JAMES STEERING OVERHAUL

THIS IS TO BE AWARDED SOLE SOURCE. 56100_TAB_0125_753 ITEM 1: Steering Actuator, Overhaul 1. SCOPE 1.1 Intent. This work item describes the requirements for the Contractor to overhaul the rotary vane steering actuator assembly for the port and starboard steering system. 1.2 Government-furnished property. MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST ($/UNIT) N Actuator Overhaul Kit NSN: 2530-01-699-0680 PN: RRM000445315 2 ea. 24,000 N Hydraulic Coupling Kit NSN: 2530-01-699-0654 PN: RRM000444570 2 ea. 2,000 2. REFERENCES Coast Guard Drawings Coast Guard Drawing 750-WMSL_100_44, Rev K, Unit 3320 Struct - Inner Bottom 2nd Deck FR 89-98 (ASC100332) Coast Guard Drawing 750-WMSL-243-003, Rev B, Shipping & Unshipping of Propulsion Shafting (ASC243004) Coast Guard Drawing 750-WMSL-556-004, Rev E, Steering Gear Hydraulic Diagram (ASC556003) Coast Guard Drawing 750-WMSL-556-022, Rev H, Steering Gear and Stern Gate Hydraulic Piping - Unit 3330 (ASC556333-HY) Coast Guard Drawing 750-WMSL-561-001, Rev D, Steering Gear Foundation (ASC561001) Coast Guard Drawing 750-WMSL-562-002, Rev C, Rudder (ASC562002) Coast Guard Drawing 750-WMSL-562-003, Rev D, Rudder Support System (ASC562003) Coast Guard Publications Coast Guard Technical Publication (TP) 7182A, SWBS 561, Jan 2022, Steering Machinery Subsystem - Operation & Maintenance Manual Coast Guard Technical Publication (TP) 7193, SWBS 561, Jan 2022, Steering System Operations and Maintenance Manual 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 3041 (SFLC Std Spec 3041), 2022, Shipboard Electrical Cable Test Surface Forces Logistics Center Standard Specification 5000 (SFLC Std Spec 5000), 2022, Auxiliary Machine Systems Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2022, Requirements for Preservation of Ship Structures Other References International Standard Organization (ISO) 4406, 2021, Hydraulic Fluid Power - Fluids - Method for Coding Level of Contamination by Solid Particles Kongsberg Maintenance Manual DMN000278736, Rev C, Kongsberg Steering Gear Type SR and SV MIL-STD-419, Sept 2021, Cleaning and Protecting Piping Tubing, And Fittings for Hydraulic Power Transmission Equipment 3. REQUIREMENTS 3.1 General. 3.1.1 CIR. None. 3.1.2 Tech Rep. The Contractor must provide the services of Tech Reps in accordance with the following subparagraphs. 3.1.2.1 The Contractor must provide the services of an OEM authorized/ licensed Tech Rep for the Kongsberg steering actuator to accomplish the following on site: Provide manufacturer's proprietary information, software, and tools pertinent to the equipment/system. Assist with proper repair methods and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system. Perform all actual repair work on the actuator. 3.1.2.1.1 Ensure the Tech Rep is an OEM Certified Representative for the system/equipment stated above and demonstrated on their r'sum. 3.1.2.2 Tech Rep. The Contractor must provide the services of a Qualified Technical Representative who is familiar with the WMSL Steering System Hydraulic Power Units to accomplish the following on site: Advise on manufacturer's proprietary system information. Ensure compliance with manufacturer's procedures and standards during system disassembly, inspection, repair, modification, calibration, and reassembly of the equipment/system as applicable. 3.1.2.2.1 Ensure the Tech Rep has experience with the system/equipment stated above and demonstrated on their r'sum. 3.1.2.2.2 Submit the name and r'sum of the Tech Rep to the COR at the Arrival Conference. 3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection). 3.1.3.1 Protection of fine surfaces. The Contractor must protect all fine surfaces in accordance with SFLC Std. Spec 5000. 3.1.3.2 Hydraulic system contamination protection. The Contractor must maintain existing hydraulic cleanliness in accordance with SFLC Std. Spec 5000. 3.1.3.3 Maintain the strictest standards of cleanliness in accordance with MIL-STD-419 while hydraulic system is open. Work on the steering hydraulics is not permitted while any blasting, grinding, welding, etc. is being performed in, or adjacent to, the steering gear space. 3.1.3.4 Hatch opening must be covered and roped off to prevent a falling hazard to personnel when not in use. NOTE Plastic bags may be used only when arrangement or configuration prevents the use of the other sealing methods specified above. 3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following: Access plate (BERP) located above the port and starboard steering actuator. Piping Electrical wires Padeye plate covers Rudder support covers Hydraulic Oil (approx. 560 gals.) Overhead Ventilation Ducts Insulation Pipe hangers/brackets NOTE Coast Guard personnel will operate all shipboard machinery and equipment. 3.2 Operational test, initial. Prior to commencement of work, the Contractor must, under the direction of the OEM Tech Rep, witness Coast Guard personnel perform an initial operational test of all items or shipboard devices to be disturbed, used, repaired, or altered, to demonstrate existing operational condition. Perform the following inspections. Use Data sheet No. 1 (section 4 of this WI) to record results for Starboard actuator only. Submit a CFR. 3.2.1 Verify that all rudder angle indicators (manual indicator on actuator, MCMS indicator, local indicator, and remote indicators on bridge) must be within a 2-degree tolerance throughout range of motion. WARNING Special care should be taken not to hold the rudder hard over for more than a few seconds at a time to avoid overheating the system. 3.2.2 Starboard Steering Gear: In the presence of the Coast Guard inspector, place the 1A HPU online, with the controller set to - REMOTE, cycle the rudder from Zero to Port (hard-over), from Port to Starboard (hard-over), from Starboard to Port (hard-over) and from Port to Zero. On the Port to Starboard and Starboard to Port transitions, record the time from 30 degrees on one side to 30 degrees on the other side (speed should be 3 degrees/second or 20 (+/-1) seconds total). With the rudder at Zero degrees and the HPU running, inspect all hoses, fittings and seals for leakage. 3.2.3 Set the steering controller to - LOCAL. Using the pushbuttons operators on the pump, cycle the rudder from Zero to 15 degrees Port, from 15 degrees Port to 15 degrees Starboard and from 15 degrees Starboard to Zero. It is not necessary to record times on this evolution - this portion of the test only demonstrates that local control can be achieved. Record the result as SAT or UNSAT. 3.2.4 Switch to 1B HPU and perform the same tests to complete the Starboard Steering Gear System test. Note The Cutter is currently outfitted with recessed padeyes as located on CG Drawings 750-WMSL_100_44 and 750-WMSL-243-003 and are in place in the hull above each propeller and rudder. Padeye numbers are 22, 23, 24, and 25 as identified on Coast Guard Drawing 750-WMSL-243-003. Access covers for the recessed padeyes are not required to be reinstalled. Each rudder weighs approximately 12,000 lbs. 3.3 Rudder support. The Contractor must ensure the rudder has been supported in place to allow repairs of the steering actuator assembly. Coast Guard Divers will remove metal plate covers to access the recessed padeyes above each rudder. The Contractor must pull test all existing recessed padeyes to 150% of their maximum expected working load for 10 minutes. In no case may a padeye's - expected working load (a) exceed the tabulated maximum working load for the padeye's size or (b) exceed the structure's (that padeye is attached to) ability to carry the load. At conclusion of the pull test, visually inspect each padeye for damage. NOTE The centerline of the rudder post is located forward of Frame 96, above the stern gate utility room and forward of an inaccessible void. If additional padeyes are necessary, it may be necessary to clean and gas free these spaces. 3.4 Hydraulic reservoir inspection. The Contractor must take oil samples for testing of existing oil from each reservoir and send out for analysis. Label and retain one extra oil sample from each system for back-up testing if necessary. Drain all 2135 TH hydraulic oil from the HPU actuators and reservoirs (approximately 550 gallons total), and dispose of in accordance with all state, local and federal regulations. Provide CFR with test results. For steering gear hydraulic system details, see Coast Guard Drawings 750-WMSL-556-004 and 750-WMSL-556-022. 3.4.1 Remove access covers from reservoirs and storage tanks. Take samples of any heavy sludge or particulate matter in the tanks. Remove all sludge and debris and wipe down with lint free rags. If any metallic debris (metal filings, shavings, babbitt) is present, notify the Coast Guard Inspector immediately. 3.4.2 When all tanks are thoroughly clean, and just prior to closure ensure all foreign objects have been removed (e.g. rags, caps, towels, plugs). Contractor must present these areas to the Coast Guard Inspector, then close in the presence of the Coast guard inspector. Install new gaskets. 3.5 Steering actuator disassembly and inspection. The Contractor must, under the direction of or performed by the OEM Tech Rep support, overhaul the Starboard steering actuators in accordance with OEM procedures. Rudder foundation, rudder stock, and rudder support system are shown on CG Dwgs 750-WMSL-561-001 and 750-WMSL-562-003. At a minimum, the Contractor must renew the following parts: Piston Seals HP Seals and Backing Strips LP Seals Bearing Shells O-rings 3.5.1 Collect and dispose of all drained fluids in accordance with all federal, state, and local regulations. 3.5.2 Prior to disassembly, wipe down the exterior of the actuator assembly and the general area near the actuator to remove dirt and contaminants. Maintain a clean environment when working around open hydraulic equipment. 3.5.3 Actuator internal inspection. Inspect the interior of the actuators (including, but not limited to, the piston, piston dividers, upper and lower housings, hydraulic coupling, rotor, and rudder stock) for any indications of wear or damage. Submit a CFR documenting the existing condition of the actuators. 3.5.4 During final installation of the actuator, ensure the rudder and rudder stool are aligned, and the actuator and helm are set at 0 degrees. WARNING Foreign materials present a high risk of severe damage to steering gear system. Extra precautions are required to ensure cleanliness of the hydraulic system. Note Suction strainers are located inside the service tanks. 3.6 Filters and strainers, renew. The Contractor must renew the return, charge, and servo filters on each of the Starboard HPU's. Close up filter housings and torque fasteners in accordance with Chapter 5.3 of CG Tech Pub 7182A. Renew the suction strainers and reservoir filter breather on each HPU. 3.7 Manifold and valve inspection and testing. The Contractor must clean, inspect and test the hydraulic manifold and valves (i.e. control, relief, and locking valves) for the starboard system. Clean and visually inspect all parts for defects, deterioration, dirt, scale, rust, grease, and foreign material. Submit a CFR. NOTE Hydraulic hoses life is 12 years 3.8 Hose inspection. The Contractor must visually inspect the condition of all flexible hoses identified in Tables 1 and 2 and submit a CFR with the following information. Hoses that require renewal will be subject to a Change Request. Hose physical condition Service life dates (date for required hose renewal; if not specified, add 12 years to installation date) TABLE 1 - STBD STEERING GEAR (COMPARTMENT: 2-94-1-E) Hose Serial # Length (in.) Size (in.) Part Number Fitting #1 Fitting #2 Test Pressure (psi) SG-F-001 20 1 F20606-16-16-16C-20.00 Female JIC Female JIC 200 SG-F-002 26 1/2 F20606-8-8-8C-26.00 Female JIC Female JIC 375 SG-F-003 49 2 2651-32 Female JIC Male CPV 5000 SG-F-004 35 2 2651-32 Male CPV Male CPV 5000 SG-F-005 31.5 3/4 F20606-12-12-12C-31.50 Female JIC Female JIC 200 SG-F-006 43 2 2651-32 Male CPV Male CPV 5000 SG-F-007 43 2 2651-32 Male CPV Male CPV 5000 SG-F-008 26.5 3/4 F2060606-12-12-12C-26.50 Female JIC Female JIC 200 SG-F-009 32 1/2 F2060606-8-8-8C-32.00 Female JIC Female JIC 375 Table 2 - Port Steering Gear (COMPARTMENT: 2-94-2-E) Hose Serial # Length (in.) Size (in.) Part Number Fitting #1 Fitting #2 Test Pressure (psi) SG-F-011 20 1 F20606-16-16-16C-20.00 Female JIC Female JIC 200 SG-F-012 26 1/2 F20606-8-8-8C-26.00 Female JIC Female JIC 375 SG-F-013 31.5 3/4 F20606-12-12-12C-31.50 Female JIC Female JIC 200 SG-F-014 49 2 2651-32 Female JIC Male CPV 5000 SG-F-015 35 2 2651-32 Male CPV Male CPV 5000 SG-F-016 26.5 3/4 F2060606-12-12-12C-26.50 Female JIC Female JIC 200 SG-F-017 43 2 2651-32 Male CPV Male CPV 5000 SG-F-018 43 2 2651-32 Male CPV Male CPV 5000 SG-F-019 32 1/2 F2060606-8-8-8C-32.00 Female JIC Female JIC 200 3.9 Hydraulic oil refilling. The Contractor must refill the reservoirs with hydraulic oil per MIL-H-17672, symbol 2135, in accordance with CG Tech Pub 7182A. The Contractor must filter new hydraulic oil in accordance with SFLC Std Spec 5000, paragraph C2.1.2 prior to entry into the Cutter's tanks or system. Cleanliness of oil must be ISO 4406 Cleanliness Code of 17/14 or better. NOTE Coast Guard personnel will operate all shipboard machinery and equipment. If covered by a separate work item, final testing of the steering system is only required to be performed once during this availability. 3.10 Operational test, post repairs. After completion of work and in the presence of the Coast Guard Inspector, the Contractor must thoroughly test and demonstrate the equipment listed below to be in satisfactory operating condition. Use Data sheet no. 2 (section 4 of this WI) to record results for Starboard actuator only. Submit a CFR. 3.10.1 Verify that the rudders operate throughout their full range with no indications of binding and appear smooth during operation. 3.10.2 All rudder angle indicators (manual indicator on actuator, MCMS indicator, local indicator, and remote indicators on bridge) must be within a 2-degree tolerance throughout range of motion. 3.10.3 The Contractor must perform the initial startup procedures in accordance with Coast Guard TP 7182, Paragraph 7-2. Upon completion, verify that the relief valves are properly set in accordance with Table 3. TABLE 3 - relief valves sERVICE DESCRIPTION Set Point (PSIG) Pump Main System Relief Valve 1530 - 25 Relief Valve (Charge) 217 - 25 Relief Valve (Servo) 1450 - 25 Cross-line Relief Valve 1580 - 25 Warning Special care should be taken not to hold the rudder hard over for more than a few seconds at a time to avoid overheating the system. 3.10.4 Starting with the Starboard Steering Gear, and in the presence of the Coast Guard inspector, place the 1A HPU online, with the controller set to - REMOTE, cycle the rudder from Zero to Port (hard-over), from Port to Starboard (hard-over), from Starboard to Port (hard-over) and from Port to Zero. On the Port to Starboard and Starboard to Port transitions, record the time from 30 degrees on one side to 30 degrees on the other side (speed should be 3 degrees/second or 20 (+/-1) seconds total). With the rudder at Zero degrees and the HPU running, inspect all hoses, fittings and seals for leakage. 3.10.5 Set the steering controller to - LOCAL. Using the pushbuttons operators on the pump, cycle the rudder from Zero to 15 degrees Port, from 15 degrees Port to 15 degrees Starboard and from 15 degrees Starboard to Zero. It is not necessary to record times on this evolution - this portion of the test only demonstrates that local control can be achieved. Record the result as SAT or UNSAT. 3.10.6 Switch to 1B HPU and perform the same tests to complete the Starboard Steering Gear System test. 3.10.7 The Contractor must perform the Internal Leakage Test per paragraph 7.10 of the Kongsberg Maintenance Manual DMN000278736 for both port and starboard actuators. Measure the total leakage during each separate segment of testing (Port to Starboard hard-over, hard-over Starboard, Starboard to Port hard-over, and hard-over Port) and submit the results via CFR. 3.11 Oil sample analysis. The Contractor must take oil samples for testing of existing oil from each reservoir and send out for analysis to demonstrate cleanliness has been maintained. Submit a CFR with the oil sample analysis report. 3.12 Touch-up preservation. The Contractor must prepare and coat all new and disturbed surfaces to match existing adjacent surfaces in accordance with SFLC Std Spec 6310, paragraph 3.1.13 (Touch-ups and minor coating repairs.) 4.0 Place of performance- CGC JAMES at Naval Station Norfolk VA. Naval Station Norfolk 1530 Gilbert Street Suite 2000. Norfolk, VA 23511 ATTN CGC James. 5.0 Period of performance- 14 MAR 2025 - 17 MAR 25 6.0 Points of Contact. USCG-SFLC-LRE PL Asset Management: CWO Matthew Temple, contact@example.gov, +1 (555) 000-0000