REPAIR / OVERHAULING OF RSS HYDRAULIC SYSTEM - IN SHIP

Hydraulic Pump.Dismantle, inspect, overhaul and assemble the pump. All drive-power shaft elements, gears and casings should be subjected to NDT. (DPI / Magnaflux).

Hydraulic Pump.Renew defective / worn out components.

Hydraulic Pump.Undertake test bed trials of the pump, with simulated load (to be organized by the Firm), to prove pump performance and characteristics and also do the necessary tuning of internal valves.

Hydraulic Motor.(a) Dismantle, inspect and overhaul / refit hydraulic motors as required. All drive-power shaft elements, gears and casings should be subjected to NDT (DPI/Magnaflux). (b) Test Bed performance trials of the motor, with simulated load (to be organized by the Firm), to prove motor performance and characteristics and effect necessary tuning of internal valves. (c) System integration with motor and STW of the system for satisfactory performance of RSS Screen.

Hydraulic Valves.Check all hydraulic valves for serviceability at firm’s test bed, authorized and certified by OEM or at OEM’s Test bed. The firm is to also provide the comparative report of the performance characteristics/curves of the valves with that of the original duly certified by OEM for performance guarantee. The hydraulic valves within the power unit assembly are as follows: - (i) Non-return valves/ Flow regulators. (10 nos.) (ii) Cut-off valve / cock (04 nos.) (iii) Cock / valve (12 nos.) (iv) Maximum pressure valve / relief valve (02 nos.) (v) Double block valves (04 nos.) (vi) Sequence valves (04 nos.) (vii) Solenoid valves (double) / Direction control valves (04 nos.) (viii) Solenoid valves (Single) / Direction control valves (04 nos.) (ix) Double control valves (02 nos.)

Hydraulic system.100% pipe survey to be undertaken and all pipe lines (3/8”& 1/2”dia) to be renewed with SS material. Carry out pressure testing of hydraulic system piping to 1.5 times of the working pressure and renew pipe lines / end fittings as required to ensure zero leakage. In case welding or brazing is undertaken, the welding debris and flux remnants should be cleaned and cleared from the pipes prior fitment.

Hydraulic system.Carryout flushing through of hydraulic system for cleanliness value of NAS 10).

Hydraulic tank.Undertake cleaning of hydraulic Tanks and renew gaskets/ joints/ fittings as necessary. Check the serviceability of magnetic plugs between the baffle and reservoir bottom renew if necessary.

Instrumentation.Carry-out serviceability checks / calibration of following instrumentation devices including pressure / temperature gauges and cut-outs. Also renew as required. The firm to provide the calibration certificate of the instrumentation from NABL accredited lab: - (a) Pressure gauges (04 nos.) (b) Thermostat (02 nos.) (c) Oil level switch (02 nos.) (d) Pressure switches (02 nos.)

Hand pump.Strip /examine /refit and overhaul the hand pump. Renew if any parts worn out/ damaged. And trials post repairs.

Filters.Renewal of filters

RSS Screen.Both RSS Screens (Port & Stbd) not operating properly. Alignment of both RSS Screens panels to be carried out. Check the clearances of both RSS screens as per manual, Rectify if necessary. RSS screen should move smoothly on closing and opening during trials.

RSS Screen.Locking mechanism of both RSS Screens (Port & Stbd) not working. DI/DR to be carried out.

RSS Screen.Locking Arm for both RSS screens damaged/deformed. To be manufactured and replaced as per sample. Qty: 04 nos.

RSS Screen.Carryout complete visual survey of the RSS Screen and rectify defects if any.

Hydraulic Cylinders.(a) Dismantle cylinder and piston rod. Check dents/ nicks/ corrosion. (b) Recondition the cylinder and piston rods if required & restore the original dimensions. (c) Renew piston seals and cover seals. (d) Pressure test the hydraulic cylinders. 1.5 times of working pressure (i.e; 200 bar)

Flexible Hoses.Renew all Flexible Hoses (1/2”- 08 nos., ¼”- 12 nos.)

Accumulators.(a) Strip/ examine/ refit accumulator. (b) Check the accumulator’s diaphragm/ bladder. (c) Test the accumulator with nitrogen gas of 1.5 time working pressure (200 bar).

Pulleys.(a) Dismantle/ overhaul all pulleys. (b) Renew all bearings

Rollers.Check/Inspect all rollers, renew if necessary.

Steel wire rope.(a) Carryout visual survey of steel wire ropes/ end fittings and renew as necessary. (b) Load test certificate of wire rope to be provided by the firm. (c) Carryout alignment of RSS Screen.

Transmission shafts.(a) Dismantle/ inspect the transmission shafts. (b) Check the bent of transmission shaft, remove the bend if necessary. (c) Transmission shaft joint washer sheets to be manufactured and replaced as per sample. Qty: 20 in nos. Mat : SS

Locking bar.(a) Dismantle/ inspect the locking bar. (b) Remove the locking bar bends.

Shutter Pushing Levers.(a) Dismantle/ inspect the shutter pushing levers. (b) Remove the bend of pushing levers.

Electric Motors.Degutting / regutting of electrical works. Completed overhaul of motor and other electrical accessories and renew necessary spares, test the motors with no load and stimulating loads.

Control Panel.Degutting /regutting of electrical motors complete overhaul of motors and other electrical accessories and renew necessary test the motors with no load the stimulated loads.

Trials and STW, including load testing..Post integration and re-fitment onboard, trials and STW to be undertaken by the Firm in harbor and at sea till satisfactory performance iaw Naval requirements/Naval Testing Agencies. Identification Labels mounted on the equipment/system components are to be renewed as indicated.

Documentation / Records.A comprehensive report to be submitted with record-photographs of work/ repair/ refit undertaken, test/ trial/ calibration reports, drawings and catalogues as relevant.

Mandatory Spares.Bearing Kit for Reduction Gear.EM7160D-56500175B

Mandatory Spares.Gasket Kit for Reduction Gear.EM7160D-56500175G

Mandatory Spares.Gasket Kit for Hydraulic Motor.56401265G

Mandatory Spares.Sequence Valve (Steel/Accioio).56910787

Mandatory Spares.Solenoid Valve Kit.20200669S

Mandatory Spares.Non-Return Valve.56910443

Mandatory Spares.Flow Regulator + Not Return Valve.56921027

Mandatory Spares.Thermostat (temperature control switch).56923502

Mandatory Spares.Filter (return line).56925094

Mandatory Spares.Cock (Low Pressure).20200669A

Mandatory Spares.Cock (Low Pressure).20200669A

Mandatory Spares.Cock (High Pressure).56915126

Mandatory Spares.Valve fitting (Adopter, Ferrule& Nut).NIL

Mandatory Spares.Pipeline & fittings.NIL

Mandatory Spares.Gaskets/Joints/Fittings.NIL

Mandatory Spares.SS Pipe, End Fitting and Supporting Brackets/ Clamps.NIL

Mandatory Spares.Seal Kit for Pulley.50201068

Mandatory Spares.Bearing Kit for Pulley (2 Bearings for each pulley).51001352

Mandatory Spares.Fastener for Roller Support.NIL

Mandatory Spares.Screen locking cylinder.EM7160D-21300380

Mandatory Spares.Shutter locking cylinder.EM7160D-21300428

Mandatory Spares.Wire Rope.EM7160D-21300434

Mandatory Spares.Manometer kit.EM7160D-56920040

Mandatory Spares.Oil level control switch.EM7160D-56923014

Mandatory Spares.Cartridges for Return line filter.EM7160D-56925030

Mandatory Spares.Pressure Switch.20200669A

Mandatory Spares.Oil Level Switch.--

Mandatory Spares.Flexible Hoses (1/2”).--

Mandatory Spares.Flexible Hoses (1/4”).--

Royalle Engineering Enterprise

Industrial Engineers And Manufacturers

JAMI HYDRAULIC

SAGAR SHIP REPAIRERS AND MARINE SERVICES

YEOMAN MARINE SERVICES PVT. LTD.