label this measurement “C”. Document the results and sign for this checkpoint on Enclosure 4.

(Q)(G) “ADJUSTED NEW PILOT BEARING MEASUREMENTS”

3.8.2.3. Label this distance “A”. Add dimension “B” or “C” to dimension A and compare to 0.059”. If dimension “C” must be increased to get the 0.059” result, then dimension “D” on the inner spacer must be adjusted to the same amount as shown on drawing 1407*0041. If Dimension “B” must be increased to get the .059 result, then a new green spacer must be machined with Dimension “D” set to the sum of the width of the existing spacer plus the required increase. Note: Actual Bearing pull-up distance can be 0.059” +/- 0/004”.

Document the results and sign for this checkpoint on Enclosure 4.

(Q)(G) “REPLACE SEAL ASSEMBLY”

3.8.2.4. Replace Seal Assembly. PN 36000-1055, if over size seal is required PN 36001-1106, record DFS Number in the space provided below (write ‘N/A’ if DFS is not required).

DFS Number:

(Q)(G) “BEARING RETAINER PLATE INSTALL AND TORQUE”

3.8.2.5. Using 4 Hex Head bolts 33000-0307, install bearing retainer plate 50085-3118 on the quill shaft and pull up until assembly is snug. Torque bolts to 85 FT-LBS. Remove bolts and verify bearing pull up remains at 0.059”. Re-install bolts and Torque to 85 FT-LBS

(Q)(G) “RELATIVE POSITION MEASUREMENTS”

3.8.2.6. Measure distance identified as 2.25” reference dimension on Reference D (Drawing 14070*0041) and record the dimension on Enclosure 4. Measure the FWD and AFT relative Dimension from the coupling flange to the Gieslinger. Compare these measurements with the measurement taken in paragraph 3.5.1.

Measurements must be within 0.010”. If not, notify the SUPERVISOR immediately and submit a CFR to MARMC Engineering for review.

(Q)(G) “AIR MANIFOLD PLATE ALIGNMENT”

3.8.2.7. Realign clutch air manifold plate to within 0.005” TIR and drill, ream and install new socket head fitted cap screws using Reference C for guidance. Document the final results and sign for this checkpoint on Enclosure 4.

(Q)(G) “AIR MANIFOLD HUB ALIGNMENT”

3.8.2.8. Realign clutch air manifold hub to within 0.005” TIR and drill, ream and install new socket head fitted cap screws using Reference C for guidance. Document the final results and sign for this checkpoint on Enclosure 4.

(Q)(G) “GREASE CLUTCH BEARING”

3.8.3. Grease the clutch bearing using Reference C for guidance. Grease shall fill 1/2 of the clutch bearing hub.

Verify grease is filled from grease fitting (9).

3.8.3.1. Reassemble clutch working in reverse order of Reference C steps 6.10.1.1.f. thru 6.10.1.1.n.

(Q)(G) “TORQUE ROTOSEAL ADAPTER PLATE FASTENERS”

3.8.3.2. Torque four rotorseal adapter plate (14) hex head screws (26) to 110 ft-lbs dry.

NOTE: DO NOT ATTEMPT TO START DIESEL ENGINES DURING STATIC CHECK. DIESEL ENGINES

SHALL NOT BE OPERATED UNTIL ALL PARAGRAPH 3 REQUIREMENTS HAVE BEEN COMPLETED.

(Q)(G) “VERIFY STATIC CHECK”

3.8.4. Verify static preoperational checks in accordance with Reference C, Section 6-10.1.6a. By signing below, Contractor, OEM and SUPERVISOR agree that the static check has been properly completed.

(G) SUPERVISOR Signature SUPERVISOR Printed Name Date/Time

(Q)(G) “INTERMEDIATE CERTIFICATION”

NOTE: THIS CHECKPOINT WILL BE SCHEDULED A MINIMUM OF 72 HOURS PRIOR TO SCHEDULED

START OF PARAGRAPH 4.

3.9. Bar over engine and verify no rotation of clutch.

3.10. Verify the proper completion of Paragraphs 3.1 through 3.8.4 and review the associated Objective Quality Evidence. By signing below, the Contractor, OEM and SUPERVISOR agree that subject paragraphs have been properly completed.

4. ACCEPTANCE AND CERTIFICATION TESTING

(G) “VIBRATION ANALYSIS”

4.1.1. Do not operate either diesel engine until the clutch is ready for testing and Paragraph 3 has been completed without prior written concurrence from the TME via ESR. Contact the TME in advance to conduct vibrational analysis of the clutch with it disengaged in accordance with MRC: 56 T4T1 U MIP: 3002 Periodicity: AP-1. Document results of test on Enclosure 7. Attach copy of report as Enclosure 7.

(Q)(G)“VERIFY PIER SIDE TESTING”

4.2.1. Accomplish pier-side testing of the reduction gear and clutch assembly.

4.2.1.1. Start unaffected engine and engage clutch for 15 minutes. Monitor clutch and clutch bearing for unusual noise or vibration.

4.2.1.2. Disengage unaffected engine.

4.2.1.3. Start affected engine and engage clutch for 15 minutes. Monitor clutch and clutch bearing for unusual noise or vibration.

4.2.1.4. Start unaffected engine and engage clutch for 15 minutes. Monitor clutch and clutch bearing for unusual noise or vibration.

4.2.1.5. Verify that pier-side testing has been properly accomplished in accordance with the above steps and no unusual conditions, noise or vibration was observed. By signing below, Contractor, OEM and SUPERVISOR agree that pier-side testing has been properly completed. Attach/Insert Objective Quality Evidence as Enclosure 8.

(Q)(G) “PERFORMANCE TEST”

4.3. Accomplish At-Sea testing of the clutch and bearing.

4.3.1. Start unaffected engine and engage clutch for 15 minutes. Monitor clutch and clutch bearing for unusual noise or vibration. Engine shall be at 100% Load.

4.3.2. Disengage unaffected engine.

4.3.3. Start affected engine and engage clutch for 15 minutes. Monitor clutch and clutch bearing for unusual noise or vibration Engine shall be at 100% Load.

4.3.4. Start unaffected engine and engage clutch for 15 minutes. Monitor clutch and clutch bearing for unusual noise or vibration. Both engines shall be at 100% Load.

4.3.5. Verify that performance testing has been properly accomplished in accordance with the above steps and no unusual conditions, noise or vibration was observed. By signing below, Contractor, OEM and SUPERVISOR agree that performance testing has been properly completed. Attach/Insert Objective Quality Evidence as Enclosure 9.

5. TRANSFER OF TESTING

5.2. None

6. SYSTEM RESTORATION AND PROCEDURE CLOSEOUT

(Q)(G) “CLOSEOUT”

6.1. CLOSEOUT: By signing below, the craftsman, OEM and TME verifies all work has been completed, as described in this EATP, onboard USS (LPD- ); and that all inspections and documentation have been completed correctly, all applicable tags have been cleared and WAFs have been signed.

6.2. Submit completed EATP to the SUPERVISOR.

Enclosure 1

1. A “best practice” has been to go around the room to allow each participant to introduce themselves, this way all in attendance will have an awareness of who is who pertaining to the task execution.

2. It is possible that an EATP could be revised after the work package has been provided for bid. Prior to the RTS Brief, the LMA shall ensure that this and all associated invoked EATP revisions are the most current available. If more recent revisions exist, the disparity shall be vetted as soon as possible after contract award via an ESR through the TWH. Any EATP revisions that are contractually invoked and change the scope of work will be negotiated through the CFR / RCC process.

3. By having the LMA (or his designated representative) convey to all in attendance the description of the critical system repair task to be performed it will be clear the LMA understands the task he is intended to accomplish.

4. There may be occasions where other documentation will be required ISO of the primary EATP such as stability calculation PCP, Divers and cofferdam PCP, and the relationship they have on the critical system repair covered by the EATP should be clearly understood by all in attendance.

5. Primary responsibility for implementing the QMP lies with the MT Project Manager and Quality Assurance Specialist (QAS) assigned to the Availability. (Having the QAS provide a copy of the applicable QMP at the RTS may be helpful)

6. A discussion of the status of tag outs and WAF's or the plan to execute them based on ships force and LMA requirements should be solidified now.

7. This discussion should be to ensure each material requirement has been identified as being on hand or is tracking to be available to support the repair in the event it is not already on hand, additional discussion may involve identifying the responsible party to ensure parts and materials are obtained ISO the EATP. (materials include repair parts, special tools, consumables, etc...)

8. Prior to the scheduling of the RTS if OEM qualifications are required they should have already been submitted via CFR by the LMA and reviewed and approved by the PSE (Per 009-90 the Supervisor is to be notified 15 days prior to commencement of work). Other qualifications should be discussed as applicable.

9. The Project Manager has primary cognizance over this but remember that an EATP is a technical task covering a critical system that should always be monitored by the PSE. (I.E.: MOA for single valve protection etc...)

10. A Risk Mitigation Strategy should be in place for unplanned circumstances which may arise during the course of the work. What might happen that would endanger personnel, ship/equipment, or successful completion of work? Discuss coordination between multiple parties concerned with the repair. For example when conducting waterborne stern tube seal repairs where divers are installing a cofferdam, a Risk Mitigation Plan should be developed to identify the immediate response for flooding should a failure of the cofferdam occur during the critical repair. It should identify the initial conditions (dewatering pumps, communication plan) that are to be in place prior to commencement of work and clearly define the roles and responsibilities of each organization involved with risk mitigation. More information on the formulation of a risk strategy can be found in NAVSEAINST 4790.28.

11. This is where the PSE should lead the discussion through any identified exceptions that must be accomplished IOT begin the EATP.

Ensure it is clear that the designated responsible party acknowledges their role in completing the requirements needed to clear the exception prior to the start of the EATP.

12. The PSE should recap any pertinent issues brought forth during the meeting and ensure any applicable safety concerns have been clearly identified and addressed. This is a good time to remind all involved with the execution of the EATP that should an unplanned event occur, work should be stopped and proper notifications made so that all concerned parties can be involved in the planned corrective actions required to restore system/repair before scheduled/planned work continues.

13. By this point all known potential issues and concerns impacting the successful execution of the EATP should have been identified and the applicable representatives should sign the RTS signature check sheet.

Date: EATP 15-0005, Rev A Ship:

No. Attendee Name

(Print or Type) KTR/Gov/ Mil

Position / Title Attendee Signature

Comments:

PRE-JOB BRIEF FORM

1. EATP WORK PRIEF CHECKLIST

Pre-job requirements: The lead shop / Trade Supervisor will verify and initial those steps that have been completed.

NOTE: IF THE PROCEDURE REQUIRES A REVISION DURING THE COURSE OF WORK, THE

AFFECTED PERSONNEL WILL INITIAL IN THE BLOCK PROVIDED ACKNOWLEDGING THE CHANGE

IN SCOPE.

All required Work Control Documents (WCD), (Work Items, EATP, etc.) are complete, reviewed and approved by the RMC Engineering Department.

Prerequisites and Initial Conditions have been established or a clearly defined plan of action has been developed to ensure these conditions will be established to support the work.

The required repair parts, materials / consumables and Test Measurement and Diagnostic Equipment (TMDE) are available to support work.

Proper drawings / prints, tech manuals are on site or included as enclosures within the EATP.

Workers assigned to this job are qualified and trained to the work including subcontractors as appropriate.

All workers, and subcontractors as appropriate, have reviewed and understand their duties and responsibilities.

Lead trade Supervisor briefs the workers and subcontractors as appropriate, on all Check Points (I, V, Q, D, G) in the EATP.

Identify any required Memoranda of Agreement (MOA) for this EATP (i.e. single valve protection cofferdam).

2. Brief the job: include Safety, Environmental, FME requirements, Test Measuring and Diagnostic Equipment (TMDE). Require participation from the group. Ensure elements of each of the following are included:

Safety

Prerequisites

Tasks of each person

Procedural sequence

Lessons Learned (Based on past experience)

Enclosure 2

1. SHIP HULL NO. 2. W/I 3. LWC/SHOP 4. EATP SER NO. 5. SYSTEM/COMPONENT

15-0005, Rev C LPD Class MRG Clutch

PRE-JOB BRIEF (Continued)

3. ACKNOWLEDGEMENT SHEET

SHOP / EMPLOYEE

NUMBER

LAST NAME (PRINT) SIGNATURE DATE QUALIFICATIONS INITIAL FOR

REVISION

PRE-JOB BRIEF FORM (Continued)

3. ACKNOWLEDGEMENT SHEET

SHOP / EMPLOYEE

NUMBER

LAST NAME (PRINT) SIGNATURE DATE QUALIFICATIONS INITIAL FOR

REVISION

Page intentionally left blank. Reserved for insertion of LMA’s FME Log upon completion of

EATP.

Enclosure 3

Enclosure 4

TEST AND INSPECTION RECORD

OBJECTIVE QUALITY EVIDENCE (OQE) SHEET Planning / Executing Activity shall fill in blocks identified by a prior to beginning work.

1. SHIP HULL NO. 2. W/I 3. LWC/SHOP 4. EATP SER NO. 5. SYSTEM / COMPONENT

15-0005, Rev C LPD Class MRG Clutch

6. REFERENCES (COMPONENT DETAIL / ASSEMBLY DRAWING AND REV)

A. B. C.

D. E. F.

7. PART DESCRIPTION / PIECE NO.: LPD Class MRG Clutch OQE Sheet

8. DESCRIPTION OF TEST AND/OR INSPECTION:

(Q)(G) “CLUTCH AIR MANIFOLD PLATE TIR”

(Q)(G) “VERIFY POSITION MEASUREMENTS”

3.5.1. Take relative position measurements in accordance with Reference C from the aft end of the quill shaft to the end of the pinion.

Take additional relative position measurements on the forward end from the quill shaft to the geislinger coupling. These readings will provide reference points for reinstallation. Document the results and sign for this checkpoint on Enclosure 4.

(Q)(G) “QUILL SHAFT CLUTCH BEARING MEASURMENTS”

3.5.4. Disassemble clutch assembly in accordance with Reference C, Section 6-10.1.1, steps o through t. Inspect the quill shaft clutch bearing using the illustrations in Figure 2 and Reference D. Measure and record as found clutch bearing race OD and thickness measurements and bearing hub dimensions. Note any damage found to the shaft, clutch bearing, bearing hub, grease seal, or any existing repair sleeves. Document the results and sign for this checkpoint on Enclosure 4. Submit results to SUPERVISOR

(Q)(G) “FRICTION SHOE, TORQUE BARS & SPRINGS AND CLUTCH RIM INSPECTION”

3.6.2. Measure the thickness of each friction shoe and inspect for abnormal conditions using Reference C, Table 6-7 (Criteria:

greater than 3/8”). If friction shoes are found to be within tolerance, the TME may determine that replacement is not necessary. Visually inspect torque bars and springs as well as torque bar holes in the clutch rims using the criteria in the OEM drawing. Document the results and sign for this checkpoint on Enclosure 4

(Q)(G) “CLUTCH DRUM FLATNESS MEASUREMENTS”

(Q)(G) “NEW PILOT BEARING MEASUREMENTS”

(Q)(G) “ADJUSTED NEW PILOT BEARING MEASUREMENTS”

8. DESCRIPTION OF TEST AND/OR INSPECTION (CONTINUED):

(Q)(G) “RELATIVE POSITION MEASUREMENTS”

(Q)(G) “AIR MANIFOLD PLATE ALIGNMENT”

(Q)(G) “AIR MANIFOLD HUB ALIGNMENT”

CALIBRATION DATA:

EQUIPMENT: EQUIPMENT: EQUIPMENT: EQUIPMENT:

Ser #: Ser #: Ser #: Ser #:

Cal. Date: Cal. Date: Cal. Date: Cal. Date:

Cal Due: Cal Due: Cal Due: Cal Due:

Range: Range: Range: Range:

EQUIPMENT: EQUIPMENT: EQUIPMENT: EQUIPMENT:

Ser #: Ser #: Ser #: Ser #:

Cal. Date: Cal. Date: Cal. Date: Cal. Date:

Cal Due: Cal Due: Cal Due: Cal Due:

Range: Range: Range: Range:

EQUIPMENT: EQUIPMENT: EQUIPMENT: EQUIPMENT:

Ser #: Ser #: Ser #: Ser #:

Cal. Date: Cal. Date: Cal. Date: Cal. Date:

Cal Due: Cal Due: Cal Due: Cal Due:

Range: Range: Range: Range:

EQUIPMENT: EQUIPMENT: EQUIPMENT: EQUIPMENT:

Ser #: Ser #: Ser #: Ser #:

Cal. Date: Cal. Date: Cal. Date: Cal. Date:

Cal Due: Cal Due: Cal Due: Cal Due:

Range: Range: Range: Range:

EQUIPMENT: EQUIPMENT: EQUIPMENT: EQUIPMENT:

Ser #: Ser #: Ser #: Ser #:

Cal. Date: Cal. Date: Cal. Date: Cal. Date:

Cal Due: Cal Due: Cal Due: Cal Due:

Range: Range: Range: Range:

9. RESULTS:

3.3.

Comments:

(V) Contractor Print / Signature Badge #: Date

(Q) OEM Print / Signature Date