USCGC James Steering Actuator Overhaul

56100_TAB_0125_753

1. 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 Starboard steering system.

1.2 Government-furnished property.  All parts are onboard JAMES.

MTI

ITEM DESCRIPTION

NSN/PN

QTY

ESTIMATED COST
($/UNIT)

N

Actuator Overhaul Kit

NSN: 2530-01-699-0680

PN: RRM000445315

1 ea.

24,000

N

Hydraulic Coupling Kit

NSN: 2530-01-699-0654

PN: RRM000444570

1 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 résumé.

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:

• Advice 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 résumé.

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 starboard steering actuator.
• Piping
• Electrical wires
• Padeye plate covers
• Rudder support covers
• Hydraulic Oil (approx. 560 gals.)
• Overhead
• Ventilation Ducts
• Insulation
• Pipe hangers/brackets
• Divers needed to rig and support rudder 

3.1.5 Rigging of tools and materials.  The Contractor shall propose a rigging plan to the Coast Guard inspector for approval. The Contractor is advised to follow the equipment removal plan shown in CG Drawing 750-WMSL-101-27  

3.1.5.1 The Contractor is responsible for all rigging operations for all materials and equipment needed to accomplish this work item.  

3.1.5.2 The Contractor must provide all rigging equipment.  

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.

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.  In the presence of the Coast Guard inspector and the Tech Rep, The Contractor must rig (for lift and support) the rudder in place to allow repairs of the steering actuator assembly. Support pad eyes are shown on CG Dwg 750-WMSL-114-004 (sheet 13, items 22 thru 25).  

NOTE 

The pad eye covers may have been previously removed. Pad eye covers will not be reinstalled.  

3.3.1 Contractor must open access to use the internal pad eyes. Do not use torch.  

3.3.2 The Contractor must visually inspect each of the existing pad eyes. Pad eyes have a capacity of 12 M. Tons per Submit a CFR if inspection reveals any damage to pad eyes, or if any additional pad eyes are required. Upon reinstallation of the actuator, the Contractor must remove all installed rudder support rigging. 

WARNING 

DO NOT lift the rudder and rudder stock assembly more than 0.062”. Lifting the rudder stock more than 0.062” may result in damage to rudder stock seal and or water leaks  

3.3.3 In the presence of the Tech Rep and the Coast Guard inspector, the Contractor must use dial indicator positioned above and adjusted to measure all upward movement of rudder post. Ensure rudder post is supported by rigging and chains but not lifted more than minimum amount necessary to verify that rigging is holding rudder/rudder post assembly, (approximately 0.010”). Do Not Exceed 0.062”.  

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.

Note 

The system cleanliness requirement for the hydraulic oil: ISO 4406 cleanliness code of 17/14 or better and moisture content of less than 500 ppm. 

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.

WARNING 

Foreign materials present a high risk of severe damage to the steering gear system. Extra precautions are required to ensure cleanliness of the hydraulic system. 

3.5 Steering actuator disassembly and inspection.  The Contractor must, under the direction of or performed by the OEM Tech Rep support, overhaul the port 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
• Top and Bottom Actuator Seals

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. 

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.

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 housing 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.

NOTE

Hydraulic hoses life is 12 years.

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.

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.

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.  

3.10.1 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

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 the port 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).

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.

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 FLETC Base Charleston

1050 Register St. North Charleston SC 29405 ATTN CGC James. 

5.0 Period of performance- 05 JAN26 – 15JAN26 as availability and contractor can schedule with technicians for repair.

6.0 Points of Contact.  USCG-SFLC-LRE PL Asset Management: CWO Matthew Temple, contact@example.gov, +1 (555) 000-0000