Ministry of Defence

Defence Standard 02-305
Issue 2 Publication Date 13 January 2003

Requirements for Gearing
-Main Propulsion

Category 2

AMENDMENTS ISSUED SINCE PUBLICATION
AMD NO

DATE OF
ISSUE

TEXT AFFECTED

SIGNATURE &
DATE

Revision Note
This Issue of this Standard has been prepared to incorporate changes to text and presentation.
The technical content has been updated in line with current practice.
Historical Record
Def Stan 02-305 Issue 1
NES 305 DRAFT Issue 5
NES 305 Issue 4

1 April 2000
May 1998

DEFENCE STANDARD 02–305 (NES 305)

REQUIREMENTS FOR GEARING – MAIN PROPULSION

ISSUE 2

This Defence Standard is
authorized for use in MOD contracts
by the Defence Procurement Agency and
the Defence Logistics Organization

Published by:
UK Defence Standardization
Defence Procurement Agency
An Executive Agency of The Ministry of Defence
Kentigern House
65 Brown Street
Glasgow G2 8EX
1

control and surveillance instrumentation) and with those items mounted directly on the Gearcase (e. (4) The responsibility for the successful installation and commissioning of the high speed line(s). All local controls and surveillance instrumentation associated with the Main Gearing. starters. only if stated in the SRD. 3.g.g. Turning Gear. The electrotechnical equipment associated with the Gearbox (e.DEF STAN 02–305 / ISSUE 2 (NES 305 ) SCOPE 1. specifies the minimum requirements which must be met by the Main Gearing Contractor and other authorities. Requirements relating to the design and manufacture of Main Thrust Bearings are given in DEF STAN 02-304. The lubricating system internal to the Gearbox downstream from the Gearbox supply point(s) (to be defined). (2) Dehumidification. when integral. clutches. couplings and bearings contained therein. it includes all items such as motors. Gearbox seating arrangements. cable conduit and wiring. Dehumidifier. The extent of the equipment covered by this Standard is as follows: a. etc. (2) For driven units mounted remotely. which comprises: (1) The gearcase.g. brakes. including the local Plant Control Unit (PCU). g. b. h. shafts (main and lay). installation and commissioning of a Main Propulsion Gearbox intended for use in Vessels for the Royal Navy. 2 . This Standard will be called into use by the contract placed on the Main Gearing Contractor to design and/or manufacture a Gearbox. 2. junction boxes. c. Motor Driven Lubricating Oil (LO) pumps). Gearbox Atmospheric Control: (1) Venting.g. The Main Gearing. For futher information and guidance refer to DEF STAN 02-303. f. (3) The Gearbox output flange(s) and Main Shaft Flexible Coupling where applicable. e. Turning Gear) or. on the Vessel’s structure.g. This Defence Standard (DEF STAN) 02-305. The Main Thrust Bearing. All other Gearbox auxiliaries (e. Auxiliary drives required by the System Requirement Document (SRD) as follows: (1) For gear driven units mounted on the Gearcase or. including balancing. on the Drain Tank (e. i. during the design. in conjunction with the documents referred to herein. As this Standard also places responsibility on Prime Contractors or other manufacturing/installation authorities. it will also be called into use by contracts concerned with the building of Vessels and Shore Test Facilities (STF). when integral on the Drain Tank. (2) The input flexible coupling including control of the interface with prime mover output flange and its satisfactory performance where applicable. d. e. oil seals.) required by this Standard or by the SRD. The term ‘Electrotechnical’ is formally defined in DEF STAN 08-107. if specified. dipsticks. and all gears. manufacture.

4. When Defence Standards are incorporated into MOD contracts. This standard has been reissued to reflect changes in Departmental Nomenclature due to MOD reorganization and the changes to technical requirements. This Standard is the property of the Crown. To the extent permitted by law. 7. When this Standard is used in connection with a MOD tender or contract. Conditions of Release General 8. and those directly applicable to a particular contract are to be dealt with using contract procedures. the MOD hereby excludes all liability whatsoever and howsoever arising (including but without limitation. users are responsible for their correct application and for complying with contractual and other statutory requirements. 13. reference in this Standard to approval. 6. authorized and similar terms. Unless otherwise stated. reproduced or published without written permission of the MOD. It is not to be released.DEF STAN 02–305 / ISSUE 2 (NES 305 ) FOREWORD Sponsorship 1. in connection with which it is issued. 12. Compliance with a Defence Standard does not of itself confer immunity from legal obligations. or submission of the tender. This Defence Standard has been devised solely for the use of the MOD. 2. Proposals for amendments that are not directly applicable to a particular contract are to be made to the publishing authority identified on Page 1. including related documents. 3 . Any significant amendments that may be made to this Standard at a later date will be indicated by a vertical sideline. 5. Any user of this Standard either within MOD or in industry may propose an amendment to it. Unless otherwise authorized in writing by the MOD must be returned on completion of the contract. MOD Tender or Contract Process 11. liability resulting from negligence) for any loss or damage however caused when the Standard is used for any other purpose. approved. 10. No alteration is to be made to this Standard except by the issue of an authorized amendment. means by the MOD in writing. and its contractors in the execution of contracts for the MOD. This document is Crown Copyright and the information herein may be subject to Crown or third party rights. Enquiries in this connection may be made to the authority named in the tender or contract. Deletions will be indicated by 000 appearing at the end of the line interval. relevant to each particular tender or contract. 3. This Defence Standard is sponsored by the Warship Support Agency (WSA). the user is to ensure that he is in possession of the appropriate version of each document. Ministry of Defence (MOD). 9. If it is found to be unsuitable for any particular requirement MOD is to be informed in writing of the circumstances. The Crown reserves the right to amend or modify the contents of this Standard without consulting or informing any holder.

standards and drawings. W4 4AL UK Defence Standardization Defence Procurement Agency An Executive Agency of the Ministry of Defence Kentigern House 65 Brown Street Glasgow. b. including specifications. together with the sponsoring Directorate and the Tender or Contract Sponsor. Health and Safety Warning This Defence Standard may call for the use of processes. substances and/or procedures that are injurious to health if adequate precautions are not taken. 18. 389 Chiswick High Road. Other documents Tender or Contract Sponsor to advise. those quoted may not necessarily be exhaustive. Current support practice. its systems or equipment. its systems or equipment. If not applied may have a Critical affect on the following: Safety of the vessel. If not applied may have a Significant affect on the following: Safety of the vessel. c. Category 2. All applications to the MOD for related documents are to quote the relevant MOD Invitation to Tender or Contract number and date. In the tender and procurement processes the related documents listed in each section and Annex A can be obtained as follows: a. G2 8EX. Defence Standards British Standards Institution. British Standards b. Corporate experience and knowledge. Category 1. London. Prime Contractors are responsible for supplying their subcontractors with relevant documentation. Additional Information (There is no relevant information included. The Category of this Standard has been determined using the following criteria: a. 19. If not applied may have a Minor affect on the following: MOD best practice and fleet commonality. Category 3. 17. Operational performance of the vessel. Through life costs and support. This Standard has been written and is to be used taking into account the policy stipulated in JSP 430: MOD Ship Safety Management System Handbook. Related Documents 15. 20.) 4 . its complement or third parties. 16. Operational performance of the vessel. Where attention is drawn to hazards.DEF STAN 02–305 / ISSUE 2 (NES 305 ) Categories of Defence Standard 14. It refers only to technical suitability and in no way absolves either the supplier or the user from statutory obligations relating to health and safety at any stage of manufacture or use. c. its complement or third parties.

. 5 SECTION 1. . .1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Design . . . . . . . . . . . . . . . . . . . . . . . . . .2 3. Drawings and Information Required for a Design Contract or Gearbox Order . .6. . . . . . . . . . . . . . . . . . .2. . . . . . . .1 3. . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . .3 3. . . . . . . . . . . . . . . . . . . . . . . . . Basic Requirements . . . . . . . . . . . . . 4 Health and Safety . . . . . . . . Information Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DEF STAN 02–305 / ISSUE 2 (NES 305 ) CONTENTS Page No TITLE PAGE . . . 1. . . . . 3 Categories of Defence Standard . . . . . .5 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearings . . . . .1. . . . . . .2. . . . . . . .1. . . . . . . . . . . . . NATIONAL/INTERNATIONAL REGULATIONS . . . 4 Related Documents . . . . . . . . . . . . . . . . . . . Design Justification and Drawing Standards . . .1. . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . Wheels and Pinions . . . . . . . . . . . . . . . . . .1 3. . . . . . . . . . . . . .1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CONTENTS . . . . . . . . . . . . .4 3. . . . . . . . . . . . . .1. . . Materials . . . . . . . SECTION 2. 3. . . . . . . . . . . . . .2. . . . . . . . . . . . . . . .1 Table 3. . . . . . . . . . . . . . . . . . . . . . . . . . Design Justification. . . Gearcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . .2 3. . . . . .6.3 3. . 3 Conditions of Release . . . . . .6 3. . . . . . . . . . . . . . . .2 3. . . . . Design Justification Process . . . . . . . . . . . . . 4 Additional Information . . . . . Information Required . .2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . .5. . . . . . . . Information to be Supplied by Prime Contractor in Support of a Design Contract . . . . . . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . .1 MILITARY STANDARDS/REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SCOPE . . . . . . . . . . . . . . . . . Information Required . . . .6. . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . Preliminary Design Information Required . . . Drawings and Information Required . . . . . . . . . . . . . . . . . . . . 3 Sponsorship . . . . . Design Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. Quality and Format . 11 SECTION 3. .1. . .1. . . . . . . . .1. . 2 FOREWORD . . . . . . . . . .2 PERFORMANCE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1. . . . . . . . . . . . . . . . . .4 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3. . . . . . . . . . . . . . .1 3. . . . . . . . . . . . . . . . . . . .1 3. . . . . . . . . . .1 1. . . . .3 5 8 8 8 9 11 11 11 12 12 13 13 14 15 15 16 17 17 17 19 20 21 21 21 21 . Design Objectives . . . . . . Additional Information Quality Assurance of the Design . . . . . . . . . . . . Drawings and Information Required in Support of a Gearbox Tender . . . . . . . . . . . . . . . . . . . .

. . . . . 32 General . . . . 29 White Metal Lining .7. . . . . . . . . . . . . . . . . . . . .7. . . . . . .6 3. . . 33 Oil Injections Loose Couplings . . . . . . . . 35 Clutches . . . . . . . . . . 31 Temperature Measurement . . .8 3. . . . . . . 24 Gear Construction . . . . . . . . . . . . 25 Gear Case Design . . . . . . . . . . . . . . . . .DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. . . . .1 Page No Lubrication Suction. . . . . . . . . . . . . . . . . . . . . . . . . 30 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3. . . . . . . . . . . . . .7 3.9. . . . . . . . . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Keyed Loose Couplings . . . .4 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3. . . . . . . . 34 Justification of Alternative Designs . . 25 General . . 24 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 3. . . . . . . . . . . . . . . .9. . . . .1 3.4. . . 25 Lubrication and Venting . . .5 3. . 35 Information to be Provided . . . . . . .9. . . . . . . . . . . . . . . . . . . . 21 Shafts and Couplings .2 3. . . . 35 Power Transmission . 31 Turning Gear . . . . . . . . . 34 Involute Splined Couplings . . . . . . . . . Delivery and Drain Pipework . . . . . 27 Lubrication . . . . . . . . . . . . . . . . . . .3 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Loose Couplings . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . .4 3. . . . . . . . . . . . . . . . . . . . . .2 3. . . 21 Electrical Equipment . . . . . . . 30 Housing .7 3. . . . . . . . . . .10 3. . . . . . . . . . . . . . . . . . . . . .6 3. . . . . . . . . . . . . . 24 Gear Element Construction . . . .8 3. . . . . . 31 General . . . . 30 Caps . . . . .9. . . .3 3. . . .5 3. .2 3. . . . . . . 37 6 .4 3. . . . . . . . . . 22 Tooth Loading Analysis . . . . . . . . . . . . 21 Rubber ‘O’ Rings . . . . . . . . .7. . . . . . . . . . . . . . . . .9. . . . . . .6 3. . . . . . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 3. . . . .4 3. . . . 29 Bearing Design and Analysis . . . . . . . 22 Tooth Form . . . . . . . . . . .3 3. . . . . . .7. . . . 22 Tooth Load Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . .9. . . . .5. . . . .7 3. . . . 31 Vibration Measurement .7.1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . .3. .4 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 General . . . . . . . . . . .6.1 3. . . . . . . . . . . . 23 Scuffing . . . . . 28 Bearings . . . . . . . . .11. .10 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Identification . . . . . . . . . .3.4 3. . . . . . . . . . . . . . . . .5 3. .5 3. . . . . . . . . . . .6 3.3. . . . . . . . . . . . . . . . .9. . .9 3. . . . . . . . . . . . . . . . . . . . .3 3. . .7. . . . .2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3. . . . . . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Gear Tooth Design . 31 Shafts and Couplings . . . . . . . . . . . . . . . . .1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . .1 3. . . . . . . . . . . 29 Oil Inlets . . . . . .8 3.7. . . . . . . . . . 28 Steel Backings . 24 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fasteners . . . . . . . . . . . . . . . . . . .9 3. . . . . . . . . . . .11 3. . . . . . . 36 Threaded Fasteners . . 23 Gear Element Safety Factors . . . . . . . . . . . . . . . . . . . . . . .2. .3. . . . . . . . . .4. . . .8. . . .1 3. 22 Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . .1 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 General . . . .6 3.

. . . . . . . . . .4 3. . . . . 44 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3. . . . . . 46 General . . . . . . .18. . . . . 52 General . . . . . . . . . .2 3. . 52 Distribution . . . . . . . . . . . . . . . . 47 Cleanliness During Installation . . . . . . . . 52 Records Required During Contractor Sea Trials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12. . . . .17. . 41 General . . . . . . .12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20. . . . . . . . . . . . . . 44 Acceptance Standards . . 46 After Shop Trials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Shop Testing . . . . . . . 53 SECTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 3. . . . . .19 3. . . . . .2 3. 59 ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . .12. . . . .17. . . . . . . . . . . . . . . . . . . .4 3. . . .1 3. . . . . . . . . . . . . . . . 45 Shop Flushing . 54 ANNEX B ABBREVIATIONS AND DEFINITIONS . . . . .13. . . . .1 3. . . . . . . . . . . . . . . . . . 38 Instrumentation . .2 3. . 51 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3. .19. . . . . . . . . . . . .3 3. . 46 Cleanliness and Preservation After Delivery .14. . . . . . . . . . . . . . . . . . . . . .5 3. 61 7 . . . . . . . . . . CORPORATE EXPERIENCE & KNOWLEDGE . . . . . . . . . . . . . . . 58 ANNEX C PROCUREMENT CHECK LIST . . . . . . . .17. . . . 48 Production Test .12 3. . . . . . . . 49 Records Required During Tests . . . . . . . . . 48 Performance Testing of a New Gearbox Design . .2 3.17. . . . . . . . . .18 3. . . . . .14. . . . . . . . . . . . . . . .17 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Preservation and Cleanliness up to Acceptance . . . . . . . . . . . . . . . .17. . . . . . . . . . . .1 3. . . . . . . . . 40 Design Constraints . .6 3. . . . .18. . . . .2 3. . . . . . . . . . . . . . . . . . . 53 ANNEX A RELATED DOCUMENTS . . . . . . 46 During Manufacture . . . .2 3. . . . . . . . . .17. . . . . . . . . . . . .14 3. . . . .2 3. . . . . .1 3. . .16 3. . . . . . . . . . . . . . . . . . . . . . . . 46 Cleanliness and Preservation . . . . . . . . . . . . . . . . 48 Testing . . . . . .18. . . . . . . . . . . . . . . . .4 3. . . . .18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Local Control and Surveillance . . . . . . 41 Gearcase Manufacture . . . . . .19. . . .18. . .12. . . . . . . . . . . . . . . . . . . . . .20. .11. . . . .1 3. . . 41 Balancing and Vibration . . . . . . . . . . . . . . . . . . 42 Vibrations . . . . . . . . . . . . . . . . . .DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. . . . . . . . . . .19. . . . . . .15. . . . . . .3 3. . . . . . . . . . . . . . . . 51 General . . . . . . . . . . . . . . . . .15. . . . . . . . .5 3. . .15 3. . . . . . . . . . . . . . . 50 Contractor Sea Trials . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Preservation During ‘Setting to Work’ . . . . . . . . . . . . . . .1 3. . . . . .20 3. . . . . . . . 49 Post Test Inspections . . 40 Remote Control and Surveillance . . . . . . . DESIGN REQUIREMENTS/GUIDANCE . . . . . . . . . . . 43 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Balancing . . . . . . . . . . . . . . . . 52 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3. . . . . . . . 53 SECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . .3 3. . . . . . . . . . .16. . . . . . . . . . . . . 38 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3. . . . . .2 Page No Non-Threaded Fasteners .

(2) Maintainability: The Gearbox shall be designed for minimum maintenance and for ease of such essential maintenance as is required. Where specific noise and vibration targets have to be met these shall be detailed in the SRD. BR 8470.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 1. (See Clause 1. instruments and gauges shall be such as to permit local operation by the minimum number of personnel. (5) Shock: This aspect shall be considered in both the layout and mounting of components and in the detailed design. The Gearbox controls may be subject to a numerate reliability target which will be derived from an assessment of the complete propulsion Plant Control System (PCS). Specific requirements and targets shall be defined in the System Requirement Document (SRD). 1. Experience has shown that Gearbox reliability is often lowered rather than improved by maintenance activities.1. The Gearbox shall be suitable for both local and remote control and the siting of control levers. The Gearbox manufacturer may be required to participate in such assessments but will not normally be expected to lead them. 8 .2b(11)).1 Design Objectives a.1. DEF STAN 08-123. As Main Propulsion Gearing is not amenable to reliability prediction techniques a numerical reliability target will not be specified. which shall be conducted by Naval personnel on the first Gearbox produced. However. The requirements for resistance to underwater shock shall be detailed in the SRD. The provisions made for maintenance shall be reviewed throughout the design process as explained in Clause 3. The design should therefore incorporate facilities to ease visual inspection so that the internal components are not disturbed except when faults are evident. DEF STAN 02-304 Part 1.1 Basic Requirements 1. Wherever possible reliability shall be obtained by designing equipment which is robust and simple. The likely periodicity of major maintenance periods shall be detailed in the SRD. handwheels.1 and the manufacturer shall be required to co-operate in a Maintenance Evaluation exercise. The design shall be based upon the following principles: (1) Reliability: The achievement of adequate reliability is of overriding importance in the design of Naval Gearboxes and no compromise of this principle shall be made with any other requirement. (3) Operation: The Gearbox shall be simple to operate and the controls shall be arranged so that no modes of operation can be achieved other than those intended by the designer. PERFORMANCE SPECIFICATION Related Documents: see also Annex A. a full reliability assessment shall be required during the design as described in Clause 3. (4) Noise: Airborne and structure borne noise shall be minimized by adherence to the specified accuracies and by designing the gear meshes for minimum transmission error.1.

Brakes. This shall include 5. b. It is therefore essential that interchangeability is complete for all assemblies and components without the need for hand fitting or machining or rearranging of electrical connections. (c) Initial loads on spring assemblies shall be fully released before the spring is freed for dismantling. (2) Design Full Power: The power rating of the Gears shall be specified as the maximum continuous power requirement at the Gearbox input coupling(s).000 hours at design Full Power and 50. Couplings. 9 . other than the main output shaft. weight and space shall be kept to the minimum consistent with other requirements herein. To Specifying Authority: It is essential that the requirements listed below. shall be enclosed.DEF STAN 02–305 / ISSUE 2 (NES 305 ) (6) Accessibility: (a) The design shall be within space limitations and provide the maximum accessibility to gear parts which require routine examination. Gear elements. (7) Standardization: The Gearbox shall be subject to refit/repair/overhaul by an upkeep by exchange policy.2 (a) Moving parts of gearing such as Clutches.000 hours of operation (this represents 25 years of life at 70 per cent utilization per year). Design Basis a. (b) Arrangements shall be made for access for examination and maintenance without the necessity for disconnecting associated pipework cables or any major components or assembly from the auxiliary unit. If no specific instructions pertain. Pipes shall not be led through covers and doors. (9) Efficiency: Power losses shall be minimized for the normal operating range. (8) Weight and Space: Specific limitations on weight and size shall be given in the SRD. which are based on typical past practice. (b) Hand operating gear shall be interlocked or arranged to disengage when there is a possibility of power operation. The space required for maintenance of the equipment shall also be minimized. Design shall be based on life expectancy of typically over 150.000 hours between 50 per cent and 100 per cent of design Full Power or as specified in the SRD. The design shall be based on the following requirements unless specific instructions to the contrary are provided in the SRD. are carefully examined for relevance to the particular application for which this Standard is being used and that the Prime Contractor is informed of any changes considered necessary: (1) Life: The design shall be based on the concept of infinite life with respect to fatigue stresses. maintenance and repairs.1. (10) Safety: Gearing designs shall embody the following safety features to prevent injury to operating and maintenance personnel in both normal and action damage conditions: 1.

(4) Maximum Full Power Torque: The maximum full power torque is that developed when transmitting design Full Power at the specified input speed. in selecting the number of teeth. 10 . using procedure 1 of BR 8470. (10) Emergency Operation: The requirements for operation in other than normal ahead and astern modes shall be specified separately. (6) Astern Operation: The Gearing shall be capable of transmitting 30 per cent design Full Power in the astern direction at speeds up to 105 per cent of the specified Full Power astern rpm. (c) Speed: An overspeed 15 per cent above the specified input speed. Manoeuvring: (a) Reversing Gearboxes – the frequency and times allowed for any necessary manoeuvres shall be defined in the SRD.DEF STAN 02–305 / ISSUE 2 (NES 305 ) (3) Shaft Speeds and Gear Ratio: The required speed of the input and output shaft shall be specified at the design Full Power condition with Vessel’s hull deep and dirty. The specified input speed and the actual Gear ratio shall then be used to define the design output shaft speed. (8) Overload Capability: The design shall be capable of accepting the following overloads without risk of damage: (9) (a) Torque: A non-transient ahead torque overload (duration of more than three seconds) of 125 per cent maximum Full Power torque in Steam and Diesel Installations and of 150 per cent maximum Full Power torque in Gas Turbine installations. Full Power centrifugal loadings and stresses. (11) Shock Loads: All Naval Gearing shall be designed to withstand Naval Shock Standard I. those associated with Controllable Pitch Propeller (CPP) or reversing prime movers) restrictions on the frequency or timing of changes in the level or direction of torque and speed would not normally be acceptable. (b) Non-reversing Gearboxes – (i. The gear unit shall be capable of continuously transmitting design Full Power at speeds up to 105 per cent of the specified input speed. (5) Basis for Stress Calculations: Calculations of transmission loadings and stresses shall be based upon the specified input speed. the gear ratio may be varied by not more than one half per cent. Gears and shafts shall also be capable of withstanding 200 per cent of full power statically as might occur if the Propeller/Propulsor becomes jammed. If. Torques up to these levels shall occur during high power turns and rapid accelerations up to a total of five hours during the Ship’s life. (b) Thrust: See DEF STAN 02-304 Part 1. Thrust bearing design requirements are specified in DEF STAN 02-304 Part 1. (7) Thrusts: The Gearing shall be capable of withstanding such thrusts and movements as are likely to be imposed by the Main Shafting. it proves impractical to exactly match both speeds.e. and calculations on whirling speeds shall be based on 105 per cent specified input speed.

3.1.2.4a. (b) Quality and Format (see Clause 3. (13) Submersibility: Gearboxes shall be capable of operation in sea water for a specified minimum duration and depth as quoted in the SRD.1a.DEF STAN 02–305 / ISSUE 2 (NES 305 ) (12) Environmental Conditions: The gearing shall meet the requirements of DEF STAN 08-123.6.2.1.1 General a.6.5.1(a).1.1 Design Justification.).1). drawings and other documentation which shall be supplied. 2. This section describes the process by which the Prime Contractor shall control the design of the main gearing and identifies the programmes.1. NATIONAL/INTERNATIONAL REGULATIONS (No relevant information included) 3. 11 .1. MILITARY STANDARDS/REQUIREMENTS See Annex A for a full list of all Related Documents. The Gearing shall achieve the specified duty when the Ship is in Extreme Tropical and Sub-Arctic (Winterization) conditions and shall be capable of safe continuous operation up to 70 per cent Full Power under Arctic conditions and under Closed Down conditions (ambient temperatures may be derived from DEF STAN 08-123). – 3.1.2). (ii) Information Required (see Clause 3. Drawings and Information Required for a Design Contract or Gearbox Order: (a) Preliminary Design: (i) (b) Information Required (see Clause 3. Drawings and Information Required 3.). Final Design: (i) Design Justification and Drawings Standards (see Clause 3.3. (14) Cold Start: The Gearing shall be capable of transmitting up to 20 per cent design Full Power with a Lubricating Oil (LO) inlet temperature of 5°Celsius and of transmitting 70 per cent design Full Power with a LO inlet temperature of 20°Celsius.1d.1. This section incorporates the following sub-headings: (1) Design Justification Process: (a) (2) (3) Information Required (see Clauses 3. Drawings and Information Required in Support of a Gearbox Tender: (a) Information Required (see Clause 3.).1a.1.

The Prime Contractor shall provide a design justification to demonstrate that all necessary work has been undertaken during the design process to ensure that: (1) All the requirements of the SRD and of this Standard have been or shall be met.. The form of assurance selected should take account of the risk and significance of the failure and the effort required to provide such assurance.6.2a. c. (4) A formal assessment of these failure modes to determine and record what assurance shall be provided against them.6. Objective evidence of the systems’ effectiveness shall be provided by: (1) Describing the system to be applied to each design. (2) All potential sources of unreliability have been identified and their optimum elimination means determined.1a.3).4).1.2 Design Justification Process 3. b. (6) Methods for calculating or estimating the forces and/or movements likely to be encountered by each component. As the first step is providing the assurance required by Clause 3. assembly and sub-assembly. sub-assembly and assembly within the Gearbox.6. 3. (5) A statement of the calculation method and acceptance criteria used for each failure mode to be checked by calculation.1. maintain and support the Main Gearing throughout its working life at the lowest through-life cost.1. (8) A means for ensuring that appropriate calculations are repeated if any changes are made to the design or to external conditions.2. (3) A comprehensive list of possible failure modes considered for each component. This system shall include the following elements: (1) A formal record of the loads and movements assumed to be applied to the Gearbox by its service environment.1. taking account of the most adverse conditions likely to occur.1 Information Required a.1. (3) Proper account has been taken of the need to operate. (2) A means of defining the Gearbox in terms of assemblies. (This may conveniently be accomplished by means of the Functional Block Diagram (see Clause 3.2.(5)). sub-assemblies and components and for identifying the interfaces between them.DEF STAN 02–305 / ISSUE 2 (NES 305 ) (iii) Additional Information (see Clause 3. (iv) Quality Assurance of the Design (see Clause 3. 12 .1. (7) A means for recording that ‘calculated’ and ‘allowable’ values have been compared and found acceptable. the Prime Contractor shall establish a formal system to control the design process.

13 . shall include the misalignment capability under continuous running and shock. (3) Conducting a series of formal Design Reviews which shall progressively approve the design.1. prepared in accordance with DEF STAN 00-40 Part 1. (2) An outline sectional arrangement of the Gear trains. reference circle. strengths and pitting load rating calculations using BS ISO 6336-1. (3) A statement giving Gearing particulars. BS ISO 6336-2. static holding torque and dynamic braking torque compared with the maximum duty estimated for the particular application. NOTE For calculations using BS 436-3 it is acceptable at the tendering stages to use estimates for load correction factors. (6) Details of any brake including the capacity of the unit in terms of total absorbed energy. including Main Shaft Couplings. The number and timing of these reviews may vary from one design to another and a specific Design Justification Programme shall be agreed during the preliminary design phase. as applicable. control signals and maximum torque capabilities.3. modules. however. (2) Requiring the gear manufacturer to justify the list derived from Clauses 3. (8) Details of the Flexible Couplings.1. An assessment statement of the likelihood of damage due to scuffing (using at least two different methods) and stating the methods used shall also be submitted. (9) A control diagram showing the method of control proposed for the Brakes. Estimated weight of fluids in the unit at the normal working level.1 Information Required a. including power requirements. the estimated values used shall be stated. where applicable. showing which activities shall be undertaken to ensure that the proposed design meets the requirements of DEF STAN 08-141 Parts 1 and 2. Clutches. Arrangements for monitoring these activities shall be included in the Design Justification Programme. The Prime Contractor shall supply the following in respect of each gearing design submitted for consideration by the MOD: (1) General Arrangement of the machinery and/or system including sufficient cross-sectional drawings to give an appreciation of the design and construction. (2). (3). (7) Details of any Clutches. The anticipated misalignment shall be quoted. (10) Position and size of mountings. pressure and helix angles. including numbers of teeth. The Prime Contractor shall submit a plan. (4) and (5). (11) Estimated dry weight of all equipment covered by the tender.DEF STAN 02–305 / ISSUE 2 (NES 305 ) d.2. 3. (5) A mass elastic diagram giving details of Gearbox inertia stiffness. BS ISO 6336-3 and/or BS ISO 6336-5. (1). addendum and root circle diameters. (4) A statement on the manufacturing and measuring techniques that shall be adopted for all Gear elements in order to satisfy the requirements stated in the SRD. peak energy input rate. Couplings and Turning Gear and the interlocks between them.3 Drawings and Information Required in Support of a Gearbox Tender 3.1. face widths.1b.

The diagram shall be presented as a left-to-right flow diagram. (2) Drawings submitted with the tender shall meet the requirements of DEF STAN 02-722. diameter.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. maximum speed and L10 life calculated for a specific power spectrum. a description and sketch of the methods proposed for repair by replacement. (15) A statement on the maintenance requirements including services and maintenance envelope of the Gearbox and. Quality and Format a. rubbing speed. minimum oil film thickness.1. a notation of where special bearings are specified. For Thrust Bearings the information required by Clauses 3. then a statement is required giving the manufacturer. his serial number. e. inclusive shall be submitted. (18) A programme and procedures for both shop testing and Contractor Sea Trials (CST).g. (17) A statement on the ‘Running-in’ requirements for the Gearbox.4b. Quality and Format requirements are that: (1) The tender submission should normally be in the form required by the tender document. 14 . oil temperature rise through the Bearing and bearing power losses. Programme to include order dates for all long lead items. specific bearing pressure. static and dynamic capacity. (c) A programme for the detailed design and manufacture of the STF and/or first Vessel Gearboxes. and d. single versus double Helical Gears. maximum oil temperatures. (14) Main unit Journal Bearing loads and directions and a statement giving principal bearing particulars. (16) A statement on the methods that shall be used for inspecting all Gearing elements. (23) The following estimates of timescales are required: (a) Time required from receipt of contract to the delivery of the first Gearbox to the Vessel or Shore Test Facility (STF). if appropriate. c. including such justification as does exist for any claims made about the relative noise performance of different design features.7. (b) Maximum rate of production of subsequent Gearboxes. If rolling contact bearings are proposed. the maximum loads. (20) A detailed statement on the design philosophy used to minimize noise. (19) A list of spare parts or whole assemblies which shall be retained by the manufacturer during build. components and Bearings. These calculations shall be based on normal running conditions. (21) A functional block diagram. identifying the functional arrangements and signal flow paths inside the Gearbox and showing all external services or signals entering or leaving the Gearbox. (13) A statement of Gearing efficiency at maximum Full Power.4 (12) Diagram of LO distribution arrangement including the calculated design oil flow and the corresponding bulk oil temperature rise at Full Power. (22) A preliminary reliability assessment explaining how it is intended to demonstrate design-for-life aspects and reliability. which shall include length.

Bearing Cap bolts. The Gear manufacturer shall submit the following information: (1) A preliminary Functional Block Diagram showing functional relationships within the Gearbox and between the Gearbox and the rest of the Vessel.) in accordance with the latest schedule or SRD. etc. c.2b. pressure transducer. Sections 2 and 3.5. (2) A set of preliminary drawings showing the basis for design. The prime Contractor shall supply the following information for review by the MOD: (1) An estimate of the polar moment of inertia and flexibility characteristics of all rotating elements in the transmission. The following paragraphs define the requirements in more detail and define the standards to which the work shall be carried out. sub-assemblies and components to assist the Prime Contractor in specifying the Upkeep Codes (see DEF STAN 07-200).1. the Prime Contractor shall prepare or revise the technical portion of the submission report (see Clause 3.1 Preliminary Design Information Required a. (3) A tabular statement on the safety factors under shock. (e. On receipt of the contract. (3) A detailed design programme showing the expected delivery dates for all the items of design information listed in Table 3. (6) A list of all assemblies. with parameters that shall be monitored and signalled. shall be proposed by the manufacture type. solenoid. state switch. (4) A detailed summary of the logistic requirements of the design such as LO and Hydraulic Oil types quoting the various tank maximum and working levels. 15 . relative to the permissible shock stresses. b.1. NOTE The Prime Contractor shall ensure that the requirements of DEF STAN 02-54 shall be invoked at this stage. The information required to be supplied as part of the design contract is listed in Table 3.1.1. (5) A draft Design Justification Programme proposing dates for the Formal Design Reviews and Design progress monitoring meetings. The diagram shall indicate the limits of supply under the terms of the design contract.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. number etc. amplifier for speed probe. If any of these preliminary drawings shall be updated to final design drawings. in all shafts. (4) A Reliability and Maintainability programme plan showing the activities which shall be undertaken during the design and in accordance with DEF STAN 00-40 Part 1. Attention should be drawn to any items which have required additional strengthening to meet the shock duty. (5) A schedule of the active electrotechnical equipment.g.. the requirements of DEF STAN 02-722 shall be observed.5 Drawings and Information Required for a Design Contract or Gearbox Order 3. (2) The calculation sheets relating to the design of all shafts and shaft connections in the main transmission path showing allowable and actual material stresses.). shaft bolts. starter. and in the Gearcase structure.1. motor.

2.3 One copy of all drawings required to manufacture the Gearbox.1. The date by which submission is required shall be specified in the Design Contract: 1.10 A comprehensive Maintenance Schedule for the Gearbox. fixtures. 2.14 A tabular statement on external loads and movements.6. 2. 3.(16) 3.2a. 2.1.5 A full set of physical interface drawings. 1.5.DEF STAN 02–305 / ISSUE 2 (NES 305 ) Line Description No 1 PRELIMINARY DESIGN The following items shall be submitted for Project Authority approval before starting detail design.6.3 A loose leaf report containing all information required by the Shipbuilder or STF Authority.(9) 3. 3.5.6.2 Preliminary Functional Block Diagram.(14) 3.g.6.(3) 3.1.15 A Reliability and Maintainability Report.6.1 A suitably indexed Comprehensive Drawing Schedule..1 One `As Made' process master of each Datum Pack Drawing.1. 3. 2.2a.1.(5) 3.1.1.2a.6. 2.(12) 3.1.2a.(3) 3.13 Spares Recommendation.6.(8) 3.2a.(3) 3.4 A design programme showing the expected delivery dates of the information listed at 2 and 3 below.1.6. 2.1.5.6.1.2a.2a.7 A list of all external services required by the Gearbox.1.1. 2.(1) 3. 2. etc.2a.(11) 3.6 A full set of signal/interface specification sheets identifying all signals and their relevant interfaces with the rest of the Vessel.1.4 A full functional block diagram.2a.4 Where called for in the contract.2a.1.3a.1 – Information to be Supplied by Prime Contractor in Support of a Design Contract 16 . 3 ADDITIONAL DRAWINGS AND INFORMATION The following additional items shall be supplied to the Project Authority in accordance with an agreed Schedule: 3.2a. 2 DESIGN DRAWINGS AND INFORMATION The following items shall be submitted to the Prime Contractor in accordance with an agreed programme: 2.5.3a.1. 2.6.(7) 3.2a. microfilm/CD ROM).(2) 3.6.(4) 3.6.1.1c. in a format to be agreed with the MOD (e. necessary for an alternative contractor to manufacture the Gearbox. special tools and equipment required to install and maintain the Gearbox.6.1. 2.(1) 3.(13) 3. copies of all drawings.(6) 3.3a.8 A list of and drawing of all jigs.1b. specifications. 1. covering all modes of operation.6.(1) 3.1c.(2) 3.1.1.2a.9 A statement on the operating limitations for the Gearbox.(5) Table 3.(10) 3.2 One `As Made' process master of specified additional drawings required by the Prime Contractor. 2.2a.1 Updated Tender Report. Reference Clause 3.6.3 Additional drawings. 1.12 Production Backup Spares.1.6. 2.1.1c.2 A twoway crossreferencing index between Manufacturer's Drawing Numbers and Service Drawing Numbers.6.3a. 2.6. 3.11 A detailed set of Maintenance Envelope drawings.

(3) Drawing Number Cross-Reference: A two-way cross-referencing index between gear Manufacturer’s Drawing Numbers and Service Drawing Numbers. CD-ROM. (b) Wiring Diagram. (4) Manufacturing Drawings and Setting to Work Procedures: One copy of all drawings required to manufacture the Gearbox in a format to be agreed with the MOD (e. flexible conduit. (c) Topographical drawing of the electrotechnical equipment inside and outside the Gearbox.1b.5.1. Information Required a. marked up to show the position of all physical interfaces shall be provided. (d) Schedule of all electrotechnical equipment active.6. etc. This document shall itemize all the production drawings required to manufacture the Gearbox plus all the drawings in the Datum Pack which are not production drawings. etc. (6) Physical Interface Drawings: A General Arrangement of the Gearbox. junction boxes. (2) Although no attempt is made to quantify the mechanical equipment drawings required to manufacture the Gearbox.1. electrical drawings. control panels.6. solid conduit. bolting down and levelling procedures). and passive (e. b.2 a.g.6 Final Design 3. cable. Datum Pack and other Process Masters shall conform to the requirements of DEF STAN 02-722.5. microfilm.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. It shall be presented in assembly and sub-assembly groups. 17 .1. (5) Functional Block Diagram: The preliminary Functional Block Diagram provided under Clause 3.6.).1. The document will finally be used as a comprehensive access document to the production prints held by the MOD. alignment or balancing procedures. Work on the final design of the Gearbox shall not commence until the basis for the design has been reviewed by the MOD in the form of the Preliminary Design Information as listed in Table 3..1b. in the case of electrotechnical equipment in the Gearbox the following drawings shall be provided: (a) Circuit Diagram. (e) Connection Diagram for all junction boxes.) and any information required to set the Gearbox to work (e.1.g. The Prime Contractor shall supply the following information on the final design of the Gearbox: (1) Comprehensive Drawing Schedule and Index: A suitably indexed Comprehensive Drawing Schedule shall be provided to the MOD. All manufacturing drawings.g.(1) as expanded and updated by the design approval process shall be redrawn to the datum pack standard (see Clause 3. etc.). as in Clause 3.1c.1 Design Justification and Drawing Standards 3.1.(5).1.

NOTE Method of initiating action on spares is contained in DEF STAN 02-54. External Loads and Movements: A tabular statement on the loads and movements assumed to be imposed on the Gearing from external sources.DEF STAN 02–305 / ISSUE 2 (NES 305 ) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) Signal Interface Specification Sheets: The physical and functional properties of each interface between the Gearbox and the rest of the Vessel shall be defined on a Signal Interface Specification Sheet. The righting moment.. as applicable. (e) Space required for access by lifting gear. (b) Installed in a vessel prior to Setting to Work (STW).6. Spares Recommendation: A recommendation for general spares support covering the following: (a) On-board spare (First Category Spares).(7). Jigs and Special Equipment: A list and drawings of all jigs. (b) Back-up spares for two-year period (Second Category Spares). which show and identifies the purpose of individual portions of the envelopes. running misalignment curve based on the expected maximum thrust and the maximum allowable righting moment based on the highest loaded pad pressure. This area shall be highlighted. Production Back-up Spares: A list of parts or whole assemblies which are retained by the manufacturer during build.5. The items shall be cross-referenced with Clause 3. Thrust Block: (Where fitted within the Gearbox). transport devices. Maintenance Envelope: A drawing or drawings to meet the requirements of DEF STAN 02-302 Part 1 and/or DEF STAN 08-103 Part 2.1.1. etc. (b) The operational area of the envelope.). as follows: (a) The overall dimensions and chain dotted outline of the maintenance envelope. Each signal interface shall be identified with regard to the Functional Block Diagram and/or Physical Interface Drawings. It shall also show the limit of Gearbox manufacturer’s supply. (d) Spares for shelf-life maintenance.1c. fixtures.. 18 . (d) During refitting. etc.2a. Maintenance Schedule: A Maintenance Schedule indicating the degree and periodicity of maintenance required during the following periods: (a) In store prior to installation. (c) Operational. (c) Areas where access is only required for painting and preservation. External Services: A list of external services required by the Gearbox. etc. Reliability and Maintainability (R and M) Report: The report shall show the results of the R and M plan agreed during the preliminary design stage (see Clause 3.. (d) All withdrawal spaces for sub-assemblies. special tools and equipment required to install and maintain the Gearbox. (c) Spares for reconditioning equipment (Third Category Spares). The Specification sheet shall provide a cross-reference to the manufacturer’s own detailed drawings of the interface and to any drawings produced by other contractors which are known to the Gearbox manufacturer.

operate and maintain the Gearbox.6. (viii) Direction of load on Main Wheel.3 Additional Information a. set to work. (vii) Axial clearances of input and output Shafts. (iii) Weights of the Main Wheel and Shaft. facilities and equipment required to lift. the manufacturer shall submit a proposed list of drawings for inclusion in the Datum Pack. The report shall contain at least the following items of information: (a) Detailed definition of terminal points and interfaces (see Note 1). including the Prime Mover. One ‘As Made’ process master of each Datum Pack drawing shall be supplied to the MOD at least one month before the first Vessel’s Gearbox is delivered. (3) Information to Prime Contractor: The Gearbox manufacturer shall provide the Prime Contractor with a loose leaf report in respect of each Gearbox containing all the information required by the shipbuilder to install. 3. It shall be progressively updated as significant changes are made to the class or to individual Vessel. After discussion with the Prime Contractor. (v) Thermal growth of the Gearbox. including limitations relating to input and output shaft alignment (see Note 2) and the following information: (i) Detailed drawing of the Main Wheel Shaft. The detailed requirements are as follows: (1) Datum Pack: The Datum Pack is a comprehensive set of drawings which define the mandatory aspects of the Vessel’s design. (e) A list of precautions and/or special requirements that shall be met when STW. the manufacturer shall submit one ‘As Made’ process master of additional major drawings required by the Prime Contractor. This report shall be passed to the Prime Contractor at the time of the delivery of each Gearbox to the shipyard. (b) Requirements for and terminal points of all services. (ii) Detailed drawing of the Main Wheel. A list of such drawings shall be provided when the Datum Pack contents are approved.DEF STAN 02–305 / ISSUE 2 (NES 305 ) (17) Dynamic Analysis of the High Speed Line(s): Details of the vibration characteristics of the input lines. (iv) Clearances at the Main Wheel Bearings. shall be supplied with each Vessel as a record of the design to which it was built. transport and install the Gearbox.1. Datum Pack drawings shall conform fully to the requirements of DEF STAN 02-722. 19 .1 shall be supplied before the first equipment is delivered. Certain additional information as listed in Table 3. (d) Installation instructions. (c) A list of special tools. It is used to control the build of follow-on Vessel’s and a microfilm copy. at the relevant state of amendment. These drawings shall be of the same quality and format as the Datum Pack drawings. (2) Additional Process Masters: In addition to the Datum Pack. (vi) Shaft attitude in Bearings.

4 Control of Design Changes: (a) Alteration State Zero: At the end of the detailed design stage the manufacturer shall propose ‘Alteration State Zero’ definition.1. 20 . (5) Alternative Manufacture: Where called for in the contract.(10). NOTE 1. The items listed shall be subject to progressive design approval as the design proceeds. copies of all drawings. The Gearbox manufacturer is responsible for defining any limitations or constraints which shall be observed and for approving the target tolerances and methods proposed by the alignment procedure. 4. Prime Contractor’s drawing or other authorized document. etc. Original.DEF STAN 02–305 / ISSUE 2 (NES 305 ) (f) A statement on the operating limitations which shall apply up to acceptance. It is essential that the date and issue number of the relevant document is quoted. 2. 2 or 3. The minimum requirement for this report shall be a detailed cross-reference to the Prime Contractor’s installation and alignment procedures which have been accepted by the Gearbox manufacturer. Amendment 1. (4) 3. The Prime Contractor is responsible for writing the installation instructions and alignment procedures.) shall be shown at the front of the report. Any subsequent changes shall be termed Modifications and shall be considered for action under the Sea System Controllerate Equipment Modification Procedure. Issue numbers shall be quoted. etc. ‘Modification State Zero’ shall be declared. After the basin trial the Prime Contractor shall maintain the Gearbox in accordance with the Maintenance Schedule referred to at Clause 3. specifications. This and subsequent requirements may be met by cross-reference to the appropriate Gearbox. Conformance to Technical Requirements: During the preliminary approval process any items covered by the SRD. Drawings covering such items shall not be used for manufacture until design approval has been obtained from the Prime Contractor. necessary for an alternative contractor to manufacture the Gearbox.g. which cannot be demonstrably met because of the preliminary nature of the information available. 3.1. (b) Modification State Zero: One month before the first Vessel’s Gearbox is delivered. shall be listed. Quality Assurance of the Design a. Each page of the report shall be marked with a date and issue number.6. (g) A statement on the Gearbox maintenance required up to completion of the Basin Trial (see Note 3).6. Any subsequent changes shall be termed Alterations and shall be sequentially numbered and recorded for approval by the Prime Contractor. The status of each page (e.2a. (h) A statement on which items of work the Gearbox manufacturer would require to perform himself during the guarantee period.. Proposals for such design changes shall be submitted to the Prime Contractor.

6 3. Main Propulsion Gearboxes shall be of fabricated Steel to the requirements of BS EN 10028-1. c.5 3. For oil operation Loose Couplings.1b. unless forming part of the Gear elements. unless forming part of the Gear elements. shall be made from Forged Steel having a minimum UTS of 850 N/mm2.2 3.2. BS EN 10028-3. 3. Materials. etc.4 3.2. b.7 Quality of Drawings: Drawings submitted by the manufacturer shall be sampled at prescribed intervals to ensure that they conform to the requirements of Clause 3. for all gearing elements shall be in accordance with DEF STAN 02-381. Paint used on external surfaces of the Gearbox shall conform to BS 4800 colour code 00A01 and DEF STAN 02-737. Elastomeric Toroidal Sealing Rings (‘O’ Rings) shall conform to DEF STAN 02-337 Part 1. d. b.. BS EN 10028-2. Shafts and Couplings a. b.2. Guidance on LO is given in DEF STAN 02-303.6. as applicable. The Shaft.2 3.3 3. The DPA will require the contractor to amend any errors found and to certify that other drawings likely to contain similar errors have been examined and are correct. BS EN 10028-6. (2) Keys 550 N/mm2. BS EN 10028-7 and/or BS EN 10029.2. BS EN 10028-4.2. Bearings a.1 Materials Wheels and Pinions a. hubs shall be made from Forged Steel having a Yield Stress of not less than 750 N/mm2. (1) Hub and Shaft 850 N/mm2. For involute Splined Couplings. shall be made from Forged Steel having a minimum Ultimate Tensile Strength (UTS) of 850 N/mm2.1.2.2. unless forming part of the Gear elements. Quill Shafts and Torque Tubes shall be of Forged Steel. and shall meet the requirements of DEF STAN 02-848 Part 1 and/or Part 2 as applicable. Delivery and Drain Pipework a. Lubrication Suction. BS EN 10028-5. all components shall be made from Forged Steel having the following minimum values of UTS: c. All welding shall meet the requirements of DG Ships/PS/9023. both the Hub and the Shaft. Gearcases a. Rubber ‘O’ Rings a. The materials of Electrotechnical equipment fitted to the Gearbox shall conform to DEF STAN 07-224. White metal to BS 3332 Type A shall be used for Journal and Thrust Bearings. Wheel Shafts. heat treatment processes and testing requirements. Phosphate Coating of any surfaces shall be in accordance with DEF STAN 03-11. 21 . Proposed methods for the protection of Gearcases internal surfaces from the risk of corrosion shall be submitted to the MOD. Electrical Equipment a. For keyed Loose Couplings. 3.DEF STAN 02–305 / ISSUE 2 (NES 305 ) b.

If steps are formed in the root and fillet section. taking account of end reliefs. root and end relief) shall be provided for consideration by the MOD.g. f. The tip radius on the Gear cutting tool shall be not less than 0. the calculations shall be submitted for agreement by the MOD. shall be at least two. in the case of the second reduction.1 Helix Angle a. A normal pressure angle of Main Propulsion Gears shall be 20. Tooth Load Distribution a. Justified proposals for Profile Modification (tip. No handwork shall be done without Prime Contractor approval. Protuberance hobbing). d. Tooth pitches shall be minimized. This does not apply to steps formed deliberately as part of the normal manufacturing process (e. Single Helical Gears. (consistent with providing adequate location) taking into account the possible need to avoid heavy thrust on the high speed shaft. e.3. misalignment shall be taken into account when calculating tooth load distribution. Grinding of the root and fillet section to remove steps shall not be carried out without Prime Contractor approval. Consideration shall be given to correcting tooth load distribution in the ahead load condition by incorporating an adjustable bearing.2 3. All such concessions shall be forwarded for consideration by the MOD. b. b. The unbalanced thrust in the intermediate shaft shall be a minimum.3. the first and second reduction helix angles shall be arranged so that. b. The helix angle shall be as large as possible within the following constraints: c. Single Helical Gears.08 of the normal pitch. the concession application shall include evidence of the effect on the total bending stress and any other penalties. 3.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. With Single Helical Gears. the number of overlaps is as high as possible consistent with satisfactory thrust arrangements and. The Gear Teeth shall be finished ground. (2) For Double Reduction. 22 . If it is necessary to obtain even distribution of load by correction of the pinion helices.3 (1) For Single Reduction. The ends of pinion and wheel teeth shall be rounded-off or chamfered and the edges at the ends of the teeth shall be well radiused. g. consistent with Gear Tooth loadings and stresses.3. Other pressure angles may be adopted when justified to be of advantage.3 Gear Tooth Design 3. This shall be supported by projections of casts of tooth sections of at least 20 magnifications. Tooth Form a. c. the desirability of keeping axial thrusts to a minimum shall be taken into account. The Gear Tooth root fillets of ground Gears shall be undercut and the transition from ground tooth flank to unground root fillet shall be free from significant stress raisers. Wheel and Pinion Teeth shall be of involute profile.

4 Tooth Loading Analysis a. The Gearbox shall exceed the minimum safety factors as detailed in the table below when rated in accordance with the above. with the following additions: (1) The face load factor for contact stress (KH) shall be calculated using Newcastle University Design Unit analysis program ‘KHBTEN’ or an equivalent accurate analytical mesh model. SF: c. the Prime Contractor shall demonstrate that achievement of the design safety factors is obtained for a credible range of values. Minimum Safety Factor Surface Stress (SH) Bending Stress (SF) Primary Gears 1.3 1. ‘DUGATES’ or an equivalent accurate analytical mesh model.: Actual safety factor against surface failure. (4) In practice. K H K F KF BS436 KHBTEN Safety factors derived from this agreed stress analysis procedure shall only be used for comparing the gears of similar design and should not be used as an absolute measure of safety margins.6 23 .6 Secondary Gears 1.3 1. This value shall be used in place KH given by simple application of BS 436-3.e. Gear Element Safety Factors a. i. For those BS 436-3 stress and load modification factors where there is a choice. the same results could be achieved by adjusting safety factors against surface failure calculated using original BS 436-3 methods (or analysis programme) by the ratio of square roots of the KH values calculated using both original BS 436-3 and KHBTEN. This value shall be used in place of the KH given by BS 436-3. SH: S H  SHBS436 *  KH KHBTEN The face load factor for bending stress (KF shall be calculated in accordance with BS 436-3 equation 108 using the KH value calculated from the analysis program ‘KHBTEN’ or an equivalent analytical mesh model.: S F  SFBS436 * NOTE 3.3. Gear elements shall be analyzed using BS 436-3.5 BS436 (3) Actual safety factor against surface failure.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. i. An analysis of the gear elements shall be provided to the MOD using BS 436-3 and the Newcastle University Design Unit analysis program ‘KHBTEN’. (2) In practice.3. the same result could be achieved by adjusting safety factors against bending failure calculated using original BS 436-3 methods (or analysis programme) by the ratio of KF calculated using the original BS 436-3 programme to that KF calculated using KH from KHBTEN.e. b.

The tolerances on runout of functional mounting surfaces given in BGA Codes of Practice DUCOP.4.4 Gear Construction 3. This variation leads to the generation during running of phantom tones which not only increase the general noise level but also give a distinctive and often unacceptable pattern to the noise quality.3.02 shall apply to the peripheries of all Coupling Flanges. d.03.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3.5 m.4. or high-duty Iron centres. Gear Wheels shall have Forged Steel. specific tolerances cannot be given. shall be forwarded for consideration by the MOD. 24 . b. Cast Steel. subject to the additional requirements described in Clauses 3. A built-up design with the Gear Tooth portion shrunk on or keyed to the shaft may be considered when the size warrants this.6 Scuffing a. However. As a guide. See Clause 3. as applicable. bolted or welded construction. The ability of the Gearing to operate without scuffing at loads up to and including the maximum specified transient overload shall be demonstrated to the MOD using at least two different methods. may be used where appropriate.4. Because of the difficulties in measuring undulations to sufficient accuracy and because insufficient work has been done to quantify the effect. The drive to the Primary Reduction Pinions shall be taken though Flexible Couplings of an approved design. i.3 Pinions shall be forged integrally with their Shafts.6 m Ra and in the roots no worse than 2. 3.9.4. together with the input data and details on the methods used.0 m Ra. e. They shall also apply to the Thrust Faces.02. Accuracy a. Notice shall be taken of the recommendations regarding drawing information and Gear specification in BGA Codes of Practice DUCOP.01 and DUCOP. f. The accuracy of all Main Propulsion Gears transmitting more than 750 kW shall comply with BS 436-4 and/or BS 436-5.3i.3d to 3. Therefore. the magnitude of the relevant component of the transmission error shall be no more than 1 m and preferably less than 0. The surface texture of the Tooth flank shall be no worse than 0. The terminology and symbols used on drawings and in all associated documentation shall be in accordance with BS ISO 701 and BS ISO 1122. 3. 3. The results of the assessment. Undulations are cyclic variations in the shape of the flanks of the teeth which are orientated such as to produce sinusoidal (pure tone) variations in transmission error.4. c. the outside diameter of the Thrust Collar being used in the formula. h. Where possible. Gear Element Construction a.1 General a. rotating elements shall not to be handed. the aim should be to minimize the effect. g.e. b. The assessment shall take full account of predicted transverse load distribution.2 Where possible. The accuracy shall be verified by use of the procedures described in the BGA Codes of Practice DUCOP. b. fabricated.

e. guards shall be provided to prevent any debris ejected from the clutches from entering the Gear meshes (see also Clause 3. without leaving pockets of oil trapped inside the Gearcase. b. Bearings.35 L m  9. (2) A unique identification number which can relate each Gear to its inspection records. i. Each Gear element shall be uniquely and indelibly marked to show the following: (1) The Manufacturer’s Drawing Number with issue status to which the Gear was made. 3. Where Clutches are fitted. This mark shall be positioned to be visible when the Gear is installed in the Gearbox and viewed through a convenient inspection plate. 25 . The Gearcase should preferably be designed so that all the high speed (input) line bearing housings are integral and not cantilevered from the Main Gearcase.e.4. Clutches and Thrust Blocks. Importance is attached to the rigidity of the Gear supporting structure and that the meshing and alignment are maintained under load. The design of the Gearcase shall ensure that it may be fully drained when required.5 Gear Case Design 3. d. Couplings.0 m Ra. i.DEF STAN 02–305 / ISSUE 2 (NES 305 ) i. Identification a. c. To this end consideration shall be given to the design of the Gearcase covers and the routeing of pipework and cables. If Double Helical Gears are used. 3.1 General a. Main Gearcases shall be designed to be supported on a limited area at three places to minimize the transmission of distortion from the ship’s structure and to provide a datum condition during manufacture and installation.10).5. the differences between the cumulative pitch errors on the helices over corresponding arc lengths Lm shall not exceed: 0. (3) A reference tooth and the identification of the ahead or loaded flank. Reference surfaces shall be provided on the Gearcase structure to facilitate alignment/level checking equipment. no covers shall be removed. j.4 The surface roughness of journals measured in the axial direction shall not exceed 2. These surfaces shall be positioned to enable any Gearcase distortion to be measured with the minimum of effort. In particular the number of penetrations through the Gearcase shall be minimized and such penetrations shall be located in covers or frames least likely to be disturbed. The Gearcase shall be suitably subdivided to provide access to the Gears. e. If a cantilevered bearing housing is unavoidable it shall be subjected to a thorough assessment of vibration modes at the design stage.5 NOTE Lm is defined as to the number of base pitches. Gearcases shall be designed to provide the maximum access to the Gearbox internals with the minimum dismantling of internal and external pipework and cabling.

temporary covers shall be provided for the Primary Pinion input flanges to close the Gearbox against ingress of air during transport and erection. removed and replaced. The Gearcase covers shall be of lightweight fabricated steel construction. shall be in accordance with DEF STAN 02-502.2.(13)) and shall be tested by immersion prior to installation. m. The whole of the cabling shall be capable of being removed and replaced without disturbance of the Gearbox fittings. pipework. j. k. The minimum bending radii for cables shall be observed. n. A diagrammatic sketch shall be produced showing location of all locking devices. p. Sufficient bearing housings shall be adjustable or fitted with intermediate liners so that the alignment of all gear meshes can be corrected if required without recourse to handwork (e. l. The arrangement of Primary Reduction Pinion input flanges shall permit alignment between Prime Movers and Gears to be checked without lifting Gearcase main covers. Sufficient inspection doors shall be provided to permit visual inspection of all Gear meshes and LO sprays. etc.). The covers shall be subdivided for ease of handling. If the Main Thrust Block is integral with the Gearcase. All electrical items shall be earthed to meet the limits stated in DEF STAN 02-502. Inspection plates shall be provided with starting screws and security shall be achieved by the use of padlocks.g. inside and outside the Gearcase. The design of the Gearcase and covers shall be such that no leakage shall occur when the Gearbox is filled completely with oil with the shaft penetrations covered by suitable blanks.1. scraping or filing). especially where oil sprays play directly on to electrotechnical equipment or cable fastenings. Gearbox fittings. Gearboxes which have a Ship cabling interface shall be sited to enable direct installation of cabling by the Shipbuilder. An Equipment Identification and Modification Plate shall be fixed to the Gearcase in a visible position.DEF STAN 02–305 / ISSUE 2 (NES 305 ) f. adequate space shall be provided for access and dismantling. The whole of the electrical installation. If necessary. i. shall be capable of removal without disturbance of cabling and conduit.. the object being to prevent or detect unauthorized access to the Gearbox. pipework. Cabling in rigid or flexible conduit or trunking shall be supported to prevent chafing under vibration.2a. Additional plates shall be provided for each major sub-assembly for which separate modification action is intended. o. Separate covers shall be fitted to Flexible Couplings. The surrounding structure shall be adequately stiffened to prevent excessive distortion of the Gearcase by the thrust forces. g. h. without opening the Main Gearcase. Bushing shall be provided where there is a need to protect the cabling. The external surfaces of Gearboxes shall be painted (see Clause 3. Consideration shall be given to equipment inside the Gearcase with regard to the oil-laden atmosphere. etc. All fasteners on the Gearcase required for Shipbuilder’s cables shall be provided by the Gearbox manufacturer. so that the Couplings can be inspected. Conversely. Internal surfaces of Gearboxes shall be treated to prevent corrosion. Interference precautions shall be observed.2d. The plates shall 26 . Junction Boxes and all cable terminals shall be in accordance with DEF STAN 02-514 (watertight to the degree required by Clause 1.

i. The maximum number of individual supplies in any one group shall not to exceed four. j. The type of LO to be used in the Gearbox shall be specified in the SRD. Thrust Block. The requirement for a separate or integral Drain Tank shall be specified in the SRD.DEF STAN 02–305 / ISSUE 2 (NES 305 ) conform to DEF STAN 02-723 and shall also identify the screw thread series used throughout the design.e. g. shall be taken from the top of this manifold. e.6. Sprayers. Provision shall be made for earthing the Gearcase to the Ship’s structure in accordance with DEF STAN 02-502. Sprayer supplies shall be similarly controlled and grouped. The LO distribution and return arrangements within the Gearbox shall conform to the requirements of DEF STAN 02-303. q. i. d. LO supplies to Bearings. Internal oil passages for oil to the Bearings and Sprayers shall consist of lengths of piping or drilled holes through thick plate sections accessible for cleaning at each end. The control of each group shall be by suitable lockable control valves with a minimum opening. The design of integral drain tanks shall conform to DEF STAN 02–303. Non-return Valves shall be supplied at each end of the manifold to preserve integrity of the LO supply during a fault condition to one side. etc. do not result in metal-to-metal contact between moving parts. A drawing of the plates shall be submitted for Prime Contractor approval. the Gear sump and drain pipework shall be of sufficient size to ensure that none of the rotating elements come into contact with the oil which collects in the base of the sump under normal operating conditions. c. A flushing outlet shall be provided on each Bearing Housing in order that the oil supply arrangements up to and including those in the housing may be flushed without the contaminated oil having to pass through the bearing clearance. b. r. Plain Thrust Bearings may be lubricated by the LO flows from adjacent Journal Bearings but Thrust Bearings of the pivoted pad type shall be provided with separate oil supplies. f. connections shall be provided to supply the common manifold from each side of a sided system.6 Lubrication and Venting 3. If a separate Drain Tank is specified. Shaft oil seals shall be designed to fail safe.1 General a. LO supplies to Journal Bearings shall be grouped on a speed basis so that the supplies to the various groups can be individually controlled. 3. 27 . For single gearbox installations. The LO supply to each Main Gearcase shall be by one connection from the Ship’s system to an external straight manifold secured to the Gearcase. Cast passages shall not be used. Pipe couplings of the olive or cone type must have their nuts secured by a method approved by the Prime Contractor. h..

7. The Gearbox shall be designed to minimize the ingress of air under all operating conditions. Therefore all Gearboxes for military applications shall be fitted with a Dehumidifier to remove moist air from the Gearcase during periods of shut-down. The dry air supply pipes shall lead from the Dehumidifier into the upper area of the Gearbox so that the Gearbox is fully ventilated.6. These pipes shall be designed. thin to medium walled Plain Bearings. 3. 3. No vents shall be fitted to the Gearcase other than a connection to the Drain Tank if this is separate or to the Drain Tank Vent (see Clause 3.DEF STAN 02–305 / ISSUE 2 (NES 305 ) k. n. The SRD shall include a requirement that where any oils or greases are used or required for any purpose they shall wherever possible be specified from those listed in DEF STAN 01-5. Dehumidifier air intakes shall take air from the compartment and shall be fitted with mesh guards to prevent ingress of dirt. All pipes going into or out of the Dehumidifier shall be fitted with lockable valves that can be locked shut when the Dehumidifier is not in use. System ventilation shall be provided from the drain tank in accordance with DEF STAN 02–303.1 General a. l. The preferred Bearing type for Gearboxes are White Metal lined.). as applicable for resolution. The moist air shall be vented from the lower area of the Gearbox via pipe(s) leading to the Drain Tank or Drain Tank Vent pipe.6. Steel backed. This results in corrosion damage of the Gearcase internal elements. All Marine Gearboxes for military applications experience significantly longer periods of shut-down when compared with commercial applications. The dry air produced by the Dehumidifier shall have a relative humidity of no more than 30 per cent at 15C. Bearing Shells shall be pre-finished.7 Bearings 3. b. m. The electrics of the Dehumidifier and instrumentation shall be in accordance with DEF STAN 02-625 and DEF STAN 59-36. (2) so that they do not become submerged by oil during Gearbox flushing.1l. Exceptionally. Main Wheel Bearings may be of thick wall construction other than of Steel if preferred by the Gear manufacturer. but subject to a minimum wall thickness of 5 mm. If this is not possible it shall be brought to the attention of the Principle Contracts Officer and/or the Design Authority. Rolling element Bearings or Thrust Cones may be used when demonstrated to be of advantage. lined with White Metal made by an approved manufacturer.2 (1) to prevent condensate running back into the Gearbox. The Shells shall be of the thin to medium walled style (wall thickness less than 4 per cent of the bearing bore). Lubrication a. Instrumentation shall be fitted that will activate an alarm if the dry air from the Dehumidifier goes above 30 per cent RH at 15C. 28 .

The following table shows the general rule for applying White Metal thickness: Bearing bore diameter in mm White Metal thickness in mm up to 250 1.4 Steel Bearing backings shall be manufactured from a low Carbon Steel (less than 0. Forged Steel backing halves shall be normalized and stress relieved.5 bar for all Bearings.3. c.2 mm.5 bar. 3. Thrust Bearings or Thrust Cones associated with fine toothed Gear Couplings or Synchronous Self Shifting (SSS) Clutches shall be sized to accept the maximum axial force which the sliding teeth could transmit at full load. b. e.2 per cent Carbon). However. b. Steel Bearing backings shall be produced by forging. ±0. Thrust Cones shall be designed using the ‘Thrust Cone Design Aid’ package available from the MOD.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. For Thrust Bearings or Thrust Cones. Steel strip may be lined with white metal prior to forming and no stress relieving shall be required. assuming a coefficient of friction of  = 0. 3. The White Metal lining thickness depends on the bore diameter of the Bearing Shell. which shall have a maximum specific load of less than 24. The variation of the White Metal thickness. Loading pressures other than those above shall be justified to the MOD.7. except Main Wheel Bearings. bending or pressing plate material. for bearings up to 250 mm bore. The rotational speed shall be adjusted for each particular diameter to minimize segregation of the White Metal constituents. The maximum specific load (maximum Bearing load divided by projected area) for Journal Bearings shall be less than 34.7. d.6 m Ra The White Metal of a pre-finished bearing shall not be scraped or finished by hand. Casting of the White Metal lining onto preformed Shells shall be be carried out centrifugally. Chemical composition of White Metal shall conform to BS 3332 Type A.0 c.5 501 and over 2. Bearing backings bent or pressed from plate material a shall be stress relieved.2 Steel Backings a. the assumptions made in estimating the axial load shall be explicitly stated. Bearing Design and Analysis a.0 251 to 500 1. 29 .8 m Ra 401 mm and over 1.25 mm thickness variation is permitted within ±20° of the Bearing butts to allow for deformation during machining operations. b.3 White Metal Lining a. Surface finish of the White Metal after final machining shall be in accordance with the following the table: f. Bearing bore diameter Surface finish to be better than up to 400 mm 0. Alternatively. in the operational area of each individual Bearing Shell shall not exceed ±0.7.

Oil Inlets a. presenting the results of the Bearing analysis carried out for all the Gearbox Bearings (Journal and Thrust Bearings).6 3. they shall only be used where there is no practical alternative. b. During design. If this limit is exceeded during Shop Tests. free of charge to the MOD. the necessary appliances being provided. shall be provided for each particular load case considered: (1) LO flow rates and temperatures. Where offset pivoted pads are used for Thrust Bearings. Fittings independent of the hull structure.5 d. The extremes of operating conditions within the specified duties shall be used. As there is a risk of cutting off the LO completely under shock or other abnormal load conditions single axial LO inlets are not preferred. A minimum requirement. for the following list of Bearing operating characteristics.7 For plain Journal Bearings. Housing a. The Bearing and housing designs shall ensure that the Bearing is located uniquely in its correct position. Fitting a. shall be provided to take the weight of the Main Gearwheel to facilitate this operation and similar fittings shall be provided for other Bearings if required. resulting in restricted LO supply or drainage. Shore Trials or Contractor’s Sea Trials (CST). c. (3) Maximum Bearing surface temperature. the Prime Contractor shall be required to fit modified Shells to the affected unit(s) and to replace or modify any spare Shells which have been purchased by the MOD or their agents. twin axial LO inlets positioned at the bearing butts shall be used. (4) Approximate threshold speeds of Journal Bearing instability (half-speed whirl).DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. cannot occur. e. 30 . The Prime Contractor shall shall submit a Bearing design justification. attention shall be drawn to the requirement to check that Journal Bearing housings have sufficient stiffness and that their clamping systems have sufficient strength to enable the necessary clamping force (nip) to be applied to the Bearing Shells.) shall not exceed 115°C under any specified operating condition. Each Bearing shall be so arranged that it can be turned out with the Journal in place.7. f. When assembled in the Gearbox the butts shall be positioned at least 20 away from the closest point of approach of the position of the calculated minimum LO film thickness under any operating condition. (2) Positions (Journal Bearings only) and thickness of minimum LO films.8a.7. 3.7. provision shall be made in the Bearing housing design to locate the pad uniquely to eliminate the possibility of incorrect assembly. The maximum temperature recorded in service by the normal Bearing Temperature Monitoring Equipment (see Clause 3.7. The mean temperature of the LO return from any individual Bearing shall not exceed 85C. thus ensuring that incorrect assembly. If this cannot be achieved a circumferential groove may be used.

Two electrically powered thermo–sensing elements shall be fitted to each Main Transmission Journal Bearing (one active. disengaged.7. c. The Gearbox shall be provided with a means of turning the Prime Movers.7. This shall be provided even if vibration instrumentation is not specified for each Bearing Cap. etc.7. the above requirements for nip location.10 Separate Steel Bearing Caps shall be fitted for each Bearing. NOTE Where the Bearing Shells are carried within a liner separate from the Gearcase housing..1 General a. Gearing and Propeller Shafting for inspection and maintenance purposes.8. The Turning Gear shall be capable of being stopped locally at all required angles of rotation for inspection purposes and to lock the Shafting System. Provision shall be made to prevent the Bearing rotating. tapped and seatings prepared to accept two transducers to measure radial vibration. Each Bearing Cap shall be drilled.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. or the Hand Turning Gear engaged.8 Turning Gear 3. 3. one in the vertical direction and one in the horizontal direction. e. Where liners are used.9 Vibration Measurement a. Arrangements shall be provided to enable the Turning Gear to be operated by hand.8 Caps a. Temperature Measurement a. one spare). The Main Turning Gear shall be designed to turn the Main Shaft continuously in the range of 5 rpm to 10 rpm. b. (4) A signal on the Turning Gear motor to inhibit operation of the Shaft Brake when the motor is running. The Turning Gear shall be capable of being engaged. this will allow instrumentation to be fitted for trials if required. shall apply to the liner. Additional sensors may be required on Bearings operating under a multiplicity of attitudes. Interlocks shall be provided as necessary to prevent inadvertent operation or potentially dangerous states arising within the Gearbox and shall be simple. (3) An interlock on the Turning Gear motor/starter to prevent operation of the motor if the Shaft Brake is pressurized. d. The Bearing Caps shall be independent of the Gearcase covers. 3. 3.12. started and stopped by both local and remote operation. Bearing Caps shall be positively located relative to the lower housing. fail-safe and of high integrity. Arrangements for measuring Bearing temperatures shall be provided in accordance with Clause 3. The following interlocks shall be provided: (1) To ensure that the Turning Gear cannot be engaged and operated at any stage during normal running configurations. 31 . (2) A signal on the Turning Gear Clutch to inhibit starting of the Main Engines when the Clutch is engaged. Turning Gear engagement and disengagement indication shall be provided both locally and remotely.

The responsibility for the design of the input line Flexible Couplings. the Gearbox input flange and the Prime Mover shall be specified. Gear Coupling elements shall be supplied as matched pairs and the most favourable tooth mesh position shall be marked for assembly purposes. Facilities for in-situ balancing shall be provided and the Prime Contractor shall be responsible for the successful installation of the high speed line including balancing. g. A Clutch. b. The details of the machining instructions and subsequent dimensional inspections for the Torque Tube. 32 . To this end reference bands shall be provided on all Torque Tubes. including the detail design of the flange connections to the prime mover(s). An inching control shall be provided at least in the ahead direction.1.9.1 General a. shall ensure that the Torque Tube and associated flanges are such that an adequate standard of concentricity and balance is achieved when the equipment is installed in the Vessel.9 Shafts and Couplings 3. h.DEF STAN 02–305 / ISSUE 2 (NES 305 ) f. The Prime Contractor shall submit a data sheet for each Coupling listing the expected and allowable coupling misalignments in both axial and transverse directions under all modes of operation and loading on directly connected Gears. Motors shall generally be in accordance with DEF STAN 02-627 and DEF STAN 07-244.(13)). However. driving positively in both directions. Attention shall be drawn to any load or deflection conditions for which the Gearbox manufacturer is unable to provide accurate data or safe conservative estimates. Starting and control shall be in accordance with DEF STAN 02-636. Electric Turning motors and equipment shall not be required to be watertight. A locking device shall be fitted in association with the Turning Gear. The loads and movements imposed on Flexible Couplings shall not to exceed the Coupling manufacturer’s recommended values.2a. The Turning Gear motor control shall be fitted with an extension lead of sufficient length to permit operation of the Turning Gear from a position by any of the Gearbox inspection doors. d. the design of the Turning Gear for HM Surface Ship Gearboxes shall ensure that no water can enter the Main Gearcase when submerged in sea water. capable of holding the Gearing and Shafting stationary against at least 50 per cent of the design Full Power ahead torque. c. The arrangement of the Turning Gear and Engine Clutches shall be such that the Turning Gear is capable of rotating all transmission components. (See Clause 1. Arrangements shall be made whereby the Clutch can be positively secured in the engaged and in the disengaged positions. To cater for changes of components in the high speed line. i. shall be incorporated in the Turning Gear drive. the Flexible Couplings shall be supplied with spacer plates to enable the correct cold pull-up to be achieved. 3. The surfaces to be used as concentricity references during the balancing of the Prime Mover and Torque Tube assemblies shall also be specified. including the Prime Movers in both directions.

inclusive. Oil Injections Loose Couplings a. Wherever possible.7a. (3) Involute Splined Couplings fitted on a parallel shaft. (2) Keyed Couplings fitted on a tapered shaft.5. The included angle of the taper shall be between 0. dimensions and stresses. see Clause 3.9. Oil Injection Couplings are preferred.4 and 3. Keyed or Splined couplings should only be used where they offer worthwhile advantages in other respects. 3. The Coupling Hub outside diameter shall be sized.2. The MOD shall be notified of any designs which involve securing arrangements (e. The included angle of the taper shall be 0.12.3. the torque capability of the Coupling shall be at least three times the maximum continuous torque.3 The design of Loose Couplings used to connect shaft within Gearboxes shall be validated in one of the following ways: (1) By adhering to the limits specified in Clauses 3.2 Loose Couplings a. (2) By presenting a detailed justification for the design and the loadings used.9.2.06 mm/mm where the hub is fitted directly on to the shaft. 33 . rings or other screwed fasteners associated with the Coupling. Particular attention shall be given to the means of tightening and locking any nuts. access for endoscopes should be provided. The design interference fit and axial drive-up of the Coupling Hub on the shaft shall be selected so that. e. grubscrews) which cannot be sighted without dismantling so that the need for oversight during build can be assessed. when using a coefficient of friction of  = 0. d. They may not represent the most efficient design.g. A particular Gearbox design may include any one or all three of the above types of coupling.2.03 mm/mm and 0. d.9. If necessary. Keyed Loose Couplings and Involute Splined Loose Couplings are as defined in Clauses 3. b.9.9.7a. For Loose Coupling Hub and shaft materials. so that the material Yield Stress is at least 50 per cent greater than the combined stress equivalent of the radial and hoop stresses in the Coupling Hub calculated in accordance with the von Mises maximum shear strain energy criterion of failure. b. locking arrangements should be made visible so that security can be confirmed without dismantling. The requirements for Oil Injection Loose Couplings. These are conservative limits based on past practice. in respect of materials. c. e. the intermediate sleeve having a tapered outside diameter and a parallel bore. and 3.7c.75 times and not more than the nominal diameter of the shaft in way of the Coupling. c. The Coupling Hub shall fit directly on to a tapered section of shaft or on to a tapered sleeve with a parallel bore inserted between the Coupling Hub and shaft.02 mm/mm where a sleeve is inserted between the hub and the shaft. The Coupling Hub fitted length shall be not less than 0. 3.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. Loose Coupling assemblies may be any one of the following types: (1) Oil Injection Couplings fitted directly on to a tapered shaft or with an intermediate sleeve between hub and shaft.

(4) Key and Keyway tolerances shall conform to the requirements of BS EN 20286–1 and/or BS EN 20286–2. as applicable. (8) Crushing stress in the keys shall not exceed 140 N/mm2. (7) Keys shall be secured in the shaft by means of countersunk or recessed head set screws. (2) The Splines shall be cut by an approved Gear cutting method and not by milling or form cutters.06 mm/mm.5 Involute Splined Couplings a. NOTE When calculating the above key stresses.. All Involute Splined Couplings shall meet the following mandatory requirements: (1) The Splines shall be of the side fit. shaft and key materials shall satisfy the requirements of Clause 3. All Keyed Loose Couplings shall meet the following mandatory requirements: (1) Each Coupling shall be provided with two diametrically opposed keyways. as applicable. (3) The fitted length of the Coupling Hub shall be not less than the nominal diameter of the shaft and not greater than 1. Full justification for a Keyed Loose Coupling shall not be necessary if the following conditions are met: (1) Hub. which shall be not less than 0.2 times the loaded depth of the keyway. b. 3. (7) Shear stress in the keys shall not exceed 40 N/mm2. flat root type and shall conform to the requirements of BS EN 20286–1 and/or BS EN 20286–2. 34 . (5) The depth of the keyway in the Coupling Hub shall be sufficient to provide clearance between the top of the key and the bottom of the keyway. (4) Stresses in the Coupling assembly shall be based on the maximum continuous torque.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. and hence concentricity. shall be provided by direct contact between shaft and hub and not by the Splines themselves.9. shall be equal to half the key thickness.03 mm/mm and 0.9. (3) Radial location. (3) The bottoms of the keyways shall be provided with fillet radii. (4) The possible effects of centrifugal forces on the radial location of high speed Couplings shall be considered. (2) The included angle of the taper shall be between 0. (6) Shear stress in the Coupling Hub shall not exceed 20 N/mm2 based on a bore diameter circumscribing the corners of the keyways. the corner chamfers of the key and any key end radii shall be deducted when calculating the key area.25 times the nominal diameter of the shaft in way of the Couplings. (6) Coupling keys shall be chamfered on all corners. The keyways shall be machined parallel to the taper in both the shaft and the Coupling Hub. (5) Shear stress in the shaft in way of the keyways shall not exceed 150 N/mm2 based on an outside diameter at the bottom of the keyways.2.4 Keyed Loose Couplings a. (2) The depth of the keyway. The chamfers shall be of such dimensions that the keys are clear of the keyway fillet radii.7b. measured at the edge and at the mid point of the Coupling Hub fitted length.

. Information to be Provided a. (2) The Coupling Hub fitted length shall be not less than 0. (5) Shear stress in the Coupling Hub shall not exceed 30 N/mm2 based on a bore diameter equal to the Spline major diameter.DEF STAN 02–305 / ISSUE 2 (NES 305 ) b. Consideration shall be given to the use of small flanges if the above constraint is considered excessive in a particular application. listing the expected and allowable coupling misalignments in both axial and transverse directions. 3.8 (1) Justification of Alternative Designs a. including any thrust or bending loads and the assumed criteria of failure. This can be based either on previous satisfactory experience or on detailed analysis. 3. In either case. the area per Spline being determined from the Coupling Hub fitted length and the Spline radial fitted depth. under all modes of operation and loading on directly connected Gears.7c. defining how assurance shall be obtained. The Prime Contractor shall provide a data sheet for each Flexible Coupling.9.7 Full justification for an Involute Splined Coupling shall not be necessary if the following conditions are met: Power shall be transmitted through bolted couplings by friction. Power Transmission a. 35 . (2) A factor of Safety of 1. (6) Specific pressure per Spline shall not exceed 25 N/mm2.7 times and not greater than the pitch circle diameter of the Splines.12 shall be assumed for this purpose. Submission for review shall be viewed favourably if useful advantages can be demonstrated and if the Prime Contractor can provide complete assurance of the adequacy of the design.9. Attention shall be drawn to any load or deflection conditions for which it is not possible to provide accurate data or a safe conservative design.6 The Coupling Hub and Shaft materials shall satisfy the requirements of Clause 3.0 where reversal of torque is present. a written justification of the design must be provided. When sizing the flanges. as specified in DEF STAN 02-862 Part 1. 3.9. b. Particular attention shall be given to specifying the steady and transient load conditions used in the assessment. but a justification shall be required. (4) Shear stress in the shaft in way of the Splines shall not exceed 45 N/mm2 based on an outside diameter equal to the Spline minor diameter. shall be taken into account. A coefficient of friction of  = 0.5 where torque is unidirectional. Bolts shall not to be in shear and shall be of sufficient numbers and size to allow the following factors of safety on friction drive based on full power torque: (1) A factor of Safety of 2. (3) Stresses in the Coupling assembly shall be based on the maximum continuous torque. Any Coupling which does not fully meet the conditions defined above shall be used without being full justification and with the prior written consent of the MOD. pre-loading for Coupling bolts.2.

or making reference to. so that they do not move under shock and shall not dependent on the position of the covers. Clutches shall be capable of being locked both in and out of engagement. (5) A calculation sheet for each Coupling shall be provided as required by Clause 3. Clutches shall be able to be selected for engagement or disengagement for the following operating modes: (1) (2) (3) 3. The clearance. c. If a Synchro-Self-Shifting (SSS) type Clutch is used.). h.1b.11 Input and output shaft speeds are different. b. Torque values shall be quoted.). rings or fasteners. if any. g.1c. fail-safe and of high integrity (see also Clause 3. d. Fasteners a.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. fit of tapers. including safety precautions and any dimensional checks required before. checked and reassembled by inexperienced staff. it shall have a facility for endoscope inspection of the pawls and ratchet rings. including any thrust or bending loads and the assumed criteria of failure.5. i. during or after assembly (e.(2). Input and output shaft speeds are identical. The design of the Gearbox and ancillary equipment shall minimize the total number of variations of fasteners. between Clutches and their controls shall be specified and easily measured. Input and output shafts are stationary. 36 . Particular attention shall be given to specifying the steady and transient load conditions used in the assessment. fits and tolerances of mating surfaces. f. not covers.5. c. e. axial location). (4) Method of tightening and locking any retaining nuts. A design justification for the Flexible Coupling design and loadings used shall be provided.1.10 b. Clutches shall be operable both locally and remotely. which defines how the assurance shall be obtained. Clutches shall be designed and positioned in such a way that any internal debris caused by wear or failure of the clutch shall not be discharged into any Gear mesh (see also Clause 3. Clutches and their controls must be interchangeable and changing either shall not require adjustments to this clearance. An assembly drawing shall be provided showing. (2) Assembly and dismantling instructions.g. the following: (1) Dimensions. Clutch controls shall be mounted on Gearcases.1b. The Prime Contractor shall provide sufficient information to allow the Coupling to be dismantled. (3) Details of associated jigs and special tools. Clutch interlocks shall be provided to prevent inadvertent operation or potentially dangerous states arising within the Gearbox and shall be simple. Clutches shall be capable of being disengaged on reversal of torque only when unlocked.12. Clutches a.

h. Designed preloading as specified in DEF STAN 02-862 Part 1 shall be used for Bearing Cap fasteners.1 Threaded Fasteners a. Locking washers shall not be used for Gearbox internal fastenings. (2) Nylon-ring-insert nut: NYLOC. (2) Bearing stress under the head and nut (the use of hardened steel washers may be considered for this application).DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. for internal and external screw threads. i. Wiring is suitable for securing fastenings outside the Gearcase to guard against unauthorized removal. as applicable. (4) The adequacy of material in the Coupling flanges. The following ‘stiffnuts’ are approved for use inside the Gearbox: (1) All metal nut: CLEVELOC. Gearwheel side plate fasteners. Threaded studs shall be sized in accordance with BS 4439. l. The use of plated fasteners within the Gearcase shall be avoided (see Clause 3. PHYLOC. Coupling bolts and other fasteners specified in the SRD. b.4a. Welded studs shall not be used in the Gearcase.). All screws and bolts without nuts for service inside the Gearbox shall be of a self-locking type or shall have adequate locking arrangements provided. in accordance with the requirements of DEF STAN 02-862 Part 1. Any alternative requirements shall be presented to the MOD as part of the design justification. g. f. PHILIDAS MARK V. the following factors shall be taken into account: (1) Method of obtaining correct tension in the bolt.11. studbolts. When assessing the adequacy of bolted fasteners in the Main Transmission Train. The preferred types are the all-metal geometrically deformed thread type or the nylon-ring-insert type. j. k. Bolts shall not be wired as a means of securing items inside the Gearcase. All nuts for service inside the Gearbox shall be of the self-locking nut type (‘stiffnuts’) and shall conform to the requirements of BS 4929-1. Bolts. d. studs and screws shall be selected. All screw threads shall conform to the requirement of BS 3643–1 and/or BS 3643–2. BS EN ISO 7042 and/or BS EN ISO 7719 as applicable. Bolts used in conjunction with shock and vibration mountings and as safety and tension stays shall be necked so that failure does not occur within the threaded portion. tab washers may be used after approval by the Prime Contractor.2. (3) Bearing pressure on the side of the holes. Nuts and bolts shall not be locked by peening or otherwise distorting the thread form. wherever possible. Exceptionally. e. 37 . c. BS EN ISO 2320.

11. (3) Seal Temperature: A method of measuring the temperature of any contacting metallic seals shall be provided.1 General a. (iii) For each independent Thrust Bearing supply (see Clause 3.). (d) The elements and the leads shall be securely locked in position and shall be so sited that they can be renewed without the need to remove any Gear elements or Bearing Caps.1n. The use of retaining rings (circlips) within the Gearbox shall be avoided. (b) The pressure gauges shall be mounted on a Gaugeboard attached to the Main Gearbox. 38 . (iii) LO supply to Clutch or other controls. The Prime Contractor shall supply the following instrumentation with each Gearbox: (1) Bearing Temperatures: (a) Instrumentation devices of MOD approved type to measure Bearing temperatures shall be provided on each Journal Bearing and plain Thrust Bearing in the Main Transmission Train and in the drains from all tilting-pad Thrust Bearings.2 Non-Threaded Fasteners a. c. There is no limitation on the external use of spring pins. (b) For Journal Bearings.1c. (ii) For each LO spray or LO spray group.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3.6. Any specific requirements shall be presented to the MOD as part of the design justification. (c) The leads to and from the sensing elements shall be contained in a watertight junction box preferably mounted in the lower half of the Gearcase (see Clause 3.5. Spring pins shall only be used inside the Gearbox in applications where the hole is blind and the pin is trapped by subsequent fittings. Dowels shall only be used provided adequate security of the fittings can be demonstrated. The same Gaugeboard shall also display the following additional LO pressure gauges: (i) Main LO supply pressure.). 3. (2) Oil Pressures: (a) Pressure gauges of the type specified in DEF STAN 66-2 shall be provided as follows. the sensing elements shall be in contact with the back of the Bearing Shells near to the point of minimum oil film thickness. b. The tapping point shall be downstream of the last running valve or orifice in the supply pipework: (i) For each Journal Bearing or Journal Bearing group.12.12 Instrumentation 3. (ii) LO supply to Main Thrust Block. The material shall be Carbon Steel.

1 shall be reported to the Prime Contractor. (b) The transducers.8. where applicable. (see Clause 3.9a. 39 . (10) Drain Tank Instrumentation: Drain Tank instrumentation shall conform to the requirements of DEF STAN 02-303.2b.). (b) A high accuracy. sensors and transmitters required for liquid level. (6) Output Shaft Speed and Direction: Two independent systems shall be provided as follows: (a) A self-powered tachogenerator system providing a local readout. c. e. The input line(s) instrumentation shall include a tracking filter so that vibrations at once per rev discrete frequency are monitored (see Clause 3. flow rate. The Gearbox controls shall be so arranged that no modes of operation can be achieved other than those intended by the designer. Interlocks shall be provided as are necessary to prevent inadvertent or potentially dangerous states arising within the Gearbox and shall be simple. etc. Any requirements for interlocks between the Gearbox and other parts of the propulsion system other than those specified in Clause 3. (c) Versatile Console DEF STAN 02-520. (7) Vibration: The first-of-class shall be installed with accelerometers on each Bearing Cap wired to an interface external to the Gearbox. Turning Gear. (8) Machinery State Information: The Machinery State Information instrumentation shall provide information on the state of Gearbox Clutches and ancillary equipment. (5) Clutch Actuator Shoe Temperature: A method of measuring this Bearing temperature shall be provided. Shaft Brakes.g.14. This shall enable the requirement to monitor vibration at once per rev discrete frequency to be met (see Clause 3.14. Wherever possible such interlocks shall be of a simple mechanical nature. System assemblies shall conform to b..). high reliability electrical speed sensing system to provide a remote signal for control and indication purposes. temperature or pressure instrumentation shall conform to DEF STAN 02-605 Parts 1 and 4.). (11) Electrical Indicating Instruments: (a) Electrical Indicating Instruments used for instrumentation purposes shall conform to DEF STAN 02-604.2c. fail-safe and of high integrity. The Gearbox shall be suitable for both local and remote control.DEF STAN 02–305 / ISSUE 2 (NES 305 ) (4) Input Shaft Speed(s): A system for measuring the speed of the input line(s) shall be provided to enable a tracking filter to be used in conjunction with the vibration monitoring instrumentation. (9) Torque Tube Cover Temperature: A means of measuring the temperature of the cover surrounding the Torque Tubes connecting the Main Engines to the Gearbox shall be provided.7.

Ideally they shall be mounted on the Gearbox. (b) Transmission Brakes. Local manual control shall be provided for the Turning Gear. (b) Brake position and availability. (c) Input line vibration. d. The extent of the remote control and surveillance shall vary between applications but the following list of items likely to require remote control and surveillance is provided for general guidance and for use during feasibility studies and design competitions: (1) Items Requiring Remote Control: (a) Clutches. supplied by a controls contractor. b. b.12. (c) Reversing mechanism state. Local Gearbox pressure and temperature gauges shall be grouped so as to make the watchkeepers task as simple as possible. handwheels. as shall the responsibility for the supply of actuators. NOTE See the SRD for the requirements for local surveillance of other than the self powered gauges and speed sensors. (3) Alarm Signals: (a) LO supply pressure.8). A means shall be provided on all Gearboxes to permit the manual selection and engagement of all modes of drive in the absence of auxiliary power. For this purpose it may be assumed that the Vessel is stopped in the water and the Prime Movers can be controlled at will. instruments and gauges on the Gearbox shall permit local operation by the minimum number of personnel.2 Local Control and Surveillance a. to be able to achieve as many of the changes as possible in drive mode by hand when underway and the local controls and instrumentation shall be designed to facilitate this activity. (e) Turning Gear state (see Section 3.3 Remote Control and Surveillance a. c.1a. 3. The siting of control levers. (2) Output Signals Required for Control Purposes: (a) Clutch state.12.12. 40 . (d) Drain Tank oil temperature. It is desirable. (b) Seal temperatures. (d) Output shaft speed and direction (see Clause 3. (4) Warning Signals: (a) Bearing temperatures. (c) Reversing mechanisms. the Transmission Brake (assuming that brake actuating power is available) and any other Gearbox mounted equipments. The Gearbox shall normally be operated under remote control with surveillance from the Main Propulsion Plant Control System. e.(6)). Any requirement for local automatic or servo manual control to permit the Gearbox and/or other propulsion plant equipments to be operated from a locally situated console shall be specified in the SRD. but not essential.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3.

60 Hz. loss of LO. e. The contractor shall classify all welds as Level 1. 60 Hz. 3 or 4 in accordance with the following definitions: (1) Level 1: (2) Level 2: (3) Level 3: (4) Level 4: Failure of the weld could lead to immobilization of the vessel or serious hazard to personnel. The acceptance standard applicable to the various methods of examination are defined in DEF STAN 02-773. b. (b) Bearing temperatures. risk of Bearing failure. Unless specified otherwise in the SRD. 6. b. (c) Input shaft speeds. 8. 11. damage to Clutches or Couplings. All local pressure gauges shall be of the dial indicator Bourdon tube type to DEF STAN 66-2. All cables used within the Gearcase shall be insulated with Polytetrafluoroethylene (PTFE) to DEF STAN 61-12 Part 8 and DEF STAN 02-512 Parts 1.1 General a. d. 2. The electrotechnical equipment on the Gearbox shall be designed in accordance with DEF STAN 08-107. All welds which affect the integrity of the LO supply system shall be classified Level 1 because of the possibility of a Gearbox explosion following Bearing failure. 12 and 13.g. c. The extent and nature of Non-destructive Examination (NDE) required by each level of weld is defined in DEF STAN 02-773. pierce the Gearbox horizontally or in a downward direction from external to internal. 7.DEF STAN 02–305 / ISSUE 2 (NES 305 ) (5) 3. Failure of the weld could lead to serious disruption of the Main Propulsion machinery. e.12. Design Constraints a. 3-Phase. 5. 2. 41 . c. 2. where practical. Failure of the weld does not constitute a hazard. (3) 24 V dc.4 Surveillance and Health Monitoring Signals: (a) Bearing Cap vibration. 10. loss of control. the following supplies shall be available: (1) 440 V ac. All welding carried out on Gearcase fabrications shall satisfy the requirements of DG Ships/PS/9023. Failure of the weld does not constitute an immediately significant hazard.g. All cables shall be led through the Gearcase structure via sealed glands and not to pass through covers or inspection doors. NOTE: 1. 4 and 5. One cable only shall be fed through each gland. The NDE methods that shall be used are defined in DEF STAN 02-729 Parts 2.13. 3. Single Phase. 3. Glands shall be selected from the range in DEF STAN 02-514 and shall. (2) 115 V ac. as applicable.13 Gearcase Manufacture 3. The above definitions are based on DEF STAN 02-773.

2 gramme The following information shall be provided in respect of each item requiring balancing either on the appropriate drawing or in a balance procedure which itself is called up by the drawing: (1) Whether static or dynamic balance is required. Handwork (e.14 Balancing and Vibration 3. (2) Balance machine or rig to be used (alternatives may be quoted). the circumstances shall be reported to the Prime Contractor who shall advise on the acceptability of a reduced standard. shall be dynamically balanced in accordance with BS 6861-1. Coupling maximum rotational speed Bolt weight tolerance below 1000 rpm 4 grammes 1000 to 5000 rpm 1 gramme above 5000 rpm 0. the residual imbalance shall not exceed 0. b. 3. shall be checked by applying soft marking to the back of the Shell and clamping the Shell at the correct bolt tension in the housing. scraping and/or filing) to correct misalignment between Bearing housings and Bearing bores shall not be conducted. d. Main Wheels operating up to 200 rpm shall be statically balanced. As a minimum requirement.1 Balancing a. If in the opinion of the manufacturer. Bolts used in any Coupling assembly shall be of a uniform mass within the tolerance specified in the following table: e. 42 . c. shall be checked and recorded in the Gearbox Inspection Record. e. The fit of a standard Bearing Shell in its housing bore or liner bore. application of the above criteria to particular equipments is likely to lead to excessive penalties in time or cost. After correction for any imbalance has been made. The required level of balance shall be selected in order to ensure that the noise and vibration requirements specified in this Standard and/or the SRD are satisfied. as appropriate. including Main Wheels where appropriate.14. (4) Position of supports when balancing. All components operating above 200 rpm. The nip of the Shell in the housing or liner and circularity of the bearing bore.23 kgm/tonne.DEF STAN 02–305 / ISSUE 2 (NES 305 ) d. (3) Concentricity requirements.g. the balance quality grade shall meet or exceed the requirements of BS 6861-1. It is recognized that the standard of balance required by the above becomes increasingly difficult to achieve at higher speeds and also for components of low mass. (5) Method of correction. Such components shall be machined by precision jig borers or other similar machine tools.

(7) Whether any drive adaptors. The level of Bearing Cap and Gearbox foot vibration shall be minimized both to reduce the risk of mechanical damage and the Ship radiated noise.19. The results achieved shall be provided to the MOD. Torque Tube. A claw piece or Coupling portion of a Flexible Coupling. i. Main input Flexible Coupling assemblies shall be balanced with their reference bands running true within the limits of Clause 3. bolted.3a.e.1b. g.14.8 mm/s. h. (2) The vibration level that is expected at each Bearing Cap. When a Coupling.).2. within 10 m Total Indicator Reading (TIR) (run-out). mandrels or temporary stub shafts are required and. as measured by rollers. Work record sheets of concentricity readings obtained at final balance shall be included in the Gearbox Inspection Record to facilitate correct assembly in the Vessel.1a. NOTE The vibration level at 1x shaft rotational frequency is defined as the maximum shaft displacement relative to the axis of rotation against the time taken for one revolution of the shaft.2 (6) Position and radius of correction planes. and 3. A tracking filter shall be fitted to the Gearbox input lines so that vibrations in each Bearing Cap at once per discrete frequency can be measured.9. (1) The maximum allowable vibration at each Bearing Cap if less than 3. Torque Tube or Quill Shaft running at Turbine speed is balanced as a separate stem. 43 . Vibrations a. Turbine Rotor or Pinion shall be balanced with the item in question after being fitted to it. records of Bearing Cap and Gearcase structural vibration shall be taken in accordance with Clauses 3.18. = Shaft displacement (mm) Time taken for one rev of the shaft During Shop and Sea Trials. the level of vibration on the high speed (input) line(s) Bearing Caps shall not exceed 3. if so. keyed or shrunk-on to a Quill Shaft. f.20. When installed in HM Surface Ships or Submarines.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. the balance limits and concentricity tolerances for these items.: Vibration level (mm/s) Shaft rotational frequency d. whether these shall be in place for balancing and methods of ensuring their concentricity during subsequent reassembly. The Gearbox manufacturer shall quote the following in mm/s peak velocity at 1x fundamental: c. it shall be set up in the balancing machine to its reference band and balanced in this condition. it shall be set up to its reference band within the limits of run-out specified. b. When an individual member of a gear tooth type Coupling is balanced it shall be balanced with the teeth running concentric. (8) Particulars of any separate parts to be attached to the component in service.8 mm/s peak velocity at 1x shaft rotational frequency (known as the fundamental). Actual run-outs shall be recorded on assembly (see Clause 3. When it is assembled.

porosity. The MOD reserves the right to have additional inspections carried out. shall be applied to every Gear to facilitate examination of meshing marks during Shop and Sea Trials.18. The minimum requirement is that record sheets shall be completed for each element of the Gearbox as detailed in Clause 3. All Bearings shall be thoroughly examined for cracks. The meshing achieved with no-clearance Bearings in use is the more reliable of the two results and shall be used to assess the acceptability of the Gears. When the Gears are installed in the Gearcase. a further meshing check shall be made and the results recorded. meshing shall be satisfactory if the contact covers 50 per cent of the working depth for 50 per cent of the length and 40 per cent of the working depth for a further 40 per cent of the length of each helix. the test may be repeated at the Gear manufacturer’s discretion. or other suitable semi-permanent marking. With the gear element axis parallel. If acceptable meshing is not achieved with the normal Journal Bearings in place.15. using special ‘no-clearance’ Bearings to locate the Gears in their Full Power running positions.15 Inspection 3. Gear alignment during Shop Trials and Contractor’s Sea Trials under load shall be checked as in Clauses 3.1 General a. NDE of thin walled Journal Bearings shall be carried out in accordance with BS 7585-1 and/or BS 7585-3.19. Sellotape).5a.g. No cracks are acceptable and any other visual defects shall also be a cause for rejection. This marking shall cover at least four teeth across their full face width.15. NOTE The Contractor may offer alternative methods for achieving these requirements. g. Sufficient dimensional and other inspections shall be carried out to ensure that the design conforms to the requirements of this Standard and its referenced documents. h. depressions. c.2a. On completion of the finishing process. the meshing of each pair of Gears shall be checked and the results recorded. The contact marking obtained during the meshing check shall be recorded by taking records of the transfer of blue marking by means of transparent adhesive tape (e. as required. The Prime Contractor shall be informed immediately of any departures from allowable tolerance. and 3. the liability for the cost of such additional inspections shall be negotiated at that time. f. d. The use of packing materials to position the shafts within Bearings is not acceptable. e. b.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. NDE of the Main Transmission Gear elements and shafts shall be carried out in accordance with DEF STAN 02-381.2a. particularly by using strain gauging techniques or by using data from accurate modern Gear measuring machines. in a meshing frame. helix or profile correction has been applied. The Gears shall be supported on rollers or. 44 . inclusions. i.(3)).21. A band of Talbot Blue Lacquer. Dimensional or other inspection of any particular feature appearing in the Gearbox Inspection Record shall be carried out on completion of the particular operation involved. unless subsequent ultrasonic or liquid penetrant examination can demonstrate that the defect is within the acceptance level for those techniques (see Clause 3. due allowance being made where end relief. in no-clearance bearings. j. mechanical damage and apparent lack of bond along the White Metal to Steel interface.

DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. As a minimum standard.2 Acceptance Standards a.0 mm in length. Liquid Penetrant Examination: (i) Liquid Penetrant Examination of a Bearing surface shall be in accordance with BS 7585-3 acceptance criteria. (c) Ultrasonic Examination from Tip: All defects greater than 1.0 mm diameter.0 mm diameter and closely grouped defects. If this cannot be achieved. Gear Teeth: This Standard applies after final Gear grinding and all defects defined below may be cause for rejection and shall be reported: (a) Magnetic Particle Examination: All cracks or crackline indications.e. which is considered to be the normal production standard. within 25 mm in any direction of each other which would individually give echoes in excess of 12 dB below an ideal reflector of 1. Any indication of grinding burns shall be a cause for rejection. If this cannot be achieved. As a minimum standard. 45 . (ii) At depth greater than 50 mm: All flaws giving echoes equal to or greater than that from an ideal reflector of 4. i.5 mm in length. (b) Liquid Penetrant Test: All defects greater than 1. may be a cause for rejection and shall be reported: (a) Magnetic Particle Examination: All cracks or crackline indications. The following standards shall be applied when assessing the acceptability of test results: (1) (2) (3) Forgings: Forgings containing defects. Bearings shall not be accepted if they contain defects above the levels defined in BS 7585-1.15. Bearings shall not be accepted if they contain defects above the levels detailed below: (a) Non-Destructive Ultrasonic Testing of Bond: (i) (b) Ultrasonic Examination of a Bearing surface shall be in accordance with BS 7585-1 acceptance criteria (full area coverage). (d) Surface Temper Etch Examination (Nital Etch). which shall be in accordance with BS 7862. it shall be reported to the Prime Contractor. or an alternative technique for identifying the presence of grinding burns. bearings shall not be accepted if they do not satisfy the requirements of BS 7585-3 acceptance criteria. it shall be reported to the Prime Contractor. Bearings: This standard applies to the Bearing in the final machined condition. (b) Ultrasonic Examination: (i) In outer 50 mm: All flaws giving echoes equal to or greater than that from an ideal reflector of 1. Any indication of bad bonding in a White Metal Bearing is undesirable and zero defect bonding is considered to be the normal production standard.5 mm diameter. as defined below.

(3) During initial flushing (see DEF STAN 02-303) the supply pipework shall be bypassed at the inlet to each individual Bearing housing (see Clause 3. (4) All external unpainted Ferrous surfaces and the Gearbox internals shall be coated with an approved preservative oil.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. the Gearbox and ancillary equipments shall be completely enclosed in either a self-sealing thick plastic bag or sealed polythene envelope. proposals for preservation for a minimum period of six months shall be submitted to the Prime Contractor for approval. (3) All Gearbox openings shall be blanked. equipments shall be preserved and protected to BS 1133–6. b. the Gearbox shall be treated as a Clean Area and a polythene tent shall be constructed around any openings prior to opening up and during any inspection or internal work. ledges and other horizontal surfaces shall be wiped clean.1 and/or BS 1133-6. at intervals not exceeding six months. 46 . On completion of shop trials and any subsequent opening up for inspection and reassembly. The preservative oil film shall be repeated and the desiccant trays renewed.16 Shop Flushing 3.2. Cleanliness and preservation of all components during manufacture shall be in accordance with DEF STAN 02-341. modified by the following additional instructions: (1) The Main Gearing and Drain Tank shall be thoroughly searched for gross dirt and debris before flushing starts. If in the manufacturer’s opinion a complete enclosure is not practicable. in accordance with DEF STAN 02-303. Drain Tanks. as applicable.2 a. After completion of the flush. The MOD reserves the right to inspect the Gearbox for internal corrosion at any stage during the construction of the vessel.17.) and each group of Gear Sprays. in the presence of the Prime Contractor’s Quality Assurance Representative. b. 3. After Shop Trials a. (2) All parts of the Gearbox which have been in contact with water shall be dried.1 General a. The Gearbox shall be internally examined for signs of corrosion. Additional the following shall be observed: (1) All parts of the Gearbox shall be completely drained. (5) Where practicable.1 During Manufacture 3.16. A report on each examination shall be submitted to the Prime Contractor. (2) Supply pipework used in the Gearbox and the shop service unit shall be cleaned to Grade C Standard before installation.17 Cleanliness and Preservation 3.1i. Basic desiccant shall be used with each enclosure. The Main Gearing and its associated LO pipework shall be thoroughly flushed before shop testing. (4) A certificate shall be provided to the Prime Contractor’s Quality Assurance Representative stating that the required standard of cleanliness has been achieved.6.17.

DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3.2b.17. or welding shall take place in the vicinity. (2) The application or removal of insulation or lagging shall not be permitted in the machinery compartment when the Gearbox or any associated pipework is open to the atmosphere. If this is not possible on board. Cleanliness During Installation a. b. grinding. 47 . The Prime Contractor’s Quality Assurance Representative shall be advised. a local clean area shall be established around the work area to minimize the spread of debris. c. A log shall be maintained of all tools and equipments taken into and removed from the Clean Area. drilling. who shall be held liable for any degradation allowed to occur. When a Gearbox is opened for internal work or inspections.1b.17. The Prime Contractor’s Quality Assurance Representative shall decide on the need for and extent of such additional cleaning measures. etc.). (4) Should any items of equipment or pipework be contaminated by the ingress of dirt or foreign matter.3 3. of any such work. d. The following instructions shall be followed: (1) When equipment openings are unplugged or blanks are removed for the purpose of making pipe connections. in advance. grinding.).4 Cleanliness and Preservation After Delivery a. the items shall be removed for cleaning ashore. it shall be thoroughly cleaned before continuing with the installation.17. Access to the Gearbox shall be controlled and limited to necessary personnel only. filing. The Receiving Authority shall determine the date of the last application of preservative and shall establish a programme of routine internal inspections as required by Clause 3. On receipt at the Shipyard and in the presence of the Prime Contractor’s Quality Assurance Representative. (3) Each plug or blank shall be retained in position until immediately before the relevant joint is made. Maintaining the cleanliness and condition of the Gearbox after delivery is the responsibility of the Shipbuilder or other Receiving Authority. Clean Area protocol shall be strictly adhered to (see Clause 3. This requirement shall be satisfied if a polythene tent has been provided around areas that are unplugged or where blanks have been removed during the opened up/working period. Particular care shall be taken to avoid the ingress of dirt during installation. the Gearbox shall be internally examined. shall depend upon the amount of work done on the Gearbox and the care with which it was controlled. chipping.17.g. e. the Gearbox shall be treated as a Clean Area and a polythene tent shall be constructed around any openings. The need for flushing or lancing prior to installation in the ship. Any corrosion found or other deficiencies shall be reported in writing to the MOD. When metal-removing activities have to be performed within the Gearbox (e. A vacuum cleaner shall be used to remove the debris. no burning.

After this the LO drains down from the Gearcase relatively quickly and exposes bare metal surfaces which are not recoated with oil until Basin Trials. in association with the rest of the propulsion machinery. The preservative oil film is removed prior to system flushing when the Gearbox is internally washed down by lance flushing. (3) Spin-testing at Full Speed and Part Load. including a determination of gear efficiency.18 3.17. The procedure shall include.1 3. (2) Proving and calibrating instruments (this may be achieved by sighting copies of valid test certificates issued by the instrument supplier). Couplings and controls. Immediately prior to the system being filled.5.) shall be removed from the Gearcase and the Dehumidifier shall be proved operational.2 Preservation and Cleanliness up to Acceptance a.4a. Gearbox internal corrosion is a particular hazard during the period of LO system flushing. c.17. Each new design of Gearing shall be performance tested in accordance with the requirements of the SRD. (c) Overload and/or endurance tests.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. The MOD shall specify which type of test shall be adopted (depending on the class of vessel).). leading to corrosion of the Gearcase and Gear elements. at Full Load and Full Speed.2a.5 3. but is not limited to: (1) Running-in and part load trials.17.6 3. The Contractor shall provide a detailed performance testing procedure for the specified type of test.18. (5) Post Test Inspections: For Shore Facility and Back-to-Back testing the following tests shall also be included in the programme: (a) Full Load tests.) and the results recorded along with the tolerance allowed when the Gearbox is fitted in the Vessel. Preservation During ‘Setting to Work’ a. During this period. Performance Testing of a New Gearbox Design a. the Gearcase alignment shall be accurately checked using the reference surfaces (see Clause 3. the desiccant trays (see Clause 3. Testing Shop Testing a.18. b.1b. Failure to use the Dehumidifier will result in condensation forming on exposed bare metal surfaces. (3) Demonstration of Clutches. which shall be one of the following: (1) Shore Test Facility: Gearbox testing at Full Load and Full Speed. 48 . (2) Back-to-Back testing of the first two production Gearboxes.18. (4) Overspeed tests. the following precautions shall be taken to prevent internal corrosion: (1) The number of warm-up-and cool-down periods shall be reduced to a minimum by leaving LO Pumps running whenever possible between successive periods of activity. From this time onward the Dehumidifier shall be operated continuously whenever the LO supply to the Gearbox is isolated. (2) The Dehumidifier shall be brought into operation whenever LO is not being supplied to the Gearbox. The general requirements for the performance testing of a new Gearbox design shall be the same as the production test for all Gearboxes (see Clause 3. (b) Astern running tests (where applicable). Prior to the commencement of any Shop Testing.

shall be functionally tested and adjustments made as required. together with any additional requirements specified in the SRD. protective and control devices. which shall be replaced or modified prior to delivery. which shall be permanently fitted in the Gearbox installation.16. tests shall be carried out to demonstrate their satisfactory operation.4 Every set of Gearing shall be subjected to a production test as specified below. a sweep shall be made for vibrations at other frequencies.4a: (1) The equipment tested shall be that which shall be supplied. 49 . (5) Where Clutches and Couplings are fitted.18. (6) All warning. (7) During the test the Gearcase shall be thoroughly checked for oil leaks. Dummy Couplings and Adaptors shall be fitted to input shafts during tests to produce a moment as near as possible to that which shall be experienced when the Gearbox is fitted in the Vessel. (2) During tests the Gearbox shall be supplied with the specified LO from a shop service unit which meets the requirements of DEF STAN 02-303. The Prime Contractor shall be notified in advance of any intended substitutions or temporary fittings used to facilitate testing. The Gearing shall then to be operated for at least one hour in every specified mode of operation at the maximum continuous speed corresponding to that mode. and shall be inspected after testing in accordance with Clause 3. (8) All vibration monitoring and position indicating equipment.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 3. (9) During the production test at maximum steady speed. or immediately after. (4) The Gearing shall be operated at the maximum continuous specified speed until Bearing and LO temperatures have stabilized. accelerometers shall be attached to all Gearbox Bearing Caps and the level of vibration at the once/rev frequency recorded. especially at joints and seals. Post Test Inspections a. 3. In addition. (3) Before commencing production tests the Gearbox shall have been successfully flushed in accordance with Clause 3. shall be in use during the tests. The sweep shall be carried out on one Bearing of each rotating assembly and the Prime Contractor shall be notified of any frequencies detected where the level exceeds that of the once/rev or tooth contact frequencies. Sufficient additional equipment shall be provided to enable a positive readout to be obtained from each item of equipment under test. The following assessments and/or inspections shall be carried out (and recorded) during. Any leaks found shall be corrected. as specified by the MOD. the production test: (1) Gear Alignment: (a) Gear alignment shall be assessed during the test using strain gauge data.3 Production Test a.18.18.

Sellotape). The Talbot Blue Lacquer or other marking should be reapplied for use during Sea Trials. The manufacturer shall keep a detailed log of the following during production testing. (5) Bearing Cap vibration levels (where fitted) at once per rev frequency.5.20). (2) LO flow rate. the manufacturer shall open for inspection such Bearings as the Prime Contractor’s Quality Assurance Representative may select. The Prime Contractor’s Quality Assurance Representative shall be informed if anything unusual is found. Meshing shall be checked by noting the removal of Talbot Blue Lacquer or other marking. (b) The MOD reserves the right to call for a complete strip and inspection of the Gearing.18.) and the results recorded. (3) LO outlet (drain) temperature. 50 . making entries every 15 minutes of the first hour and every 30 minutes thereafter.1b. These records shall be included in the formal Gearbox Inspection Record (see Clause 3. (4) Gearcase Alignment: On completion of all Shop Tests the Gearcase alignment shall be accurately checked using the reference surfaces (see Clause 3. until stabilization of temperatures and vibration levels: (1) Inlet LO pressure and temperature. (3) Drain Tank: The sump and/or Drain Tank shall be emptied. wiped clean and searched for foreign matter. (7) Input power. (9) The reasons for any unprogrammed stoppages. b. the Gear unit shall be opened for visual inspection of the Gear meshes. The MOD shall be consulted in cases of dispute or uncertainty. (4) Bearing temperatures. Bearings: (a) Although full inspection of Journals.5 (b) On completion of the mechanical running tests. Bearings shall require examination if there is any indication of higher than normal temperatures or vibrations recordings or if past experience indicates a need to inspect in a particular area.g. (c) The contact marking shall be recorded by taking of records of the transfer of blue marking by means of transparent adhesive tape (e. (6) Shaft speed. Bearings and Thrust Collars shall not normally be required. Records Required During Tests a. (8) Strain gauge results (if fitted).DEF STAN 02–305 / ISSUE 2 (NES 305 ) (2) 3.

51 . Examine Bearings and other components only if there is reason to suspect malfunction. preserved and closed in accordance with Clause 3.1 General a.. to attend throughout the trials.19. unless there is a reason to suspect damage. should this be required to maintain to the trials programme.DEF STAN 02–305 / ISSUE 2 (NES 305 ) c. The specific requirements shall vary between vessel classes but the following principles shall be applied: (1) After Basin Trials: Examine Gear meshes for signs of poor load distribution or other distress. DEF STAN 02-351. (2) After First Run at Full Power: Examine Gear meshes as above and any Bearings which show higher than expected temperatures. Shipboard trials and inspections shall be carried out in accordance with the requirements of DEF STAN 02-350. Any movement of fasteners shall be reported to the MOD. The extent and timing of Gearing inspections during trials shall be defined in the Trials Programme for each vessel. (c) Check the clearance of all Thrust and Location Bearings either by inspection or by jacking the located shafts axially through their full range of travel. (3) After Full Power Trial: Examine Gear meshes and take records of tooth contact marking (see Clause 3. (4) On Completion of Contractors Sea Trials: (a) Examine all Pinion and Wheel Teeth. DEF STAN 02-352. the Bearing examinations should be limited to two per Gearbox. b.17. d. (b) Examine top and bottom halves of selected Bearings.2a. the initial production test shall not be acceptable and a repeat test shall be carried out after the replacements or corrections are made. The Gearbox manufacture shall confirm that his representative is able to authorize priority work at the manufacturer’s Works. Particular attention should be paid to the final reduction Gears. On completion of all tests and inspections the Gearing shall be reassembled. 3. taper pins. to assist with inspections and to supervise any work carried out on the Gearbox.). If improvements are required as a result of deficiencies noted during tests or inspections. (d) Check the security of ALL accessible bolted flanges in the Main Transmission Train by applying 50 per cent of the design tightening torque to at least 25 per cent of fasteners in every flange. etc.19 Contractor Sea Trials 3.19. NOTE On vessel other than First of Class. The Gearbox manufacturer shall obtain from the Shipbuilder a contract to cover the cost of such attendance. DEF STAN 02-354 and with the procedures given in DEF STAN 02-32. DEF STAN 02-353. The Prime Contractor shall provide a representative. including at weekends or other quiet periods. e. Electrical Rotating machinery shall be tested in accordance with DEF STAN 02-629 and other electrical equipment in accordance with DEF STAN 07-226. (e) Check the security of selected internal instrumentation including the associated cabling and carry out random check of terminal screws.

DEF STAN 02–305 / ISSUE 2
(NES 305 )

NOTE

3.19.2

3.19.3

(f)

Inspect the Gearbox Sump and Drain Tank and examine LO samples
and filters. The presence of any foreign matter shall be reported to the
DPA and the cause investigated. (See DEF STAN 02-303 for LO
change requirements);

(g)

Examine selected Flexible Couplings, Hydraulic Couplings, and
Clutches.

Unless malfunction has occurred or is suspected, an in-situ visual inspection
for signs of Bearing damage, rubbing seals and overheating shall normally
suffice. The condition of internal Thrust Bearings shall be checked as at
Clause 3.19.1b.(4)(c).

Alignment
a.

Gear alignment under Full Load shall be verified by removal of Talbot Blue
Lacquer or other marking and also, if specified in the SRD, by using strain gauges
in the roots of Gear Teeth.

b.

For alignment to be assessed only by the method of noting the removal of Talbot
Blue Lacquer or other marking after a Full Power Trial, the Gear Tooth markings
shall indicate freedom from hard bedding and show contact over not less than 90
per cent across the length of each Helix with full contact over the involute, but
taking into account tip and root reliefs if applicable. The contact marking shall be
recorded by taking records of the transfer of blue marking by means of transparent
adhesive tape (e.g. Sellotape).

c.

For strain gauge trials, the Prime Contractor shall provide a test programme,
including an indication of the maximum strain gauge readings that are acceptable.

Records Required During Contractor Sea Trials
a.

The Prime Contractor shall keep a detailed log of the Sea Trials programme,
including maintaining records at regular intervals of all Gearbox instrumentation
data (see Clauses 3.18.3a.(9) and 3.18.5a.).

3.20

Records

3.20.1

General
a.

The Prime Contractor shall keep the following data available for inspection by the
MOD from the date of each Gearbox order until Stage 3 acceptance:
(1)

All material certification;

(2)

Heat treatment process and hardness records;

(3)

NDE results;

(4)

Gear alignment data;

(5)

Results of Shop Tests and CST;

(6)

Dimensional inspection results.
52

DEF STAN 02–305 / ISSUE 2
(NES 305 )

3.20.2

b.

Records relating to Flexible Couplings, Clutches, Fluid Couplings and other items
supplied by sub-contractors shall be included in booklet form. The booklet shall
also include details of all concessions and modifications affecting that equipment.

c.

A collection of record sheets following the Gearbox Inspection Record format for
each design shall be submitted to the MOD before the start of manufacturing work.

Distribution
a.

b.

4.

A set of records shall be distributed to the following personnel:
(1)

MOD – (2 copies) (or MOD Project Officer);

(2)

Gear manufacturer;

(3)

Engineer Officer of the HM Ship or Submarine.

Similar records shall be taken and records produced, as applicable, for spare
Gearboxes, spare Gear elements and other Gearbox components. Two MOD
copies shall be enclosed in a plastic envelope in the crate containing the spare
components.

DESIGN REQUIREMENTS/GUIDANCE
(No relevant information included)

5.

CORPORATE EXPERIENCE & KNOWLEDGE
(No relevant information included)

53

DEF STAN 02–305 / ISSUE 2
(NES 305 )
ANNEX A.
A.
RELATED DOCUMENTS
A1. The following documents and publications are referred to in this Standard:
BS ISO 701

International gear notation. Symbols used for geometrical data

BS ISO 11221

Vocabulary of gear terms. Definitions related to geometry

BS ISO 63361

Calculation of load capacity of spur and helical gears. Basic
principals,introduction and general influence factors

BS ISO 63362

Calculation of load capacity of spur and helical gears. Calculation
of surface durability (pitting)

BS ISO 63363

Calculation of load capacity of spur and helical gears. Calculation
of tooth bending strength

BS ISO 63365

Calculation of load capacity of spur and helical gears. Strength
and quality of materials

BS EN ISO 2320

Prevailing torque type steel hexagon nuts. Mechanical and
performance requirements

BS EN ISO 7042

Prevailing torque type allmetal hexagon nuts. Property classes 5,
8, 10 and 12

BS EN ISO 7719

Prevailing torque type allmetal hexagon nuts, style 1. Property
classes 5, 8 and 10

BS EN 10028-1

Specification for flat products made of steels for pressure
purposes. General requirements

BS EN 100282

Specification for flat products made of steels for pressure
purposes. Nonalloy and alloy steels with specified elevated
temperatures

BS EN 100283

Specification for flat products made of steels for pressure
purposes. Weldable fine grain steels, normalised

BS EN 100284

Specification for flat products made of steels for pressure
purposes. Nickel alloy steels with specified low temperature
properties

BS EN 100285

Specification for flat products made of steels for pressure
purposes. Weldable fine grain steels, thermomechanically rolled

BS EN 100286

Specification for flat products made of steels for pressure
purposes. Weldable fine grain steels, quenched and tempered

BS EN 100287

Specification for flat products made of steels for pressure
purposes. Stainless steels

BS EN 10029

Specification for tolerances on dimensions, shape and mass for hot
rolled steel plates 3 mm thick or above

BS EN 202861

ISO system of limits and fits. Bases of tolerances, deviations and
fits

BS EN 202862

ISO system of limits and fits. Tables of standard tolerance grades
and limit deviations for holes and shafts

BS 4363

Spur and Helical Gears. Method for calculation of contact and
root bending stress limitations for metallic involuted gears

BS 4364

Spur and Helical Gears. Definitions and allowable values of
deviations relevant to corresponding flanks of gear teeth

54

Method for nondestructive die penetrant testing BS 7862 Gears. Surface temper etch inspection after grinding JSP 430 Ship Safety Management System Handbook: Volume 1: Policy and Guidance on MOD Ship and Equipment Safety Management DEF STAN 0040 Reliability and Maintainability: Part 1: Management Responsibilities and Requirements for Programmes and Plans DEF STAN 015 Fuels. Protection of metal surfaces against corrosion during transport and storage. Cleaning and drying of metal surfaces BS 11336. Specification for selected limits of size BS 4439 Specification for screwed studs for general purposes. Balance quality requirements of rigid rotors. Metric series BS 4800 Schedule of paint colours for building purposes BS 49291 Specification for steel hexagon prevailing-torque type nuts. DEF STAN 0254 (NES 54) Supply of Information to Determine the Shipfit of Equipment and Identification of Parts and Spares DEF STAN 02302 (NES 302) Requirements for Maintenance Envelopes and Removal Routes: Part 1: Surface Ships DEF STAN 02303 (NES 303) Lubricating Oil System for Propulsion and Generation in Surface Ships and Submarines DEF STAN 02304 (NES 304) Shafting Systems and Propulsors: Part 1: Design Requirements for Main Propulsion Shafting 55 . Principles and basic data BS 36432 ISO metric screw threads. Temporary protectives and their application BS 3332 Specification for white metal bearing alloy ingots BS 36431 ISO metric screw threads. Metric series BS 68611 Mechanical vibration. Protection of metal surfaces against corrosion during transport and storage. RFA's and other Naval Auxiliary Vessels. Definitions and allowable values of deviations relevant to radial composite deviations and runout information BS 11336.1 Packaging code.2 Packaging code. Method for determination of permissible residual unbalance BS 75851 Metallic multilayer plain bearings. Method for nondestructive ultrasonic testing of bond BS 75853 Metallic multilayer plain bearings.DEF STAN 02–305 / ISSUE 2 (NES 305 ) BS 4365 Spur and Helical Gears. Lubricants and Associated Products DEF STAN 0232 (NES 32) Requirements for Arranging and Conducting Inspections and Trials During the Construction and Conversion of Surface Ships DEF STAN 02-45 (NES 45) Requirements for the Application of Reliability Centered Maintenance Techniques to HM Ships and Submarines.

ThinWall insulated Limited Fire Hazard (LFH) for General Services Part 10: Terminations and Connectors Part 11: Glands. Components and Equipment for Fluid Systems: Part 1: Cleaning DEF STAN 02350 (NES 350) Guidance for the Pretrial Inspections of Machinery Compartments and Installations in Surface Ships DEF STAN 02351 (NES 351) Requirements for First Machinery Inspection and Official Basin Trials of Propulsion Machinery in HM Surface Ships DEF STAN 02352 (NES 352) Secondary Machinery Inspection and Contractors Sea Trials of Propulsion Machinery in HM Surface Ships DEF STAN 02353 (NES 353) Examination of Machinery in HM Surface Ships on Completion of Contractors Sea Trials DEF STAN 02354 (NES 354) Third Machinery Inspection.DEF STAN 02–305 / ISSUE 2 (NES 305 ) DEF STAN 02337 (NES 337) Requirements for Elastomeric Toroidal Sealing Rings (Orings): Part 1: General and Surface Finish Standards Relative to Manufacture DEF STAN 02341 (NES 341) Requirements for Cleaning of Items. Termination and Junction Components for Equipment DEF STAN 02520 (NES 520) Guide to Design Procedures for Versatile Console Systems 56 . Miscellaneous for Special Services Part 8: Cables. Limited Fire Hazard (LFH) or Chlorosulphonated Polyethylene (CSP) Sheathed for General Service Part 3: Cables. Radio Frequency Part 6: Cables. Electrical. Electrical. Limited Fire Hazard (LFH) or Chlorosulphonated Polyethylene (CSP) Sheathed for General Service Part 5: Cables. Electrical. Electrical. Final Machinery Trial and Demonstration of Propulsion Machinery in HM Surface Ships DEF STAN 02381 (NES 381) Forgings and Heat Treatment of Main Propulsion Gears DEF STAN 02502 (NES 502) Requirements for Electrical Installations DEF STAN 02512 (NES 512) Guide to Cables. Electrical and Associated Items: Part 1: General Part 2: Cables. Miniature and SubMinature and Equipment Wires Part 7: Cables and Wires. Grommets and Deck Tubes Part 12: Index of NATO Stock Numbers and Cable Manufacturing Specifications for Cables Listed in Parts 2 to 8 Part 13: Cables (imperial) Nearest Metric Equivalents DEF STAN 02514 (NES 514) Guide to Cable Entry. Electrical. Ethylene Propylene (EP) Rubber Insulated and Halogen Free Rubber Insulated. Electrical Silicon Rubber Insulated.

DEF STAN 02–305 / ISSUE 2 (NES 305 ) DEF STAN 02604 (NES 604) Electrical Indicating Instruments DEF STAN 02605 (NES 605) Guide to the Selection of Sensors for the Measurement of System Parameters: Part 1: Selection of Liquid Level. Temperature and Pressure Sensors Part 4: Selection of Flow Sensors DEF STAN 02626 (NES 626) Control and Surveillance Equipment for Plant and System Installations DEF STAN 02627 (NES 627) Requirements for General Application to Rotating Electrical Machinery DEF STAN 02629 (NES 629) Requirements for Testing of Rotating Electrical Machinery DEF STAN 02636 (NES 636) Requirements for ac and dc Starting and Control Gear DEF STAN 02722 (NES 722) Requirements for the Preparation. Manganese and Low Alloy Steel Forgings: Part 1: Carbon Manganese Steel Forgings Part 2: Low Alloy Steel Forgings DEF STAN 02862 (NES 862) Fasteners: Part 1: General DEF STAN 0311 Phosphate Treatment of Iron and Steel DEF STAN 07200 (NES 42) Guide to the Completion of Form DGSF114/114A Equipment Provisioning Requirement Sheets (EPRS) DEF STAN 07224 (NES 507) Requirements for Materials for Electrotechnical and Naval Weapon Equipment Interim DEF STAN 07226 (NES 511) Requirements for Electrical Testing of Equipment DEF STAN 07244 (NES 632) Requirements for ac and dc Motors DEF STAN 08103 (NES 302) Requirements for Maintenance Envelopes and Removal Routes: Part 2: Requirements for Submarines 57 . Identification and Management of Drawings DEF STAN 02723 (NES 723) Requirements for Marker Plates DEF STAN 02729 (NES 729) Requirements for NonDestructive Examination Methods: Part 2: Magnetic Particle Part 4: Liquid Penetrant Part 5: Ultrasonic DEF STAN 02737 (NES 737) Preservation and Painting of Mechanical Machinery Items DEF STAN 02773 (NES 773) Minimum Acceptance Standards for Welds in HM Surface Ships and Submarines DEF STAN 02848 (NES 848) Requirements for Carbon.

03 British Gear Association Codes of Practice for Gear Accuracy: BGA. ANNEX B.DEF STAN 02–305 / ISSUE 2 (NES 305 ) Interim DEF STAN 08107 (NES 501) General Requirements for the Design of Electrotechnical and Naval Weapon Equipment DEF STAN 08123 (NES 1004) Requirements for Design and Testing of Equipment to Meet Environmental Conditions DEF STAN 5936 Selection of Electronic and Electrical Components for Use in Defence Equipment DEF STAN 6112 Wires. DE 14 2AU. Pressure. Suite 43. Dial Indicating (Bourdon Tube Type) BR 8470 Shock and Vibration Manual BGA: DUCOP. ac Alternating Current BGA British Gear Association BR Book of Reference BS British Standard CDROM Compact Disc Readonly Memory CPP Controllable Pitch Propeller CST Contractor Sea Trials dc Direct Current DEF STAN Defence Standard DG Ships Director General Ships DNA Director Naval Architecture DUCOP Design Unit (Newcastle University) Codes of Practice Electrotechnical For formal definition see DEF STAN 08107 and DEF STAN 07224 EPRS Equipment Provisioning Record Sheet(s) FP Future Projects HM Her Majesty ISO International Organization for Standardization L10 Rolling Element Bearing Life (10% probability of failure) Lm Arc length defined to the number of base pitches LO Lubricating Oil 58 . Shobnall Road. For the purpose of this Standard the following abbreviations and definitions apply. ABBREVIATIONS AND DEFINITIONS B1. B. DUCOP. Cords and Cables.02 and DUCOP. IMEX Business Park. BurtononTrent.01. ElectricalMetric Units: Part 8: PTFE Insulated Equipment/Wires DEF STAN 662 Gauges.

59 Scope  or NA . 1. Each item is to be marked either: Check No.  = included NA = not applicable Check Clause No. This Check List is to ensure that certain aspects of this Defence Standard are consulted when preparing a procurement specification for a particular application.DEF STAN 02–305 / ISSUE 2 (NES 305 ) MOD Ministry of Defence NDE Nondestructive Examination NES Naval Engineering Standard OEP Oil Extreme Pressure OM Oil Mineral OMD Oil Mineral Diesel PCS Plant Control System PTFE Polytetraflouroethylene Ra Surface Roughness (average from centreline) R and M Reliability and Maintainability RH Relative Humidity rpm Revolutions Per Minute SH Surface Stress SF Bending Stress SSCP Sea Systems Controllerate Publication SSS Synchronous Self Shifting STF Shore Test Facility SRD System Requirement Document STW Setting to Work TIR Total Indicator Reading (runout) UTS Ultimate Tensile Strength WSA Warship Support Agency ANNEX C. Clauses where a preference p for an option p is to be used or where specific p data are to be added are iincluded l d d iin th the Ch Check k Li List. Specifying auxiliary drives required. PROCUREMENT CHECK LIST Notes: 1. C. 2. t 3 3.

4a. 3. 1. Specifying the depth at which the Gearbox shall continue to 1.6.1 8.2a. Number of copies of tender submission required. 22.(1) 11. Specifying electrical supply available.2b. Giving noise and vibration targets.2a. Defining periods for maintenance. 21. Specifying the responsibility for the Main Thrust Bearing. and astern modes? 17. 1.1a.4d.2 new Gearbox design. Scope 3.DEF STAN 02–305 / ISSUE 2 (NES 305 ) 2.1. Scope 5.1b. 19. Specifying the requirements for performance testing of a 3.1. 1. 3.2a. 10. Specifying the type of LO to be used.1a.12.6.6.1.3.(9) 16. Defining the frequency and times allowed for manoeuvres.2c the supply of actuators.1. 3. 7. 13. Defining targets for reliability. Stating the date for submission of the preliminary design.1. Specifying the requirements of the preliminary design. 24.18.1k. Specifying the Drain Tank requirement.1b. 9. 3.1.1.5.1a. 3.12. 15. Specifying the format required for supplying drawings and Table 3.1. 18. Note 23. 4. .11. 20.1a.1a. Giving weight and size limitations. setting to work procedures. powered guages and speed sensors.(2) 12. 3.1j. 1. Specifying other fasteners required. Table 3. Is there a requirement for operation in other than ahead 1. 3.2a. What design instructions shall be given? 1.14. Specifying the control requirement and responsibility for 3. 60 3. Specifying Gear accuracy requirements. Specifying the responsibility for all other Gearbox Scope auxiliaries.1.2a. Stating the date for holding down arrangement proposal.1.1.12. Requirements for local surveillance other than self 3.2e. 3.(8) 14.(4).1. 1.1.(4) 6. run and for the minimum duration required.

19 ALPHABETICAL INDEX A Acceptance Standards. information required. 17 Cabling. 26 Cabling. 9 Auxiliary drives. 13. 31 Cleanliness and preservation after delivery. 53 Drain tank instrumentation. 11. 21. 21 Bearings. 24 D Adjustable bearing housing. 12 Design objectives. 36 Clutches for turning gear and main engines. 41 Design full power. support of. 26 Caps to be fitted to bearings. 43 Bearing design and analysis. 2 Electrotechnical requirements for gearbox. 15 Astern operation. 26 Electrical indicating instruments. 2 B Balancing. 9 Components of main gearing. 13 Design constraints. 9 Estimates of timescales.DEF STAN 02–305 / ISSUE 2 (NES 305 ) Clutches requiring remote control and surveillance. 42. 19 Design competition. material. 28 Design change control. NDE requirement. 45 Access provisions within gearcase. dynamic and general requirements. thin walled. 32 F Clutches. 46 Clutch securing in engaged and disengaged positions. 19 Dehumidifier required for gearbox. 2 Comprehensive drawing schedule and index. 26 Datum pack. 26 Earthing of gearcase. 29 Bearings. 47 Cleanliness and preservation after shop trials. 38 Drain tank requirement. 27 Drainage of gearcase. 28 Electrotechnical definition. 46 Cleanliness during installation. 51 Control of design. 25 Drawings required in support of a tender. 21 Environmental conditions. 27 Electrical equipment fitted to the gearbox. 47 Cleanliness procedures during manufacture. 8 Accuracy. 44 Brakes requiring remote control and surveillance. 40 Cold start. 12 Control of design changes. 40 C E Cable terminals. 8 Design reviews. 38 Electrical requirements for dehumidifier. 29 Bearings. 13 Distribution of records. 17 Contractor sea trials. 37. 28. 25 Accessibility. removal without disturbing other fittings. general. 38 61 . 32 Fasteners. 13 External loads and movements imposed. 9 Design justification process.

41. 26. 13. 26 N Instrumentation for drain tank. check during design. 44 Materials. 24. limitation on use. 9 Manufacturing requirements for gearcase. 27 Lubricating and venting. 45 Lubricating oil distribution system. 38 Instrumentation for gearbox. 27. 22 Loose couplings. 30 Maintenance schedule. 44 Long lead items. 26 Marking to identify gear elements. 48. 32 L Flexible couplings. 21 Inspection. 40 Magnetic particle examination. 17 Junction boxes and cable terminals. 21 Lubricating Oil. 17 J Jigs and special equipment. 31 Non–destructive examination of main transmission items. 25 Inspection record sheets. 13 Gear tooth design. general requirements. 45 Holding down arrangements. 17 Manoeuvring. 14. 40. 19 Materials for components. 31 62 . 32 Flushing procedure before shop tests. 2 Locking device to hold gearing and shafting stationary. 19 Modification plate fixed to gearcase. 17 Liquid Penetrant Test. 45 Local control. 30. 44 Meshing Marks. 38 Noise. 28 Gearcase manufacture. 41. 17 Final design justification and drawing standards. 49. 46. 45 Limitations on use of materials. 41 Gearcase materials.gearboxes. 24 Instruments. 17 Housings for bearings. 26 Materials for gearcase design. 52 Installation instructions – shipbuilders responsibility. 52 Grinding burns. 32 Gear construction. 50. forgings. 25 Maintenance envelope. 40 G Local plant control unit. 27. 24. provision for in bearing caps. 2 M H Health monitoring signals. 44 Interlocks required for turning gear.DEF STAN 02–305 / ISSUE 2 (NES 305 ) Final design approval and drawing standards. 26. 46 Life expectancy period. 25. 33 Gearcase design. 38. 15. 21 Inspection doors to gearbox. 25 Information to go to the shipbuilder. 8. 42 I Identification plates to gearcase. 9 Forgings. 26 Flange connections to prime movers. 11. 25 Gear tooth alignment. 21 Functional block diagram. 21. 44. 49.

19 Pitch for gear tooth design. 9 Q Submergence precautions. 41 Reversing mechanisms requiring remote control. 2 Paint to be used. 49 Steel backing for bearings. 30 Records to be kept by manufacturer . 49. 14 Submersibility. 31 Phantom tones. 48. 48 Space and weight limitations. 8 Production back–up spares. 21 Physical interface drawings. 15 Shock loads. 26 Painting of external surface of gearboxes. 46 Spares recommendations. 52 Pads offsets. 8 Non–destructive examination of welding. 8 Preliminary design preparation. 51. 11 R T Records of spare components. 14 63 . 49. 32 Quality and format for tender. 17 Starting and control gear for turning gear. 9 Pipework materials. 48 Shop testing. 9 Preservation and cleaning up to acceptance. 51 O S Oil inlets for bearings. 48 Sensors for bearing temperature measurement. 9 Quality Assurance for the design. 30 Seating plan. 9 Safety. 20 Supply of drawings by the Prime Contractor. 26 Performance tests. 29. 11 Quillshaft materials. elements and gearboxes. 50. 44 Reliability and maintainability. 51 Shock. 24 P Sea trials. 50 Temperature monitoring. 17 Pressure gauges for gearbox. for bearings. 13. 38 Standardization of Components. 8 Scuffing – operating gearing with negative effect. information required. 29 Stress calculations basis. 24 Shaft materials. for bearings. 22 Post test inspections. 32 Production test. 8 Preservation procedures during manufacture. 21 Supply of programmes by the Prime Contractor. 21 Security of inspection plates. 31 Records required during tests.DEF STAN 02–305 / ISSUE 2 (NES 305 ) Non–destructive examination of thin walled bearings. 30 Overload capability. 53 Temperature measuring. 50. 52 Tenders. 40 Representatives of manufacturer at trials. 51 Preservation during setting to work. 17 Shaft speeds and gear ratios. 21 Shipbuilders responsibility for writing alignment procedures and installation instructions.

32 Vibration levels to be met and recorded. overload. timing for ship or submarine. materials. 23 Upkeep support. 22. 43 Torque. 29 Wheels and pinions. 38 U Thrusts. 27 Torque tubes. 8 Trials programme. 23 V Tooth load distribution. for bearings. 32 White metal linings. 9 Ultrasonic testing requirements. 38 Weight and space limitations. non–contacting displacement type. 41 Turning gear. 51 Welding on gearcase fabrications. full power. maximum. 31. 43. 9 W Transducers. 28 Tooth loading. 9 Vibration monitoring. 31.DEF STAN 02–305 / ISSUE 2 (NES 305 ) Thermosensors for gearbox. 22 Valve – isolating – to gearbox supply pipes. 12 Tooth load analysis. 38. ahead. 24. 45 Tooth bending stresses. 23 Ventilation from drain tank. 52 Torque. 21 64 . non–transient.

Inside Rear Cover .

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