HPU #1 Repair and Flush

NOAA Ship Gordon Gunter HPU#1 Pump Repair and Flush 1.0 Purpose 1.1 This work is necessitated by oil/water contamination in the HPU #1 system. 2.0 References 2.1 Drawing No. GU-556-001 Rev A., "NOAA Ship Relentless Hydraulic Piping System Modifications." 3.0 Government Furnished Material 3.1 None. 4.0 Requirements 4.1 Remove both P16H pumps; open and inspect them for damage. If damage is found, provide a report to the COTR with findings and recommendations for repair. Reassemble pumps using new seals and bearings; reinstall. 4.2 Open and clean the sump tank to remove all traces of contamination. Refill with new contractor provided hydraulic oil (Mobil DTE 10 Excel 68). 4.3 Jumper the HPU#1 hydraulic system in four sections (one for each winch - two trawl winches, one Gilson winch, and one net reel) and flush with hydraulic oil heated to at least 140oF, through 10 micron filters. See sheet 2 of Reference 2.1 for HPU #1 schematic and system components. Flush for a minimum of 8 hours or until no water or any other type of residue can be found in the oil. The net reel is currently located off the ship, but will be reinstalled prior to the flush. This unit was operated while the hydraulic system was contaminated with water and must be flushed as well. 4.4 Remove all the hydraulic motors transport to shop and hook up to flushing rig in the shop; operate the motors to flush out any contaminates; reinstall motors. 4.5 Remove the directional control valves; disassemble, clean and reassemble the valves using new seals and o-rings; reinstall. 4.6 Remove the heat exchanger to the shop and perform a hydrostatic pressure test to verify that the heat exchanger is not faulty. Provide a report to the COTR with findings and recommendations for repair. Reinstall heat exchanger following testing and repairs. 4.7 Renew the suction valve for the #2 HPU pump. 4.8 Test run the HPU and all components (i.e., trawl winches, Gilson winch, net reel) for a minimum of 2 hours to prove system operation and that there are no leaks. 4.9 Rewrap with new Densyl tape all external fittings whose wrappings were disturbed. 5.0 Quality Assurance 5.1 Results of examination of bags and/or filters used for flushing for water, sludge content. 6.0 Notes 6.1 Reference 2.1 Drawing title refers to NOAA Ship Relentless. "Relentless" was renamed "Gordon Gunter" following conversion in 1999.