MACHINERY, AUXILIARY SYSTEMS September 26, 2016

USNS MARY SEARS T-AGS 65 Solic. No.: MLL-16-T65-0001 MACHINERY, AUXILIARY SYSTEMS April 7, 2018

ITEM NO. 0507 Category “A” USMMI/MLL/RCS Revision X

REFURBISH ANCHOR WINDLASS & REPLACE GEAR BOX SEALS

1.0 1.0 Abstract:

1.1 This item describes the work required to overhaul the unit and replace the shaft output gear box seals on the anchor windlass.

2.0 References:

2.1 Technical Manual T9581-AN-MMO-010 Anchor Windlass Model MDW 193-H

1.0 Item Location/Description:

1.1 Location:

2.1.1 Anchor Windlass, (2-15-1)

1.2 Description/Manufacturers Data:

1.2.1 Anchor Windlass McElroy Marine Machinery Model: MDW-193-H

3.0 USMMI Furnished Material:

3.1 All the below parts and materials to be provided by the ship.

3.1.1 Gear Box Seals

3.1.2 Gear Box oil

3.1.3 Bushings

3.1.3.1 Pillow Block Bushings P/N 205-15A-M (2) each

3.1.3.2 Wildcat Bushings P/N 205-19A-m (4) each

3.1.4 Shell Oil Co. Alavania EP2 or Equal

3.1.5 Shell Oil Co., Omala 85-140 or Equal

3.1.6 Mobil 150-46 or 150-68 or Equal

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0507 - 1 USNS MARY SEARS T-AGS 65 Solic. No.: MLL-16-T65-0001 MACHINERY, AUXILIARY SYSTEMS April 7, 2018

3.1.7 Brake band standoff springs bearing P/N B-BBRBCY72L (2) each

3.1.8 Brake band Standoff Springs P/N H-C-975-125-3000S (4) each

3.1.9 Brake band Standoff Housing P/N 205-65C-M (2) each

3.1.10 Split Brake band Ear Pin P/N 205-65A-M (2) each

3.1.11 Brake band standoff Bearing Pins P/N 205-65D-M (2) each

3.1.12 Upper Brake band lining P/N A.500X60GG (2) each

3.1.13 Lower Brake band lining P/N B.500X60GG (2) each

3.1.14 ¼”-20 N. C. x 1 ¼ “ L.G. Cont. Sunk Cap Screw Brass P/N JBS .250 X1.25 (140) each

3.1.15 ¼” -20 N. C. Hex HD. Lock Nut P/N KBX .250 (140) each

3.1.16 One each 3000 PSI Non-metallic hose Aeroquip 1 ½ inch diameter by 23 inches long

3.1.17 One each 3000 PSI Non-metallic hose Aeroquip 2 inch diameter by 34 inches long

3.1.18 One each 3000 PSI Non-metallic hose Aeroquip 1 ½ inch diameter by 32 inches long

3.1.19 One each 3000 PSI Non-metallic hose Aeroquip 2 1/2 inch diameter by 31 inches long

3.1.20 One each 3000 PSI Non-metallic hose Aeroquip 3/4 inch diameter by 42 inches long

4.0 Notes:

4.1 The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTR’s.

4.2 The contractor and all subcontractors, regardless of tier are advised to review other work items under this contract to determine their effect on the work required under this work item.

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REFURBISH ANCHOR WINDLASS & REPLACE GEAR BOX SEALS 4.3 It shall be the responsibility of the contractor to schedule the to notify the Port Engineer 24 hours in advance to arrange for an ABS surveyor to attend the ship and complete a repair survey related to this work item. 4.4 The contractor shall comply with all requirements of equipment tag out program as established by COMSCINST 3540.6, as amended, section 15.2.2, Engineering Operations and Maintenance Manual. The Chief Engineer is to administer the program. Prior to the start of work, the contractor shall contact the USMMI Port Engineer and / or the Chief Engineer to coordinate the implementation of the Tag Out Program for the entire performance period of this item. The prime contractor shall be responsible for compliance by both prime and subcontractor personnel.

4.5 Several fasteners on inspection covers and the hydraulic motors are corroded and require replacement. Several hydraulic hoses have severe UV and paint exposure and require replacement. 5.0 Quality assurance requirements:

5.1 All workmanship, materials and testing shall be in accordance with the latest ABS Rules for Building and Classing Steel Vessels.

6.0 Statement of work:

7.1 Arrangements/Outfitting:

6.1.1 Check with the chief engineer and chief mate prior to commencing any work on this eq uipment to allow unit to be electrically, mechanically and hydraulically isolated and tag ged out and prepared for repairs. Disengage clutch and lockout in the disengaged position.

6.1.2 Once the anchor chains have been removed and ranged on the dock the anchor windlass is to be hydraulically and mechanically disconnected, removed from the vessel, and transported to a facility where it can be disassembled, up to the point where replacement of the speed reducer shaft oil seals can be performed. This requires complete removal of the gypsy heads, wild cat bushing/pillow block, wild cats, and wild cat clutch mechanisms and wild cat brakes. The Anchor Windlass weighs 15,600 lbs.

6.1.2.1 The Contractor is to remove all hydraulic hoses, caps the shipboard connection side to prevent contamination and then using the existing hose fabricate and provide new hoses.

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6.1.2.2 Once the anchor windlass has been removed, all of the shims are to be marked as to location, orientation and sequence installed to allow accurate realignment once repairs are completed and the unit is returned and reinstalled. There are 8 leveling pads.

6.2 Structural: None additional 6.3 Mechanical/Fluids: 7.3.1 Remove the port and starboard side shaft assemblies to include the brake band, brake, front and rear chain strippers, cathead (using a suitable sling (weight is 1680 lbs.), cathead spacers, rope guard, cathead guard, cathead key, side frame assembly, pillow block assembly, pillow block bushing, wildcat spacer, wildcat (using suitable lifting slings as unit weighs 2500 lbs.), wildcat bushing, long clutch lever, clutch spacer, jaw clutch, reducer spacer, and clutch operator assembly.

7.3.2 The gear box and wildcat drives are to be opened, cleaned, and inspected..

7.3.3 Clean up the anchor windlass components to allow inspection and develop a condition report. The wildcat brake drum is to be grit blasted to remove all rust and then repainted using specification 0002 guidance.

7.3.4 The brake band and liners are to be inspected and the liners are to be replaced if thickness is 3/16 inch or less.

7.3.5 Remove the old seals and replace with the ship provided spares. The anchor windlass shaft accessories components shall be reassembled using anti-seize compound on all fa steners. Reassemble in the reverse of how the components were disassembled using the technical manual guidance.

7.3.6 All mating and riding surfaces are to be dressed to provide a smooth properly fitted surf ace. The contractor shall grease and lubricate all mechanisms, linkages, and grease fitti ngs, following reassembly.

7.3.7 After all repairs are completed the anchor windlass is to be transported to the ship, rigged onboard and reinstalled back to its original position. The unit is to be adjusted to make it level and aligned using the existing shims and any additional required to achieve the correct conditions in accordance with the guidance in the technical manual.

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REFURBISH ANCHOR WINDLASS & REPLACE GEAR BOX SEALS 7.3.8 The contractor is to provide and install new 1 ¼”, 7 threads per inch grade 8 bolts torqued to 1200 ft. lbs. using a torque multiplier. This step is to be witnessed by the chief mate. Level and alignment is to be rechecked once installation is completed.

7.4 Electrical/Control: None additional 7.5 Electronics: None additional 7.6 Preparation of Drawings: None additional

7.7 Inspection/Test:

7.7.1 After repairs are completed and the unit is properly leveled and aligned and reinstalled the unit is to be operationally tested with the assistance of the crew. Any discrepancies observed during the test are to be corrected at the Contractor’s expense.

7.7.2 The high pressure relief valve is to be set and tested to lift at 2600 PSI.

7.7.3 The Pilot valve is to be set and tested at 1300 PSI.

7.7.4 The Contractor is to prove proper operation of the anchor windlass in the presence of the Port Engineer, ABS surveyor and master. The system shall be operated under power as well as free fall to demonstrate proper operation.

7.8 Painting:

7.8.1 Mechanically cleaning to (SSPC-SP-2), power tool cleaning (SSPC-SP-3) and painting all disturbed areas on the anchor windlass are to be accomplished in accordance with the guidance in work item 0002.

7.9 Marking: None additional

7.10 Manufacturer’s Representative:

7.10.1 Contractor is to provide an OEM Representative or Equivalent Technician familiar with this anchor windlass to oversee the repairs and inspections. McElroy Machine & MFG. Co., Inc. 10011 Lorraine Rd. Gulfport, MS 39501

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REFURBISH ANCHOR WINDLASS & REPLACE GEAR BOX SEALS 8.0 GENERAL REQUIREMENTS:

8.1 The Contractor shall provide all labor, materials, temporary staging and tools required to accomplish this work specification, except as specified in Section 4.0.

8.2 The Contractor shall remove and reinstall interferences necessary to accomplish this work specification.

8.3 Inspection and acceptance of all work shall be by the Chief Engineer and the designated On- site USMMI Representative (Port Engineer).

8.4 All areas involved in work or traversed by workmen or equipment shall be left clean and in good order.

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