CGC HOLLYHOCK MAIN REDUCTION GEAR

Revisions Record This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package. DATE REV# WORK ITEM# CHANGES MADE NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated. Consolidated List of References The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution. All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed - free of charge - as follows: MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws:: www.gpoaccess.gov The Government is aware of the following internet web links where contractors may procure commercial specifications: American Welding Society (AWS): http://www.awspubs.com/index.php ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/ NFPA: http://www.nfpa.org SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace COAST GUARD DRAWINGS Coast Guard Drawing 225-WLB 243-001, Rev B; PROPULSION SHAFTING ARRANGEMENT COAST GUARD PUBLICATIONS Coast Guard Technical Publication (TP) 3523-241-A&B, 225 WLB MIB, VOL 5, SWBS 241, GEAR, REDUCTION, MMC PN 241-01-01 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures OTHER REFERENCES A-A-59323, Rev -; CLOTHS, CLEANING, LOW-LINT , 6/30/99 MIL-PRF-9000, Rev H; Lubricating Oil, Shipboard Internal Combustion Engine, High Output Diesel, 9/16/87 Naval Ships' Technical Manual, Chapter 241, Propulsion Reduction Gears, Couplings, Clutches, and Associated Components Consolidated List of Government-furnished Property The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings. 400 gallons of MIL-L-9000, TEP 2190 Consolidated List of Critical Inspection Items The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)): None 2411_JPH_0225_225B Main Reduction Gear, Flush 1. SCOPE 1.1 Intent. This work item describes the requirements for the Contractor to flush the reduction gear. The purpose is to remove foreign material contamination, carbon deposit residue adhering to internal surfaces, piping and components, restore proper oil flow and return system to operational state and restore the system to an acceptable operational state. Reduction gear is a Philadelphia Gear Model # 96DHCMG-CP. Photo of Carbon like residue Photo of Inadequoate Oil Spray Pattern of Gear Mesh 1.2 Government-furnished property. 400 gal 2190 TEP 1.3 Area of performance. Period of Performance will commence no later than 7 days after receipt of award. The address in which this will be performed will be at Coast Guard Yard, 2401 Hawkins Point Rd, Baltimore, MD 21226. 2. REFERENCES Coast Guard Drawings Coast Guard Drawing 225-WLB 243-001, Rev B; PROPULSION SHAFTING ARRANGEMENT Coast Guard Publications Coast Guard Technical Publication (TP) 3523-241-A&B, 225 WLB MIB, VOL 5, SWBS 241, GEAR, REDUCTION, MMC PN 241-01-01 Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures Other References A-A-59323, Rev -; CLOTHS, CLEANING, LOW-LINT , 6/30/99 MIL-PRF-9000, Rev H; Lubricating Oil, Shipboard Internal Combustion Engine, High Output Diesel, 9/16/87 Naval Ships' Technical Manual, Chapter 241, Propulsion Reduction Gears, Couplings, Clutches, and Associated Components 3. REQUIREMENTS 3.1 General. 3.1.1 CIR. 3.1.2 Identification of flushing contractor. 3.1.2.1 Due to the critical nature of the Main Reduction Gear, the company/contractor that will perform must be identified prior to contract award. 3.1.2.2 Submit the name and r'sum of the Flushing Contractor that will be performing the flush. Submit documentation to past history on flushing this WLB Main Reduction Gear (MRG) or a similar MRG of equivalent complexity. NOTE Coast Guard personnel will operate all shipboard machinery and equipment and provide necessary Tag Outs for isolation or taking systems out of service. note The Contractor should be aware that neither the cutter, nor the cutter support base, is capable of providing the 440 VAC power necessary to operate any flushing support systems and that the Contractor must provide a suitable 450 VAC power source. 3.2 Initial reduction gear cleaning and hot oil flush 3.2.1 Purpose of flush. The Main Reduction Gear (MRG) has been observed to have abnormal internal coating on surfaces. It is believed this may have been caused by a past oil overheat event causing oil breakdown and a tightly adhering coating to be created. Even after system circulation and oil changes the coating remains. The coating is suspected to have potentially clogged critical internal spray nozzles and orifices in the MRG lube oil system. The overarching objectives (performance base) is to: Remove any surface buildup which will interfere with operation or shed particles which may clog or interfere with normal operation of the lube oil distribution system. Remove all visible grease, flux, scale, dirt, loose particles, and any other foreign contamination. Obtain normal spray patterns from all observable spray nozzles 3(ea) on upper generator pinion shaft/gear teeth and 12(ea) on the MDE High Speed pinion shaft/gear teeth. 3.2.2 Identify any component that flushing contractor believes should be removed and/or jumpered for: improved flushing, inspection, hand cleaning, reporting, testing, etc. Some potential items are: Electric Pump Gear Driven Pump Cooler Amot Valve Relief valves Duplex Filter Housing Short hoses and piping Sump heater NOTE For purpose of bid and initial assumptions, assume all components will remain installed and a system wide flush via an external flushing rig - kidney looped into existing LO System. 3.2.3 Identify any jumpers recommended and obtain USCG concurrence. After concurrence, jumper any identified exterior piping and hoses together to perform hot oil flush. 3.2.4 Determine an optimal low point (suction) connection point. Determine a return (pressure side) connection point. 3.2.5 Identify chosen filter loop to Coast Guard Inspector. 3.2.6 Flushing rig shall have flow rate up to 120 GPM. And a relief valve that ensures maximum system pressure is not exceeded. Flushing rig must be capable of heating and maintain oil throughout the operation between to 140 -160 deg F. 3.2.7 Prior to draining existing oil, complete washdown of the gear casing with hot oil 3.2.7.1 Energize the installed L/O pump and use it and use it to flush the red gear system until muslin bags remain clean (no less than 30 minutes). Run L/O pump for 1 hour or longer. At conclusion of run, remove inspect and clean filters in accordance with procedure 4.4.4 titled, - Clean Oil Filter on Reduction Gears of CG Tech Pub 3523-241. 3.2.7.2 Drain existing oil and open the sump and head tank inspection covers. Hand clean sump and head tank with lint free rags to remove contamination and residue. 3.2.7.3 Replace removed sump covers, and refill with flushing fluid AW45. Normally the fill line of the reduction with system oil is quite low as indicated on dipstick, to perhaps 25% the of the overall height. The flushing fluid can be filled above the normal fill line (planning for any leakage caused by higher fluid level e.g. at dipstick) in an effort to achieve better cleaning and residual removal. 3.2.7.4 Install muslin bags in lubrication system per NSTM Chapter 241, section 3.2.2.3 (NSTM excerpt pasted below). 241-3.2.2.3 Large amounts of foreign particles may enter into and contaminate the lube oil whenever MRG casing covers or bearing caps are lifted for maintenance, inspection, or repair; and during extended system shutdowns. If contamination is present, install temporary muslin or nylon filter bags (NSTM Chapter 262) in the strainer baskets until those particles that would normally pass through the strainer are removed from the system and the bags are free from debris. Ships using filters may be able to replace the filters with temporary strainer baskets and muslin or nylon bags. When the bags are clean, remove the strainer and muslin bag assembly and reinstall the filters. Even though filters may provide a higher level of filtration, strainer bags are preferred for inspection for foreign material. 3.2.7.5 Flush until lint free muslin filter bag is clean and approved by Coast Guard Inspector. 3.2.7.6 Repeat the cycle until filters remain clean and Coast Guard Inspector concurs flushing is adequate. 3.2.7.7 Flush until the overarching objectives (performance base) are achieved: Remove any surface buildup which will interfere with operation or shed particles which may clog or interfere with normal operation of the lube oil distribution system. Remove all visible grease, flux, scale, dirt, loose particles, and any other foreign contamination.Obtain normal spray patterns from all observable spray nozzles 3(ea) on upper generator pinion shaft/gear teeth and 12(ea) on the MDE High Speed pinion shaft/gear teeth. 3.2.7.8 Contractor may use an in-line particle counter or oil sampling method to monitor progress of flushing. 3.2.7.9 Ships force to manually rotate reduction gear during flushing 180 degrees every 15 minutes. 3.2.7.10 After flushing has been completed wash down the gear casing with hot oil. 3.2.7.11 Drain flushing fluid. 3.2.7.12 Fill system with MIL-L-9000, TEP 2190 and flush for minimum of 2 hours to ensure all flushing fluid has been removed from system 3.2.7.13 Restore any jumpered connections and restore the lube oil system. 3.2.7.14 Drain MIL-L-9000, TEP 2190 and manually hand clean sump and head tank with lint free rags to remove contamination and residue. 3.2.8 Refill system with USCG furnished lube oil to the reduction gears (130 gallons). Oil must be in accordance with MIL-L-9000, TEP 2190. 3.3 Final Lube Oil Flush using system pumps - Conduct the final lube oil flush in accordance with the guidance given below. NOTE All jumpers will have been removed and all components restored to operation for this flush. 3.3.1 Reinstall all removed covers. 3.3.2 Clean duplex filter housings and install new filters. 3.3.3 Energize the installed L/O pump and use it and use it to flush the red gear system until muslin bags remain clean (no less than 30 minutes). 3.3.4 Run L/O pump for 1 hour or longer. At conclusion of run, remove inspect and clean filters in accordance with procedure 4.4.4 titled, - Clean Oil Filter on Reduction Gears of CG Tech Pub 3523-241. 3.3.4.1 Ships force to manually rotate reduction gear 180 degrees every 15 minutes during this operation. 3.3.4.2 Repeat the cycle until filters remain clean and Coast Guard Inspector concurs flushing is adequate. 3.3.5 After satisfactory flushing, oil samples show no particulate, filters are not collecting debris flushing can conclude. Obtain Coast Guard Inspector's concurrence. 3.6 Final inspection (after flushing is deemed satisfactory) 3.6.1 For the final time, open gear case inspection covers and verify lube oil spray pattern on gear teeth. Verify spray pattern in the presence of the Coast Guard Inspector. 4. NOTES This section is not applicable to this work item. POC's For the Contract Contract SOW questions Primary: ENS Kevin Colon kevin.y.colon@uscg.mil 787-914-4827 Contract SOW questions Secondary: Rob Holt robert.h.holt2@uscg.mil 810-542-1041 Place of Performance/onsite Primary: LTJG Megan Wadleigh megan.a.wadleigh@uscg.mil 443-835-8432 Place of Performance/onsite Secondary: LTJG Chris Lansing Christopher.G.Lansing@uscg.mil 443-764-4921 ENGINEER OFFICER Hollyhock: CWO4 Adam Barton adam.d.barton@uscg.mil 206-914-1412 RDD/POP: Need awarded NLT 31MAR25