NES 305 Requirements For Gearing - Main Propulsion

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 02305 (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
DEF STAN 02305 / ISSUE 2

(NES 305 )
SCOPE
1.
This Defence Standard (DEF STAN) 02-305, in conjunction with the documents referred to
herein, specifies the minimum requirements which must be met by the Main Gearing Contractor
and other authorities, during the design, manufacture, 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. 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).
3.
The extent of the equipment covered by this Standard is as follows:

a.
The Main Gearing, which comprises:

(1)
The gearcase, and all gears, shafts (main and lay), oil seals, dipsticks, clutches, brakes,
couplings and bearings contained therein;
(2)
The input flexible coupling including control of the interface with prime mover output
flange and its satisfactory performance where applicable;
(3)
The Gearbox output flange(s) and Main Shaft Flexible Coupling where applicable;
(4)
The responsibility for the successful installation and commissioning of the high speed
line(s), including balancing.
b.
The lubricating system internal to the Gearbox downstream from the Gearbox supply
point(s) (to be defined). For futher information and guidance refer to DEF STAN 02-303.
c.
Gearbox Atmospheric Control:

(1)
Venting;
(2)
Dehumidification.
d.
All local controls and surveillance instrumentation associated with the Main Gearing,
including the local Plant Control Unit (PCU), if specified.
e.
Auxiliary drives required by the System Requirement Document (SRD) as follows:

(1)
For gear driven units mounted on the Gearcase or, when integral on the Drain Tank;
(2)
For driven units mounted remotely, e.g. on the Vessels structure.
f.
The Main Thrust Bearing, only if stated in the SRD. Requirements relating to the design
and manufacture of Main Thrust Bearings are given in DEF STAN 02-304.
g.
All other Gearbox auxiliaries (e.g. Turning Gear, Dehumidifier, etc.) required by this
Standard or by the SRD.
h.
The electrotechnical equipment associated with the Gearbox (e.g. control and surveillance
instrumentation) and with those items mounted directly on the Gearcase (e.g. Turning Gear)
or, when integral, on the Drain Tank (e.g. Motor Driven Lubricating Oil (LO) pumps). The
term Electrotechnical is formally defined in DEF STAN 08-107; it includes all items such
as motors, starters, junction boxes, cable conduit and wiring.
i.
Gearbox seating arrangements.

2

(NES 305 )
FOREWORD
Sponsorship
1.
This Defence Standard is sponsored by the Warship Support Agency (WSA), Ministry of Defence
(MOD).
2.
Any user of this Standard either within MOD or in industry may propose an amendment to it.
Proposals for amendments that are not directly applicable to a particular contract are to be made
to the publishing authority identified on Page 1, and those directly applicable to a particular
contract are to be dealt with using contract procedures.
3.
If it is found to be unsuitable for any particular requirement MOD is to be informed in writing of

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

(NES 305 )
Categories of Defence Standard

14.
The Category of this Standard has been determined using the following criteria:
a.
Category 1. If not applied may have a Critical affect on the following:
Safety of the vessel, its complement or third parties.
b.
Operational performance of the vessel, its systems or equipment.

Category 2. If not applied may have a Significant affect on the following:
Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
Through life costs and support.
c.
Category 3. If not applied may have a Minor affect on the following:

MOD best practice and fleet commonality.
Corporate experience and knowledge.
Current support practice.

Related Documents
15.
16.
17.
18.
19.
20.
In the tender and procurement processes the related documents listed in each section and Annex
A can be obtained as follows:
a.
British Standards
b.
Defence Standards
British Standards Institution,

389 Chiswick High Road,
London, W4 4AL
An Executive Agency of the Ministry of Defence
Kentigern House
65 Brown Street
Glasgow, G2 8EX.
c.
Other documents
Tender or Contract Sponsor to advise.
All applications to the MOD for related documents are to quote the relevant MOD Invitation to
Tender or Contract number and date, together with the sponsoring Directorate and the Tender or
Contract Sponsor.
Prime Contractors are responsible for supplying their subcontractors with relevant documentation,
including specifications, standards and drawings.
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. 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. Where attention is drawn to hazards, those quoted may
not necessarily be exhaustive.
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.
Additional Information
(There is no relevant information included.)
4

(NES 305 )
CONTENTS
Page No
TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Categories of Defence Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION
1.
1.1
1.1.1
1.1.2
PERFORMANCE SPECIFICATION . . . . . . . . . . . . . . .
Basic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION
2.
NATIONAL/INTERNATIONAL REGULATIONS . . . . 11
SECTION
3.
3.1
MILITARY STANDARDS/REQUIREMENTS . . . . . . . .
Design Justification, Drawings and
Information Required . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design Justification Process . . . . . . . . . . . . . . . . . . . . . . .
Drawings and Information Required in Support of a
Gearbox Tender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quality and Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drawings and Information Required for a
Design Contract or Gearbox Order . . . . . . . . . . . . . . . . .
Preliminary Design Information Required . . . . . . . . . . .
Information to be Supplied by Prime Contractor in
Support of a Design Contract . . . . . . . . . . . . . . . . . . . . . .
Final Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design Justification and Drawing Standards . . . . . . . . .
Quality Assurance of the Design . . . . . . . . . . . . . . . . . . . .
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels and Pinions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1
3.1.2
3.1.2.1
3.1.3
3.1.3.1
3.1.4
3.1.5
3.1.5.1
Table 3.1
3.1.6
3.1.6.1
3.1.6.2
3.1.6.3
3.1.6.4
3.2
3.2.1
3.2.2
3.2.3
8
8
8
9
11
11
11
12
12
13
13
14
15
15
16
17
17
17
19
20
21
21
21
21

(NES 305 )
3.2.4
3.2.5
3.2.6
3.2.7
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.5
3.5.1
3.6
3.6.1
3.6.2
3.7
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
3.7.6
3.7.7
3.7.8
3.7.9
3.7.10
3.8
3.8.1
3.9
3.9.1
3.9.2
3.9.3
3.9.4
3.9.5
3.9.6
3.9.7
3.9.8
3.10
3.11
3.11.1
Page No
Lubrication Suction, Delivery and Drain Pipework . . . . 21
Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rubber O Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shafts and Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Gear Tooth Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Helix Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tooth Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tooth Load Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tooth Loading Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Gear Element Safety Factors . . . . . . . . . . . . . . . . . . . . . . 23
Scuffing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gear Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gear Element Construction . . . . . . . . . . . . . . . . . . . . . . . 24
Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gear Case Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Lubrication and Venting . . . . . . . . . . . . . . . . . . . . . . . . . . 27
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Steel Backings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
White Metal Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Bearing Design and Analysis . . . . . . . . . . . . . . . . . . . . . . . 29
Oil Inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Vibration Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Temperature Measurement . . . . . . . . . . . . . . . . . . . . . . . . 31
Turning Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Shafts and Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Loose Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Oil Injections Loose Couplings . . . . . . . . . . . . . . . . . . . . . 33
Keyed Loose Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Involute Splined Couplings . . . . . . . . . . . . . . . . . . . . . . . . 34
Justification of Alternative Designs . . . . . . . . . . . . . . . . . 35
Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Information to be Provided . . . . . . . . . . . . . . . . . . . . . . . . 35
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Threaded Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6

(NES 305 )
3.11.2
3.12
3.12.1
3.12.2
3.12.3
3.12.4
3.13
3.13.1
3.14
3.14.1
3.14.2
3.15
3.15.1
3.15.2
3.16
3.16.1
3.17
3.17.1
3.17.2
3.17.3
3.17.4
3.17.5
3.17.6
3.18
3.18.1
3.18.2
3.18.3
3.18.4
3.18.5
3.19
3.19.1
3.19.2
3.19.3
3.20
3.20.1
3.20.2
Page No
Non-Threaded Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Local Control and Surveillance . . . . . . . . . . . . . . . . . . . . 40
Remote Control and Surveillance . . . . . . . . . . . . . . . . . . . 40
Design Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Gearcase Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Balancing and Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Acceptance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Shop Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cleanliness and Preservation . . . . . . . . . . . . . . . . . . . . . . 46
During Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
After Shop Trials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cleanliness and Preservation After Delivery . . . . . . . . . . 47
Cleanliness During Installation . . . . . . . . . . . . . . . . . . . . . 47
Preservation and Cleanliness up to Acceptance . . . . . . . 48
Preservation During Setting to Work . . . . . . . . . . . . . . 48
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Shop Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Performance Testing of a New Gearbox Design . . . . . . . 48
Production Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Post Test Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Records Required During Tests . . . . . . . . . . . . . . . . . . . . 50
Contractor Sea Trials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Records Required During Contractor Sea Trials . . . . . . 52
Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SECTION
4.
DESIGN REQUIREMENTS/GUIDANCE . . . . . . . . . . . 53
SECTION
5.
CORPORATE EXPERIENCE & KNOWLEDGE . . . . . 53
ANNEX A
RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . 54
ANNEX B
ABBREVIATIONS AND DEFINITIONS . . . . . . . . . . . . 58
ANNEX C
PROCUREMENT CHECK LIST . . . . . . . . . . . . . . . . . . . 59
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7

(NES 305 )
1.
PERFORMANCE SPECIFICATION
Related Documents:
see also Annex A.
1.1
Basic Requirements
1.1.1
Design Objectives
a.
DEF STAN 02-304 Part 1; DEF STAN 08-123; BR 8470;
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. As Main Propulsion
Gearing is not amenable to reliability prediction techniques a numerical
reliability target will not be specified. However, a full reliability assessment
shall be required during the design as described in Clause 3.1. 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).
The Gearbox manufacturer may be required to participate in such
assessments but will not normally be expected to lead them. Specific
requirements and targets shall be defined in the System Requirement
Document (SRD). Wherever possible reliability shall be obtained by
designing equipment which is robust and simple;
(2)
Maintainability: The Gearbox shall be designed for minimum maintenance

and for ease of such essential maintenance as is required. Experience has
shown that Gearbox reliability is often lowered rather than improved by
maintenance activities. The design should therefore incorporate facilities to
ease visual inspection so that the internal components are not disturbed
except when faults are evident. The provisions made for maintenance shall
be reviewed throughout the design process as explained in Clause 3.1 and the
manufacturer shall be required to co-operate in a Maintenance Evaluation
exercise, which shall be conducted by Naval personnel on the first Gearbox
produced. The likely periodicity of major maintenance periods shall be
detailed in the SRD;
(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. The Gearbox shall be suitable for both local and
remote control and the siting of control levers, handwheels, instruments and
gauges shall be such as to permit local operation by the minimum number of
personnel;
(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. Where specific noise and vibration targets have to be met
these shall be detailed in the SRD;
(5)
Shock: This aspect shall be considered in both the layout and mounting of
components and in the detailed design. (See Clause 1.1.2b(11)). The
requirements for resistance to underwater shock shall be detailed in the SRD;
8

(NES 305 )
(6)
Accessibility:
(a)
The design shall be within space limitations and provide the maximum
accessibility to gear parts which require routine examination,
maintenance and repairs;
(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. Pipes shall not be led through covers and doors;
(7)
Standardization: The Gearbox shall be subject to refit/repair/overhaul by

an upkeep by exchange policy. 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;
(8)
Weight and Space: Specific limitations on weight and size shall be given in
the SRD. If no specific instructions pertain, weight and space shall be kept to
the minimum consistent with other requirements herein. The space required
for maintenance of the equipment shall also be minimized;
(9)
Efficiency: Power losses shall be minimized for the normal operating range;
(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:
1.1.2
(a)
Moving parts of gearing such as Clutches, Brakes, Couplings, Gear

elements, other than the main output shaft, shall be enclosed;
(b)
Hand operating gear shall be interlocked or arranged to disengage

when there is a possibility of power operation;
(c)
Initial loads on spring assemblies shall be fully released before the

spring is freed for dismantling.
Design Basis
a.
The design shall be based on the following requirements unless specific

instructions to the contrary are provided in the SRD.
b.
To Specifying Authority: It is essential that the requirements listed below, which

are based on typical past practice, 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. Design shall be based on life expectancy of typically over
150,000 hours of operation (this represents 25 years of life at 70 per cent
utilization per year). This shall include 5,000 hours at design Full Power and
50,000 hours between 50 per cent and 100 per cent of design Full Power or as
specified in the SRD;
(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);
9

(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 Vessels hull
deep and dirty. If, in selecting the number of teeth, it proves impractical to
exactly match both speeds, the gear ratio may be varied by not more than one
half per cent. The specified input speed and the actual Gear ratio shall then be
used to define the design output shaft speed. The gear unit shall be capable of
continuously transmitting design Full Power at speeds up to 105 per cent of
the specified input speed;
(4)
Maximum Full Power Torque: The maximum full power torque is that
developed when transmitting design Full Power at the specified input speed;
(5)
Basis for Stress Calculations: Calculations of transmission loadings and

stresses shall be based upon the specified input speed. Full Power centrifugal
loadings and stresses, and calculations on whirling speeds shall be based on
105 per cent specified input speed;
(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;
(7)
Thrusts: The Gearing shall be capable of withstanding such thrusts and

movements as are likely to be imposed by the Main Shafting. Thrust bearing
design requirements are specified in DEF STAN 02-304 Part 1;
(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. Torques up to these levels shall
occur during high power turns and rapid accelerations up to a total of
five hours during the Ships life. 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;
(b)
Thrust: See DEF STAN 02-304 Part 1;
(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;
(b)
Non-reversing Gearboxes (i.e. 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;
(10) Emergency Operation: The requirements for operation in other than

normal ahead and astern modes shall be specified separately;
(11) Shock Loads: All Naval Gearing shall be designed to withstand Naval
Shock Standard I, using procedure 1 of BR 8470;
10

(NES 305 )
(12) Environmental Conditions: The gearing shall meet the requirements of

DEF STAN 08-123. 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);
(13) Submersibility: Gearboxes shall be capable of operation in sea water for a
specified minimum duration and depth as quoted in the SRD;
(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 5Celsius
and of transmitting 70 per cent design Full Power with a LO inlet temperature
of 20Celsius.
2.
NATIONAL/INTERNATIONAL REGULATIONS
(No relevant information included)
3.
MILITARY STANDARDS/REQUIREMENTS
See Annex A for a full list of all Related Documents.
3.1
Design Justification, Drawings and Information Required
3.1.1
General
a.
This section describes the process by which the Prime Contractor shall control the
design of the main gearing and identifies the programmes, drawings and other
documentation which shall be supplied. This section incorporates the following
sub-headings:
(1)
Design Justification Process:

(a)
(2)
(3)
Information Required (see Clauses 3.1.2.1a. 3.1.2.1d.);
Drawings and Information Required in Support of a Gearbox Tender:

(a)
Information Required (see Clause 3.1.3.1a.);
(b)
Quality and Format (see Clause 3.1.4a.);
Drawings and Information Required for a Design Contract or Gearbox

Order:
(a)
Preliminary Design:
(i)
(b)
Information Required (see Clause 3.1.5.1(a);
Final Design:
(i)
Design Justification and Drawings Standards

(see Clause 3.1.6.1);
(ii)
Information Required (see Clause 3.1.6.2);

11

(NES 305 )
(iii) Additional Information (see Clause 3.1.6.3);

(iv) Quality Assurance of the Design (see Clause 3.1.6.4).
3.1.2
Design Justification Process
3.1.2.1
Information Required
a.
b.
c.
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;
(2)
All potential sources of unreliability have been identified and their optimum
elimination means determined;
(3)
Proper account has been taken of the need to operate, maintain and support
the Main Gearing throughout its working life at the lowest through-life cost.
As the first step is providing the assurance required by Clause 3.1.2.1a., the Prime
Contractor shall establish a formal system to control the design process. 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, taking account of the most adverse
conditions likely to occur;
(2)
A means of defining the Gearbox in terms of assemblies, sub-assemblies and

components and for identifying the interfaces between them. (This may
conveniently be accomplished by means of the Functional Block Diagram
(see Clause 3.1.6.2a.(5));
(3)
A comprehensive list of possible failure modes considered for each

component, assembly and sub-assembly;
(4)
A formal assessment of these failure modes to determine and record what

assurance shall be provided against them. The form of assurance selected
should take account of the risk and significance of the failure and the effort
required to provide such assurance;
(5)
A statement of the calculation method and acceptance criteria used for each
failure mode to be checked by calculation;
(6)
Methods for calculating or estimating the forces and/or movements likely to

be encountered by each component, sub-assembly and assembly within the
Gearbox;
(7)
A means for recording that calculated and allowable values have been
compared and found acceptable;
(8)
A means for ensuring that appropriate calculations are repeated if any

changes are made to the design or to external conditions.
Objective evidence of the systems effectiveness shall be provided by:

(1)
Describing the system to be applied to each design;

12

(NES 305 )
d.
(2)
Requiring the gear manufacturer to justify the list derived from Clauses
3.1.2.1b. (1), (2), (3), (4) and (5);
(3)
Conducting a series of formal Design Reviews which shall progressively

approve the design. 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.
The Prime Contractor shall submit a plan, prepared in accordance with

DEF STAN 00-40 Part 1, showing which activities shall be undertaken to ensure
that the proposed design meets the requirements of DEF STAN 08-141
Parts 1 and 2. Arrangements for monitoring these activities shall be included in the
Design Justification Programme.
3.1.3
Drawings and Information Required in Support of a Gearbox Tender
3.1.3.1
a.
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) An outline sectional arrangement of the Gear trains;
(3) A statement giving Gearing particulars, including numbers of teeth,
reference circle, addendum and root circle diameters, pressure and helix
angles, modules, face widths, strengths and pitting load rating calculations
using BS ISO 6336-1, BS ISO 6336-2, BS ISO 6336-3 and/or BS ISO
6336-5; as applicable. 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;
NOTE For calculations using BS 436-3 it is acceptable at the tendering
stages to use estimates for load correction factors, however, the
estimated values used shall be stated.
(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;
(5) A mass elastic diagram giving details of Gearbox inertia stiffness;
(6) Details of any brake including the capacity of the unit in terms of total
absorbed energy, peak energy input rate, static holding torque and dynamic
braking torque compared with the maximum duty estimated for the particular
application;
(7) Details of any Clutches, including power requirements, control signals and
maximum torque capabilities;
(8) Details of the Flexible Couplings, including Main Shaft Couplings, where
applicable, shall include the misalignment capability under continuous
running and shock. The anticipated misalignment shall be quoted;
(9) A control diagram showing the method of control proposed for the Brakes,
Clutches, Couplings and Turning Gear and the interlocks between them;
(10) Position and size of mountings;
(11) Estimated dry weight of all equipment covered by the tender. Estimated
weight of fluids in the unit at the normal working level;
13

(NES 305 )
3.1.4
(12) Diagram of LO distribution arrangement including the calculated design oil

flow and the corresponding bulk oil temperature rise at Full Power. These
calculations shall be based on normal running conditions;
(13) A statement of Gearing efficiency at maximum Full Power;
(14) Main unit Journal Bearing loads and directions and a statement giving
principal bearing particulars, which shall include length, diameter, specific
bearing pressure, rubbing speed, minimum oil film thickness, maximum oil
temperatures, oil temperature rise through the Bearing and bearing power
losses. If rolling contact bearings are proposed, then a statement is required
giving the manufacturer, his serial number, a notation of where special
bearings are specified, the maximum loads, static and dynamic capacity,
maximum speed and L10 life calculated for a specific power spectrum. For
Thrust Bearings the information required by Clauses 3.7.4b, c. and d.
inclusive shall be submitted;
(15) A statement on the maintenance requirements including services and
maintenance envelope of the Gearbox and, if appropriate, a description and
sketch of the methods proposed for repair by replacement;
(16) A statement on the methods that shall be used for inspecting all Gearing
elements, components and Bearings;
(17) A statement on the Running-in requirements for the Gearbox;
(18) A programme and procedures for both shop testing and Contractor Sea Trials
(CST);
(19) A list of spare parts or whole assemblies which shall be retained by the
manufacturer during build;
(20) A detailed statement on the design philosophy used to minimize noise,
including such justification as does exist for any claims made about the
relative noise performance of different design features, e.g. single versus
double Helical Gears;
(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. The diagram shall be presented as a
left-to-right flow diagram;
(22) A preliminary reliability assessment explaining how it is intended to
demonstrate design-for-life aspects and reliability;
(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);
(b) Maximum rate of production of subsequent Gearboxes;
(c) A programme for the detailed design and manufacture of the STF
and/or first Vessel Gearboxes. Programme to include order dates for all
long lead items.
Quality and Format
a.
Quality and Format requirements are that:

(1) The tender submission should normally be in the form required by the tender
document;
(2) Drawings submitted with the tender shall meet the requirements of
DEF STAN 02-722.
14

(NES 305 )
3.1.5
Drawings and Information Required for a Design Contract or Gearbox Order
3.1.5.1
Preliminary Design Information Required

a.
The information required to be supplied as part of the design contract is listed in

Table 3.1. The following paragraphs define the requirements in more detail and
define the standards to which the work shall be carried out.
b.
On receipt of the contract, the Prime Contractor shall prepare or revise the technical
portion of the submission report (see Clause 3.1.2b.) in accordance with the latest
schedule or SRD. 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;
(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;
(3)
A tabular statement on the safety factors under shock, relative to the

permissible shock stresses, in all shafts, shaft bolts, Bearing Cap bolts, and in
the Gearcase structure. Attention should be drawn to any items which have
required additional strengthening to meet the shock duty;
(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;
(5)
A schedule of the active electrotechnical equipment, with parameters that

shall be monitored and signalled, shall be proposed by the manufacture type,
number etc., (e.g. pressure transducer, amplifier for speed probe, state
switch, solenoid, motor, starter, etc.).
NOTE The Prime Contractor shall ensure that the requirements of
DEF STAN 02-54 shall be invoked at this stage.
c.
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. The
diagram shall indicate the limits of supply under the terms of the design
contract;
(2)
A set of preliminary drawings showing the basis for design. If any of these
preliminary drawings shall be updated to final design drawings, the
requirements of DEF STAN 02-722 shall be observed;
(3)
A detailed design programme showing the expected delivery dates for all the
items of design information listed in Table 3.1, Sections 2 and 3;
(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;
(5)
A draft Design Justification Programme proposing dates for the Formal

Design Reviews and Design progress monitoring meetings;
(6)
A list of all assemblies, sub-assemblies and components to assist the Prime

Contractor in specifying the Upkeep Codes (see DEF STAN 07-200).
15

(NES 305 )
Line
Description
No
1 PRELIMINARY DESIGN
The following items shall be submitted for Project Authority approval before
starting detail design. The date by which submission is required shall be
specified in the Design Contract:
1.1 Updated Tender Report;
1.2 Preliminary Functional Block Diagram;
1.3 Additional drawings;
1.4 A design programme showing the expected delivery dates of the information
listed at 2 and 3 below;
2 DESIGN DRAWINGS AND INFORMATION
The following items shall be submitted to the Prime Contractor in accordance
with an agreed programme:
2.1 A suitably indexed Comprehensive Drawing Schedule;
2.2 A twoway crossreferencing index between Manufacturer's Drawing Numbers
and Service Drawing Numbers;
2.3 One copy of all drawings required to manufacture the Gearbox, in a format to
be agreed with the MOD (e.g. microfilm/CD ROM);
2.4 A full functional block diagram;
2.5 A full set of physical interface drawings;
2.6 A full set of signal/interface specification sheets identifying all signals and their
relevant interfaces with the rest of the Vessel;
2.7 A list of all external services required by the Gearbox;
2.8 A list of and drawing of all jigs, fixtures, special tools and equipment required
to install and maintain the Gearbox;
2.9 A statement on the operating limitations for the Gearbox, covering all modes
of operation;
2.10 A comprehensive Maintenance Schedule for the Gearbox;
2.11 A detailed set of Maintenance Envelope drawings;
2.12 Production Backup Spares;
2.13 Spares Recommendation;
2.14 A tabular statement on external loads and movements;
2.15 A Reliability and Maintainability Report.
3 ADDITIONAL DRAWINGS AND INFORMATION
The following additional items shall be supplied to the Project Authority in
accordance with an agreed Schedule:
3.1 One `As Made' process master of each Datum Pack Drawing;
3.2 One `As Made' process master of specified additional drawings required by the
Prime Contractor;
3.3 A loose leaf report containing all information required by the Shipbuilder or
STF Authority;
3.4 Where called for in the contract, copies of all drawings, specifications, etc.,
necessary for an alternative contractor to manufacture the Gearbox.
Reference
Clause
3.1.5.1b.
3.1.5.1c.(1)
3.1.5.1c.(2)
3.1.5.1c.(3)
3.1.6.2a.(1)
3.1.6.2a.(3)
3.1.6.2a.(4)
3.1.6.2a.(5)
3.1.6.2a.(6)
3.1.6.2a.(7)
3.1.6.2a.(8)
3.1.6.2a.(9)
3.1.6.2a.(10)
3.1.6.2a.(11)
3.1.6.2a.(12)
3.1.6.2a.(13)
3.1.6.2a.(14)
3.1.6.2a.(16)
3.1.6.3a.(1)
3.1.6.3a.(2)
3.1.6.3a.(3)
3.1.6.3a.(5)
Table 3.1 Information to be Supplied by Prime Contractor in Support of a Design Contract

16

(NES 305 )
3.1.6
Final Design
3.1.6.1
Design Justification and Drawing Standards
3.1.6.2
a.
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 3.1.
b.
All manufacturing drawings, electrical drawings, Datum Pack and other Process
Masters shall conform to the requirements of DEF STAN 02-722.
a.
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. 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. It shall be presented in assembly and sub-assembly
groups. The document will finally be used as a comprehensive access
document to the production prints held by the MOD;
(2)
Although no attempt is made to quantify the mechanical equipment drawings

required to manufacture the Gearbox, in the case of electrotechnical
equipment in the Gearbox the following drawings shall be provided:
(a)
Circuit Diagram;
(b)
Wiring Diagram;
(c)
Topographical drawing of the electrotechnical equipment inside and

outside the Gearbox;
(d)
Schedule of all electrotechnical equipment active, as in Clause

3.1.5.1b.(5), and passive (e.g. junction boxes, solid conduit, flexible
conduit, cable, etc.);
(e)
Connection Diagram for all junction boxes, control panels, etc.;
(3)
Drawing Number Cross-Reference: A two-way cross-referencing index

between gear Manufacturers Drawing Numbers and Service Drawing
Numbers;
(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.g. microfilm, CD-ROM, etc.) and any information required
to set the Gearbox to work (e.g. alignment or balancing procedures, bolting
down and levelling procedures);
(5)
Functional Block Diagram: The preliminary Functional Block Diagram

provided under Clause 3.1.5.1c.(1) as expanded and updated by the design
approval process shall be redrawn to the datum pack standard (see Clause
3.1.6.1b.);
(6)
Physical Interface Drawings: A General Arrangement of the Gearbox,

marked up to show the position of all physical interfaces shall be provided;
17

(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. Each signal
interface shall be identified with regard to the Functional Block Diagram
and/or Physical Interface Drawings. The Specification sheet shall provide a
cross-reference to the manufacturers own detailed drawings of the interface
and to any drawings produced by other contractors which are known to the
Gearbox manufacturer. It shall also show the limit of Gearbox
manufacturers supply;
External Services: A list of external services required by the Gearbox. The
items shall be cross-referenced with Clause 3.1.6.2a.(7);
Jigs and Special Equipment: A list and drawings of all jigs, fixtures,
special tools and equipment required to install and maintain the Gearbox;
Maintenance Schedule: A Maintenance Schedule indicating the degree and
periodicity of maintenance required during the following periods:
(a) In store prior to installation;
(b) Installed in a vessel prior to Setting to Work (STW);
(c) Operational;
(d) During refitting;
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, as applicable,
which show and identifies the purpose of individual portions of the
envelopes, as follows:
(a) The overall dimensions and chain dotted outline of the maintenance
envelope;
(b) The operational area of the envelope. This area shall be highlighted;
(c) Areas where access is only required for painting and preservation;
(d) All withdrawal spaces for sub-assemblies, etc.;
(e) Space required for access by lifting gear, transport devices, etc.;
Production Back-up Spares: A list of parts or whole assemblies which are
retained by the manufacturer during build;
Spares Recommendation: A recommendation for general spares support
covering the following:
(a) On-board spare (First Category Spares);
(b) Back-up spares for two-year period (Second Category Spares);
(c) Spares for reconditioning equipment (Third Category Spares);
(d) Spares for shelf-life maintenance, etc.;
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;
Thrust Block: (Where fitted within the Gearbox). The righting moment,
running misalignment curve based on the expected maximum thrust and the
maximum allowable righting moment based on the highest loaded pad
pressure;
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 3.1.5.1c.);
18

(NES 305 )
(17) Dynamic Analysis of the High Speed Line(s): Details of the vibration
characteristics of the input lines, including the Prime Mover.
3.1.6.3
a.
Certain additional information as listed in Table 3.1 shall be supplied before the
first equipment is delivered. 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 Vessels design. It is used to control the
build of follow-on Vessels and a microfilm copy, at the relevant state of
amendment, shall be supplied with each Vessel as a record of the design to
which it was built. It shall be progressively updated as significant changes
are made to the class or to individual Vessel. After discussion with the Prime
Contractor, the manufacturer shall submit a proposed list of drawings for
inclusion in the Datum Pack. One As Made process master of each Datum
Pack drawing shall be supplied to the MOD at least one month before the first
Vessels Gearbox is delivered. Datum Pack drawings shall conform fully to
the requirements of DEF STAN 02-722;
(2)
Additional Process Masters: In addition to the Datum Pack, the

manufacturer shall submit one As Made process master of additional major
drawings required by the Prime Contractor. A list of such drawings shall be
provided when the Datum Pack contents are approved. These drawings shall
be of the same quality and format as the Datum Pack drawings;
(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,
set to work, operate and maintain the Gearbox. This report shall be passed to
the Prime Contractor at the time of the delivery of each Gearbox to the
shipyard. The report shall contain at least the following items of information:
(a)
Detailed definition of terminal points and interfaces (see Note 1);
(b)
Requirements for and terminal points of all services;
(c)
A list of special tools, facilities and equipment required to lift, transport

and install the Gearbox;
(d)
Installation instructions, including limitations relating to input and

output shaft alignment (see Note 2) and the following information:
(i)
Detailed drawing of the Main Wheel Shaft;
(ii)
Detailed drawing of the Main Wheel;
(iii) Weights of the Main Wheel and Shaft;

(iv) Clearances at the Main Wheel Bearings;
(v)
Thermal growth of the Gearbox;
(vi) Shaft attitude in Bearings;

(vii) Axial clearances of input and output Shafts;
(viii) Direction of load on Main Wheel;
(e)
A list of precautions and/or special requirements that shall be met when

STW;
19

(NES 305 )
(f)
A statement on the operating limitations which shall apply up to

acceptance;
(g)
A statement on the Gearbox maintenance required up to completion of

the Basin Trial (see Note 3);
(h)
A statement on which items of work the Gearbox manufacturer would

require to perform himself during the guarantee period;
NOTE 1. This and subsequent requirements may be met by cross-reference to
the appropriate Gearbox, Prime Contractors drawing or other
authorized document. It is essential that the date and issue number
of the relevant document is quoted.
2. The Prime Contractor is responsible for writing the installation
instructions and alignment procedures. 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. The minimum requirement
for this report shall be a detailed cross-reference to the Prime
Contractors installation and alignment procedures which have been
accepted by the Gearbox manufacturer. Issue numbers shall be
quoted.
3. After the basin trial the Prime Contractor shall maintain the Gearbox
in accordance with the Maintenance Schedule referred to at Clause

3.1.6.2a.(10).
4. Each page of the report shall be marked with a date and issue number.
The status of each page (e.g. Original, Amendment 1, 2 or 3, etc.)

shall be shown at the front of the report.
(4)
3.1.6.4
Control of Design Changes:

(a) Alteration State Zero: At the end of the detailed design stage the
manufacturer shall propose Alteration State Zero definition. Any
subsequent changes shall be termed Alterations and shall be
sequentially numbered and recorded for approval by the Prime
Contractor;
(b) Modification State Zero: One month before the first Vessels
Gearbox is delivered, Modification State Zero shall be declared. Any
subsequent changes shall be termed Modifications and shall be
considered for action under the Sea System Controllerate Equipment
Modification Procedure. Proposals for such design changes shall be
submitted to the Prime Contractor;
(5) Alternative Manufacture: Where called for in the contract, copies of all
drawings, specifications, etc., necessary for an alternative contractor to
manufacture the Gearbox.
Quality Assurance of the Design
a.
Conformance to Technical Requirements: During the preliminary approval
process any items covered by the SRD, which cannot be demonstrably met because
of the preliminary nature of the information available, shall be listed. The items
listed shall be subject to progressive design approval as the design proceeds.
Drawings covering such items shall not be used for manufacture until design
approval has been obtained from the Prime Contractor.
20

(NES 305 )
b.
3.2
3.2.1
Materials
Wheels and Pinions
a.
Materials, heat treatment processes and testing requirements, etc., for all gearing
elements shall be in accordance with DEF STAN 02-381.
b.
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
Quality of Drawings: Drawings submitted by the manufacturer shall be sampled

at prescribed intervals to ensure that they conform to the requirements of Clause
3.1.6.1b. 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.
Wheel Shafts, 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.
Gearcases
a.
Main Propulsion Gearboxes shall be of fabricated Steel to the requirements of BS
EN 10028-1, BS EN 10028-2, BS EN 10028-3, BS EN 10028-4, BS EN 10028-5,
BS EN 10028-6, BS EN 10028-7 and/or BS EN 10029, as applicable.
b.
All welding shall meet the requirements of DG Ships/PS/9023.
c.
Proposed methods for the protection of Gearcases internal surfaces from the risk of
corrosion shall be submitted to the MOD. Phosphate Coating of any surfaces shall
be in accordance with DEF STAN 03-11.
d.
Paint used on external surfaces of the Gearbox shall conform to BS 4800 colour
code 00A01 and DEF STAN 02-737.
Bearings
a.
White metal to BS 3332 Type A shall be used for Journal and Thrust Bearings.
Lubrication Suction, Delivery and Drain Pipework
a.
Guidance on LO is given in DEF STAN 02-303.
Electrical Equipment
a.
The materials of Electrotechnical equipment fitted to the Gearbox shall conform to
DEF STAN 07-224.
Rubber O Rings
a.
Elastomeric Toroidal Sealing Rings (O Rings) shall conform to
DEF STAN 02-337 Part 1.
Shafts and Couplings
a.
For oil operation Loose Couplings, hubs shall be made from Forged Steel having a
Yield Stress of not less than 750 N/mm2. The Shaft, unless forming part of the Gear
elements, shall be made from Forged Steel having a minimum Ultimate Tensile
Strength (UTS) of 850 N/mm2.
b.
For keyed Loose Couplings, unless forming part of the Gear elements, all
components shall be made from Forged Steel having the following minimum
values of UTS:
c.
(1)
Hub and Shaft
850 N/mm2;
(2)
Keys
550 N/mm2.
For involute Splined Couplings, both the Hub and the Shaft, unless forming part of
the Gear elements, shall be made from Forged Steel having a minimum UTS of 850
N/mm2.
21

(NES 305 )
3.3
Gear Tooth Design
3.3.1
Helix Angle
a.
Tooth pitches shall be minimized, consistent with Gear Tooth loadings and stresses.
b.
The helix angle shall be as large as possible within the following constraints:
c.
3.3.2
3.3.3
(1)
For Single Reduction, Single Helical Gears, the desirability of keeping axial
thrusts to a minimum shall be taken into account;
(2)
For Double Reduction, Single Helical Gears, the first and second reduction
helix angles shall be arranged so that, taking account of end reliefs, the
number of overlaps is as high as possible consistent with satisfactory thrust
arrangements and, in the case of the second reduction, shall be at least two.
The unbalanced thrust in the intermediate shaft shall be a minimum, (consistent

with providing adequate location) taking into account the possible need to avoid
heavy thrust on the high speed shaft.
Tooth Form
a.
Wheel and Pinion Teeth shall be of involute profile. A normal pressure angle of
Main Propulsion Gears shall be 20. Other pressure angles may be adopted when
justified to be of advantage.
b.
The tip radius on the Gear cutting tool shall be not less than 0.08 of the normal pitch.
c.
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.
d.
Justified proposals for Profile Modification (tip, root and end relief) shall be
provided for consideration by the MOD.
e.
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.
f.
The Gear Teeth shall be finished ground.
g.
If steps are formed in the root and fillet section, the concession application shall
include evidence of the effect on the total bending stress and any other penalties.
This shall be supported by projections of casts of tooth sections of at least 20
magnifications. Grinding of the root and fillet section to remove steps shall not be
carried out without Prime Contractor approval. This does not apply to steps formed
deliberately as part of the normal manufacturing process (e.g. Protuberance
hobbing). No handwork shall be done without Prime Contractor approval. All
such concessions shall be forwarded for consideration by the MOD.
Tooth Load Distribution

a.
If it is necessary to obtain even distribution of load by correction of the pinion

helices, the calculations shall be submitted for agreement by the MOD.
b.
With Single Helical Gears, misalignment shall be taken into account when
calculating tooth load distribution. Consideration shall be given to correcting tooth
load distribution in the ahead load condition by incorporating an adjustable
bearing.
22

(NES 305 )
3.3.4
Tooth Loading Analysis

a.
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, DUGATES
or an equivalent accurate analytical mesh model.
b.
Gear elements shall be analyzed using BS 436-3, 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. This value shall be used in place
of the KH given by BS 436-3;
(2)
In practice, 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, i.e.:
Actual safety factor against surface failure, 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.
This value shall be used in place KH given by simple application of BS
436-3.
(4)
In practice, 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, i.e.:
S F SFBS436 *
NOTE
3.3.5
BS436
(3)
Actual safety factor against surface failure, SF:
c.
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.
For those BS 436-3 stress and load modification factors where there is a choice, the
Prime Contractor shall demonstrate that achievement of the design safety factors is
obtained for a credible range of values.
Gear Element Safety Factors

a.
The Gearbox shall exceed the minimum safety factors as detailed in the table below
when rated in accordance with the above.
Minimum Safety Factor
Surface Stress (SH)
Bending Stress (SF)
Primary Gears
1.3
1.6
Secondary Gears
1.3
1.6
23

(NES 305 )
3.3.6
Scuffing
a.
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. The assessment shall take full account of predicted
transverse load distribution. The results of the assessment, together with the input
data and details on the methods used, shall be forwarded for consideration by the
MOD.
3.4
Gear Construction
3.4.1
General
a.
b.
3.4.2
Where possible, rotating elements shall not to be handed.

The drive to the Primary Reduction Pinions shall be taken though Flexible
Couplings of an approved design. See Clause 3.9.
Gear Element Construction

a.
3.4.3
Pinions shall be forged integrally with their Shafts. A built-up design with the Gear
Tooth portion shrunk on or keyed to the shaft may be considered when the size
warrants this.
b.
Where possible, Gear Wheels shall have Forged Steel, Cast Steel, or high-duty Iron
centres. However, fabricated, i.e. bolted or welded construction, may be used
where appropriate.
Accuracy
a.
b.
c.
The accuracy of all Main Propulsion Gears transmitting more than 750 kW shall
comply with BS 436-4 and/or BS 436-5, as applicable, subject to the additional
requirements described in Clauses 3.4.3d to 3.4.3i. The accuracy shall be verified
by use of the procedures described in the BGA Codes of Practice DUCOP.03.
The terminology and symbols used on drawings and in all associated
documentation shall be in accordance with BS ISO 701 and BS ISO 1122.
Notice shall be taken of the recommendations regarding drawing information and
Gear specification in BGA Codes of Practice DUCOP.01 and DUCOP.02.
d.
The tolerances on runout of functional mounting surfaces given in BGA Codes of

Practice DUCOP.02 shall apply to the peripheries of all Coupling Flanges. They
shall also apply to the Thrust Faces, the outside diameter of the Thrust Collar being
used in the formula.
e.
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. 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.
f.
Because of the difficulties in measuring undulations to sufficient accuracy and

because insufficient work has been done to quantify the effect, specific tolerances
cannot be given. Therefore, the aim should be to minimize the effect.
g.
As a guide, the magnitude of the relevant component of the transmission error shall
be no more than 1 m and preferably less than 0.5 m.
h.
The surface texture of the Tooth flank shall be no worse than 0.6 m Ra and in the
roots no worse than 2.0 m Ra.
24

(NES 305 )
i.
If Double Helical Gears are used, the differences between the cumulative pitch
errors on the helices over corresponding arc lengths Lm shall not exceed:
0.35 L m 9.5
NOTE Lm is defined as to the number of base pitches.

j.
3.4.4
The surface roughness of journals measured in the axial direction shall not exceed
2.0 m Ra.
Identification
a.
Each Gear element shall be uniquely and indelibly marked to show the following:
(1)
The Manufacturers Drawing Number with issue status to which the Gear
was made;
(2)
A unique identification number which can relate each Gear to its inspection
records;
(3)
A reference tooth and the identification of the ahead or loaded flank. This
mark shall be positioned to be visible when the Gear is installed in the
Gearbox and viewed through a convenient inspection plate.
3.5
Gear Case Design
3.5.1
General
a.
Importance is attached to the rigidity of the Gear supporting structure and that the
meshing and alignment are maintained under load. Main Gearcases shall be
designed to be supported on a limited area at three places to minimize the
transmission of distortion from the ships structure and to provide a datum
condition during manufacture and installation. 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. If a cantilevered bearing housing is
unavoidable it shall be subjected to a thorough assessment of vibration modes at the
design stage.
b.
Reference surfaces shall be provided on the Gearcase structure to facilitate

alignment/level checking equipment. These surfaces shall be positioned to enable
any Gearcase distortion to be measured with the minimum of effort, i.e. no covers
shall be removed.
c.
The Gearcase shall be suitably subdivided to provide access to the Gears, Bearings,
Couplings, Clutches and Thrust Blocks. Where Clutches are fitted, guards shall be
provided to prevent any debris ejected from the clutches from entering the Gear
meshes (see also Clause 3.10).
d.
The design of the Gearcase shall ensure that it may be fully drained when required,
i.e. without leaving pockets of oil trapped inside the Gearcase.
e.
Gearcases shall be designed to provide the maximum access to the Gearbox

internals with the minimum dismantling of internal and external pipework and
cabling. To this end consideration shall be given to the design of the Gearcase
covers and the routeing of pipework and cables. 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.
25

(NES 305 )
f.
The Gearcase covers shall be of lightweight fabricated steel construction. The

covers shall be subdivided for ease of handling. Separate covers shall be fitted to
Flexible Couplings, so that the Couplings can be inspected, removed and replaced,
without opening the Main Gearcase.
g.
The arrangement of Primary Reduction Pinion input flanges shall permit alignment
between Prime Movers and Gears to be checked without lifting Gearcase main
covers. If necessary, temporary covers shall be provided for the Primary Pinion
input flanges to close the Gearbox against ingress of air during transport and
erection.
h.
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.g. scraping or filing).
i.
If the Main Thrust Block is integral with the Gearcase, adequate space shall be
provided for access and dismantling. The surrounding structure shall be adequately
stiffened to prevent excessive distortion of the Gearcase by the thrust forces.
j.
Sufficient inspection doors shall be provided to permit visual inspection of all Gear
meshes and LO sprays. Inspection plates shall be provided with starting screws and
security shall be achieved by the use of padlocks, the object being to prevent or
detect unauthorized access to the Gearbox. A diagrammatic sketch shall be
produced showing location of all locking devices.
k.
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.
l.
The whole of the electrical installation, inside and outside the Gearcase, shall be in
accordance with DEF STAN 02-502. Consideration shall be given to equipment
inside the Gearcase with regard to the oil-laden atmosphere, especially where oil
sprays play directly on to electrotechnical equipment or cable fastenings. All
electrical items shall be earthed to meet the limits stated in DEF STAN 02-502.
m.
Cabling in rigid or flexible conduit or trunking shall be supported to prevent

chafing under vibration. Bushing shall be provided where there is a need to protect
the cabling. The minimum bending radii for cables shall be observed. The whole of
the cabling shall be capable of being removed and replaced without disturbance of
the Gearbox fittings, pipework, etc. Conversely, Gearbox fittings, pipework, etc.,
shall be capable of removal without disturbance of cabling and conduit.
Interference precautions shall be observed.
n.
Junction Boxes and all cable terminals shall be in accordance with

DEF STAN 02-514 (watertight to the degree required by Clause 1.1.2a.(13)) and
shall be tested by immersion prior to installation. Gearboxes which have a Ship
cabling interface shall be sited to enable direct installation of cabling by the
Shipbuilder. All fasteners on the Gearcase required for Shipbuilders cables shall
be provided by the Gearbox manufacturer.
o.
Internal surfaces of Gearboxes shall be treated to prevent corrosion. The external

surfaces of Gearboxes shall be painted (see Clause 3.2.2d.).
p.
An Equipment Identification and Modification Plate shall be fixed to the Gearcase

in a visible position. Additional plates shall be provided for each major
sub-assembly for which separate modification action is intended. The plates shall
26

(NES 305 )
conform to DEF STAN 02-723 and shall also identify the screw thread series used
throughout the design. A drawing of the plates shall be submitted for Prime
Contractor approval.
q.
Provision shall be made for earthing the Gearcase to the Ships structure in
accordance with DEF STAN 02-502.
r.
Shaft oil seals shall be designed to fail safe, i.e. do not result in metal-to-metal
contact between moving parts.
3.6
Lubrication and Venting
3.6.1
General
a.
The LO distribution and return arrangements within the Gearbox shall conform to
the requirements of DEF STAN 02-303.
b.
The type of LO to be used in the Gearbox shall be specified in the SRD.
c.
The LO supply to each Main Gearcase shall be by one connection from the Ships
system to an external straight manifold secured to the Gearcase. For single gearbox
installations, connections shall be provided to supply the common manifold from
each side of a sided system. 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.
d.
LO supplies to Bearings, Sprayers, Thrust Block, etc., shall be taken from the top of
this manifold.
e.
LO supplies to Journal Bearings shall be grouped on a speed basis so that the

supplies to the various groups can be individually controlled. Sprayer supplies
shall be similarly controlled and grouped.
f.
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.
g.
The control of each group shall be by suitable lockable control valves with a
minimum opening. The maximum number of individual supplies in any one group
shall not to exceed four.
h.
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. 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.
i.
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.
j.
The requirement for a separate or integral Drain Tank shall be specified in the SRD.
The design of integral drain tanks shall conform to DEF STAN 02303. If a
separate Drain Tank is specified, 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.
27

(NES 305 )
k.
The Gearbox shall be designed to minimize the ingress of air under all operating
conditions. System ventilation shall be provided from the drain tank in accordance
with DEF STAN 02303. 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
3.6.1l.).
l.
All Marine Gearboxes for military applications experience significantly longer

periods of shut-down when compared with commercial applications. This results
in corrosion damage of the Gearcase internal elements. Therefore all Gearboxes
for military applications shall be fitted with a Dehumidifier to remove moist air
from the Gearcase during periods of shut-down.
m.
The dry air produced by the Dehumidifier shall have a relative humidity of no more
than 30 per cent at 15C. The dry air supply pipes shall lead from the Dehumidifier
into the upper area of the Gearbox so that the Gearbox is fully ventilated. 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. These pipes shall be designed;
n.
3.6.2
(1)
to prevent condensate running back into the Gearbox;
(2)
so that they do not become submerged by oil during Gearbox flushing.
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. Dehumidifier air
intakes shall take air from the compartment and shall be fitted with mesh guards to
prevent ingress of dirt. Instrumentation shall be fitted that will activate an alarm if
the dry air from the Dehumidifier goes above 30 per cent RH at 15C. The electrics
of the Dehumidifier and instrumentation shall be in accordance with DEF STAN
02-625 and DEF STAN 59-36.
Lubrication
a.
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. If this is not possible it shall be brought to the attention of the
Principle Contracts Officer and/or the Design Authority, as applicable for
resolution.
3.7
Bearings
3.7.1
General
a.
The preferred Bearing type for Gearboxes are White Metal lined, thin to medium
walled Plain Bearings. Rolling element Bearings or Thrust Cones may be used
when demonstrated to be of advantage.
b.
Bearing Shells shall be pre-finished, Steel backed, lined with White Metal made by
an approved manufacturer. The Shells shall be of the thin to medium walled style
(wall thickness less than 4 per cent of the bearing bore), but subject to a minimum
wall thickness of 5 mm. Exceptionally, Main Wheel Bearings may be of thick wall
construction other than of Steel if preferred by the Gear manufacturer.
28

(NES 305 )
3.7.2
Steel Backings
a.
b.
3.7.3
White Metal Lining

a.
Chemical composition of White Metal shall conform to BS 3332 Type A.
b.
The White Metal lining thickness depends on the bore diameter of the Bearing
Shell. 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
1.0
251 to 500
1.5
501 and over
2.0
c.
The variation of the White Metal thickness, in the operational area of each
individual Bearing Shell shall not exceed 0.2 mm. However, 0.25 mm
thickness variation is permitted within 20 of the Bearing butts to allow for
deformation during machining operations.
d.
Casting of the White Metal lining onto preformed Shells shall be be carried out
centrifugally. The rotational speed shall be adjusted for each particular diameter to
minimize segregation of the White Metal constituents.
e.
Surface finish of the White Metal after final machining shall be in accordance with
the following the table:
f.
3.7.4
Steel Bearing backings shall be manufactured from a low Carbon Steel (less than
0.2 per cent Carbon).
Steel Bearing backings shall be produced by forging, bending or pressing plate
material. Forged Steel backing halves shall be normalized and stress relieved.
Bearing backings bent or pressed from plate material a shall be stress relieved.
Alternatively, for bearings up to 250 mm bore, Steel strip may be lined with white
metal prior to forming and no stress relieving shall be required.
Bearing bore diameter
Surface finish to be better than
up to 400 mm
0.8 m Ra
401 mm and over
1.6 m Ra
The White Metal of a pre-finished bearing shall not be scraped or finished by hand.
Bearing Design and Analysis

a.
The maximum specific load (maximum Bearing load divided by projected area) for
Journal Bearings shall be less than 34.5 bar for all Bearings, except Main Wheel
Bearings, which shall have a maximum specific load of less than 24.5 bar. Loading
pressures other than those above shall be justified to the MOD.
b.
For Thrust Bearings or Thrust Cones, the assumptions made in estimating the axial
load shall be explicitly stated. 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, assuming a coefficient of friction of = 0.3.
c.
Thrust Cones shall be designed using the Thrust Cone Design Aid package
available from the MOD.
29

(NES 305 )
3.7.5
d.
The Prime Contractor shall shall submit a Bearing design justification, presenting
the results of the Bearing analysis carried out for all the Gearbox Bearings (Journal
and Thrust Bearings). The extremes of operating conditions within the specified
duties shall be used. A minimum requirement, for the following list of Bearing
operating characteristics, shall be provided for each particular load case
considered:
(1) LO flow rates and temperatures;
(2) Positions (Journal Bearings only) and thickness of minimum LO films;
(3) Maximum Bearing surface temperature;
(4) Approximate threshold speeds of Journal Bearing instability (half-speed
whirl).
e.
The mean temperature of the LO return from any individual Bearing shall not
exceed 85C.
f.
The maximum temperature recorded in service by the normal Bearing Temperature

Monitoring Equipment (see Clause 3.7.8a.) shall not exceed 115C under any
specified operating condition. If this limit is exceeded during Shop Tests, Shore
Trials or Contractors Sea Trials (CST), 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, free of charge to the MOD.
Oil Inlets
a.
3.7.6
3.7.7
For plain Journal Bearings, twin axial LO inlets positioned at the bearing butts shall
be used. 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. If this cannot be achieved a
circumferential groove may 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; they shall only be used where there is no practical alternative.
Housing
a.
The Bearing and housing designs shall ensure that the Bearing is located uniquely
in its correct position, thus ensuring that incorrect assembly, resulting in restricted
LO supply or drainage, cannot occur.
b.
Where offset pivoted pads are used for Thrust Bearings, provision shall be made in
the Bearing housing design to locate the pad uniquely to eliminate the possibility of
incorrect assembly.
c.
During design, 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.
Fitting
a.
Each Bearing shall be so arranged that it can be turned out with the Journal in place;
the necessary appliances being provided. Fittings independent of the hull structure,
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.
30

(NES 305 )
3.7.8
Caps
a.
3.7.9
Vibration Measurement
a.
3.7.10
Separate Steel Bearing Caps shall be fitted for each Bearing. Provision shall be
made to prevent the Bearing rotating. The Bearing Caps shall be independent of the
Gearcase covers. Where liners are used, Bearing Caps shall be positively located
relative to the lower housing.
NOTE Where the Bearing Shells are carried within a liner separate from the
Gearcase housing, the above requirements for nip location, etc., shall
apply to the liner.
Each Bearing Cap shall be drilled, tapped and seatings prepared to accept two
transducers to measure radial vibration, one in the vertical direction and one in the
horizontal direction. This shall be provided even if vibration instrumentation is not
specified for each Bearing Cap; this will allow instrumentation to be fitted for trials
if required.
Temperature Measurement
a.
Arrangements for measuring Bearing temperatures shall be provided in accordance

with Clause 3.12. Two electrically powered thermosensing elements shall be
fitted to each Main Transmission Journal Bearing (one active, one spare).
Additional sensors may be required on Bearings operating under a multiplicity of
attitudes.
3.8
Turning Gear
3.8.1
General
a.
The Gearbox shall be provided with a means of turning the Prime Movers, Gearing
and Propeller Shafting for inspection and maintenance purposes. The Main
Turning Gear shall be designed to turn the Main Shaft continuously in the range of 5
rpm to 10 rpm. Arrangements shall be provided to enable the Turning Gear to be
operated by hand.
b.
The Turning Gear shall be capable of being engaged, disengaged, started and
stopped by both local and remote operation.
c.
Turning Gear engagement and disengagement indication shall be provided both

locally and remotely.
d.
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.
e.
Interlocks shall be provided as necessary to prevent inadvertent operation or

potentially dangerous states arising within the Gearbox and shall be simple,
fail-safe and of high integrity. 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;
(2) A signal on the Turning Gear Clutch to inhibit starting of the Main Engines
when the Clutch is engaged;
(3) An interlock on the Turning Gear motor/starter to prevent operation of the
motor if the Shaft Brake is pressurized, or the Hand Turning Gear engaged;
(4) A signal on the Turning Gear motor to inhibit operation of the Shaft Brake
when the motor is running.
31

(NES 305 )
f.
The arrangement of the Turning Gear and Engine Clutches shall be such that the
Turning Gear is capable of rotating all transmission components, including the
Prime Movers in both directions. An inching control shall be provided at least in
the ahead direction. 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.
g.
A Clutch, driving positively in both directions, shall be incorporated in the Turning

Gear drive. Arrangements shall be made whereby the Clutch can be positively
secured in the engaged and in the disengaged positions.
h.
A locking device shall be fitted in association with the Turning Gear, capable of
holding the Gearing and Shafting stationary against at least 50 per cent of the design
Full Power ahead torque.
i.
Electric Turning motors and equipment shall not be required to be watertight.

However, 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.
(See Clause 1.1.2a.(13)). Motors shall generally be in accordance with DEF
STAN 02-627 and DEF STAN 07-244. Starting and control shall be in accordance
with DEF STAN 02-636.
3.9
Shafts and Couplings
3.9.1
General
a.
The responsibility for the design of the input line Flexible Couplings, including the
detail design of the flange connections to the prime mover(s), 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.
To this end reference bands shall be provided on all Torque Tubes. The details of
the machining instructions and subsequent dimensional inspections for the Torque
Tube, the Gearbox input flange and the Prime Mover shall be specified. The
surfaces to be used as concentricity references during the balancing of the Prime
Mover and Torque Tube assemblies shall also be specified. 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.
b.
The loads and movements imposed on Flexible Couplings shall not to exceed the
Coupling manufacturers recommended values. 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. 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.
c.
To cater for changes of components in the high speed line, the Flexible Couplings
shall be supplied with spacer plates to enable the correct cold pull-up to be
achieved.
d.
Gear Coupling elements shall be supplied as matched pairs and the most favourable
tooth mesh position shall be marked for assembly purposes.
32

(NES 305 )
3.9.2
Loose Couplings
a.
b.
3.9.3
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 3.2.7a. and 3.2.7c. inclusive, in

respect of materials, dimensions and stresses. These are conservative limits
based on past practice. They may not represent the most efficient design;
(2)
By presenting a detailed justification for the design and the loadings used.
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, the intermediate sleeve having a
tapered outside diameter and a parallel bore;
(2)
Keyed Couplings fitted on a tapered shaft;
(3)
Involute Splined Couplings fitted on a parallel shaft.
c.
A particular Gearbox design may include any one or all three of the above types of
coupling. Oil Injection Couplings are preferred. Keyed or Splined couplings
should only be used where they offer worthwhile advantages in other respects.
d.
Particular attention shall be given to the means of tightening and locking any nuts,
rings or other screwed fasteners associated with the Coupling. Wherever possible,
locking arrangements should be made visible so that security can be confirmed
without dismantling. If necessary, access for endoscopes should be provided. The
MOD shall be notified of any designs which involve securing arrangements (e.g.
grubscrews) which cannot be sighted without dismantling so that the need for
oversight during build can be assessed.
e.
The requirements for Oil Injection Loose Couplings, Keyed Loose Couplings and
Involute Splined Loose Couplings are as defined in Clauses 3.9.3, 3.9.4 and 3.9.5.
Oil Injections Loose Couplings

a.
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. The
included angle of the taper shall be between 0.03 mm/mm and 0.06 mm/mm where
the hub is fitted directly on to the shaft. The included angle of the taper shall be 0.02
mm/mm where a sleeve is inserted between the hub and the shaft.
b.
The design interference fit and axial drive-up of the Coupling Hub on the shaft shall
be selected so that, when using a coefficient of friction of = 0.12, the torque
capability of the Coupling shall be at least three times the maximum continuous
torque.
c.
The Coupling Hub fitted length shall be not less than 0.75 times and not more than
the nominal diameter of the shaft in way of the Coupling.
d.
The Coupling Hub outside diameter shall be sized, 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.
e.
For Loose Coupling Hub and shaft materials, see Clause 3.2.7a.
33

(NES 305 )
3.9.4
Keyed Loose Couplings

a.
All Keyed Loose Couplings shall meet the following mandatory requirements:
(1) Each Coupling shall be provided with two diametrically opposed keyways.
The keyways shall be machined parallel to the taper in both the shaft and the
Coupling Hub;
(2) The depth of the keyway, measured at the edge and at the mid point of the
Coupling Hub fitted length, shall be equal to half the key thickness;
(3) The bottoms of the keyways shall be provided with fillet radii, which shall be
not less than 0.2 times the loaded depth of the keyway;
(4) Key and Keyway tolerances shall conform to the requirements of
BS EN 202861 and/or BS EN 202862, as applicable;
(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;
(6) Coupling keys shall be chamfered on all corners. The chamfers shall be of
such dimensions that the keys are clear of the keyway fillet radii;
(7) Keys shall be secured in the shaft by means of countersunk or recessed head
set screws.
b.
Full justification for a Keyed Loose Coupling shall not be necessary if the
following conditions are met:
(1) Hub, shaft and key materials shall satisfy the requirements of Clause 3.2.7b.;
(2) The included angle of the taper shall be between 0.03 mm/mm and
0.06 mm/mm;
(3) The fitted length of the Coupling Hub shall be not less than the nominal
diameter of the shaft and not greater than 1.25 times the nominal diameter of
the shaft in way of the Couplings;
(4) Stresses in the Coupling assembly shall be based on the maximum continuous
torque;
(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;
(6) Shear stress in the Coupling Hub shall not exceed 20 N/mm2 based on a bore
diameter circumscribing the corners of the keyways;
(7) Shear stress in the keys shall not exceed 40 N/mm2;
(8) Crushing stress in the keys shall not exceed 140 N/mm2.
NOTE
When calculating the above key stresses, the corner chamfers of the key and
any key end radii shall be deducted when calculating the key area.
3.9.5
Involute Splined Couplings

a.
All Involute Splined Couplings shall meet the following mandatory requirements:
(1) The Splines shall be of the side fit, flat root type and shall conform to the
requirements of BS EN 202861 and/or BS EN 202862, as applicable;
(2) The Splines shall be cut by an approved Gear cutting method and not by
milling or form cutters;
(3) Radial location, and hence concentricity, shall be provided by direct contact
between shaft and hub and not by the Splines themselves;
(4) The possible effects of centrifugal forces on the radial location of high speed
Couplings shall be considered.
34

(NES 305 )
b.
3.9.6
The Coupling Hub and Shaft materials shall satisfy the requirements of
Clause 3.2.7c.;
(2)
The Coupling Hub fitted length shall be not less than 0.7 times and not greater
than the pitch circle diameter of the Splines;
(3)
Stresses in the Coupling assembly shall be based on the maximum continuous

torque;
(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;
(5)
Shear stress in the Coupling Hub shall not exceed 30 N/mm2 based on a bore
diameter equal to the Spline major diameter;
(6)
Specific pressure per Spline shall not exceed 25 N/mm2, the area per Spline
being determined from the Coupling Hub fitted length and the Spline radial
fitted depth.
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.
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. This can be based either on previous satisfactory
experience or on detailed analysis. In either case, a written justification of the
design must be provided, defining how assurance shall be obtained. Particular
attention shall be given to specifying the steady and transient load conditions used
in the assessment, including any thrust or bending loads and the assumed criteria of
failure.
Power Transmission
a.
b.
3.9.8
(1)
Justification of Alternative Designs

a.
3.9.7
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. 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 2.0 where reversal of torque is present;
(2)
A factor of Safety of 1.5 where torque is unidirectional.
A coefficient of friction of = 0.12 shall be assumed for this purpose.

Consideration shall be given to the use of small flanges if the above constraint is
considered excessive in a particular application, but a justification shall be
required. When sizing the flanges, pre-loading for Coupling bolts, as specified in
DEF STAN 02-862 Part 1, shall be taken into account.
Information to be Provided
a.
The Prime Contractor shall provide a data sheet for each Flexible 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.
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.
35

(NES 305 )
3.10
b.
A design justification for the Flexible Coupling design and loadings used shall be
provided, which defines how the assurance shall be obtained. Particular attention
shall be given to specifying the steady and transient load conditions used in the
assessment, including any thrust or bending loads and the assumed criteria of
failure.
c.
The Prime Contractor shall provide sufficient information to allow the Coupling to
be dismantled, checked and reassembled by inexperienced staff. An assembly
drawing shall be provided showing, or making reference to, the following:
(1) Dimensions, fits and tolerances of mating surfaces;
(2) Assembly and dismantling instructions, including safety precautions and any
dimensional checks required before, during or after assembly (e.g. fit of
tapers, axial location);
(3) Details of associated jigs and special tools;
(4) Method of tightening and locking any retaining nuts, rings or fasteners.
Torque values shall be quoted;
(5) A calculation sheet for each Coupling shall be provided as required by Clause
3.1.5.1b.(2).
Clutches
a.
Clutches shall be able to be selected for engagement or disengagement for the

following operating modes:
(1)
(2)
(3)
3.11
Input and output shaft speeds are different;

Input and output shaft speeds are identical;
Input and output shafts are stationary.
b.
Clutches shall be capable of being locked both in and out of engagement.
c.
Clutches shall be capable of being disengaged on reversal of torque only when

unlocked.
d.
Clutches shall be operable both locally and remotely.
e.
Clutch controls shall be mounted on Gearcases, not covers, so that they do not move
under shock and shall not dependent on the position of the covers.
f.
The clearance, if any, between Clutches and their controls shall be specified and
easily measured. Clutches and their controls must be interchangeable and changing
either shall not require adjustments to this clearance.
g.
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 3.5.1c.).
h.
If a Synchro-Self-Shifting (SSS) type Clutch is used, it shall have a facility for

endoscope inspection of the pawls and ratchet rings.
i.
Clutch interlocks shall be provided to prevent inadvertent operation or potentially

dangerous states arising within the Gearbox and shall be simple, fail-safe and of
high integrity (see also Clause 3.12.1b.).
Fasteners
a.
The design of the Gearbox and ancillary equipment shall minimize the total number
of variations of fasteners.
36

(NES 305 )
3.11.1
Threaded Fasteners
a.
Bolts, studbolts, studs and screws shall be selected, wherever possible, 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.
b.
All screw threads shall conform to the requirement of BS 36431 and/or BS

36432, for internal and external screw threads, as applicable.
c.
Threaded studs shall be sized in accordance with BS 4439. Welded studs shall not
be used in the Gearcase.
d.
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, BS EN ISO 2320,
BS EN ISO 7042 and/or BS EN ISO 7719 as applicable. The preferred types are the
all-metal geometrically deformed thread type or the nylon-ring-insert type. The
following stiffnuts are approved for use inside the Gearbox:
(1)
All metal nut:
CLEVELOC; PHILIDAS MARK V;
(2)
Nylon-ring-insert nut:
NYLOC; PHYLOC.
e.
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.
f.
The use of plated fasteners within the Gearcase shall be avoided (see Clause
3.2.4a.).
g.
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.
h.
Locking washers shall not be used for Gearbox internal fastenings. Exceptionally,
tab washers may be used after approval by the Prime Contractor.
i.
Bolts shall not be wired as a means of securing items inside the Gearcase. Wiring is
suitable for securing fastenings outside the Gearcase to guard against unauthorized
removal.
j.
Nuts and bolts shall not be locked by peening or otherwise distorting the thread
form.
k.
Designed preloading as specified in DEF STAN 02-862 Part 1 shall be used for
Bearing Cap fasteners, Gearwheel side plate fasteners, Coupling bolts and other
fasteners specified in the SRD.
l.
When assessing the adequacy of bolted fasteners in the Main Transmission Train,
the following factors shall be taken into account:
(1) Method of obtaining correct tension in the bolt;
(2) Bearing stress under the head and nut (the use of hardened steel washers may
be considered for this application);
(3) Bearing pressure on the side of the holes;
(4) The adequacy of material in the Coupling flanges.
37

(NES 305 )
3.11.2
Non-Threaded Fasteners
a.
Spring pins shall only be used inside the Gearbox in applications where the hole is
blind and the pin is trapped by subsequent fittings. There is no limitation on the
external use of spring pins. The material shall be Carbon Steel.
b.
Dowels shall only be used provided adequate security of the fittings can be
demonstrated.
c.
The use of retaining rings (circlips) within the Gearbox shall be avoided. Any
specific requirements shall be presented to the MOD as part of the design
justification.
3.12
Instrumentation
3.12.1
General
a.
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;
(b) For Journal Bearings, the sensing elements shall be in contact with the
back of the Bearing Shells near to the point of minimum oil film
thickness;
(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 3.5.1n.);
(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.
(2)
Oil Pressures:
(a) Pressure gauges of the type specified in DEF STAN 66-2 shall be
provided as follows. 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;
(ii)
For each LO spray or LO spray group;
(iii) For each independent Thrust Bearing supply

(see Clause 3.6.1c.).
(b)
The pressure gauges shall be mounted on a Gaugeboard attached to the

Main Gearbox. The same Gaugeboard shall also display the following
additional LO pressure gauges:
(i)
Main LO supply pressure;
(ii)
LO supply to Main Thrust Block;
(iii) LO supply to Clutch or other controls;

(3)
Seal Temperature: A method of measuring the temperature of any

contacting metallic seals shall be provided;
38

(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. This shall enable the requirement to
monitor vibration at once per rev discrete frequency to be met (see Clause
3.14.2b.);
(5)
Clutch Actuator Shoe Temperature: A method of measuring this Bearing

temperature shall be provided;
(6)
Output Shaft Speed and Direction: Two independent systems shall be

provided as follows:
(a)
A self-powered tachogenerator system providing a local readout;
(b)
A high accuracy, high reliability electrical speed sensing system to

provide a remote signal for control and indication purposes;
(7)
Vibration: The first-of-class shall be installed with accelerometers on each

Bearing Cap wired to an interface external to the Gearbox, (see Clause
3.7.9a.). The input line(s) instrumentation shall include a tracking filter so
that vibrations at once per rev discrete frequency are monitored (see Clause
3.14.2c.);
(8)
Machinery State Information: The Machinery State Information

instrumentation shall provide information on the state of Gearbox Clutches
and ancillary equipment, e.g. Turning Gear, Shaft Brakes, etc.;
(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;
(10) Drain Tank Instrumentation: Drain Tank instrumentation shall conform to

the requirements of DEF STAN 02-303;
(11) Electrical Indicating Instruments:
(a)
Electrical Indicating Instruments used for instrumentation purposes

shall conform to DEF STAN 02-604;
(b)
The transducers, sensors and transmitters required for liquid level,

flow rate, temperature or pressure instrumentation shall conform to
DEF STAN 02-605 Parts 1 and 4;
(c)
Versatile Console
DEF STAN 02-520;
System
assemblies
shall
conform
to
b.
Interlocks shall be provided as are necessary to prevent inadvertent or potentially

dangerous states arising within the Gearbox and shall be simple, fail-safe and of
high integrity. The Gearbox controls shall be so arranged that no modes of
operation can be achieved other than those intended by the designer. Wherever
possible such interlocks shall be of a simple mechanical nature. Any requirements
for interlocks between the Gearbox and other parts of the propulsion system other
than those specified in Clause 3.8.1 shall be reported to the Prime Contractor.
c.
The Gearbox shall be suitable for both local and remote control, where applicable.
39

(NES 305 )
3.12.2
Local Control and Surveillance

a.
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. It is desirable, but not essential, 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.
b.
Local manual control shall be provided for the Turning Gear, the Transmission
Brake (assuming that brake actuating power is available) and any other Gearbox
mounted equipments.
c.
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, as shall the responsibility for the supply of
actuators.
d.
Local Gearbox pressure and temperature gauges shall be grouped so as to make the
watchkeepers task as simple as possible. Ideally they shall be mounted on the
Gearbox.
e.
The siting of control levers, handwheels, instruments and gauges on the Gearbox
shall permit local operation by the minimum number of personnel.
NOTE
See the SRD for the requirements for local surveillance of other than the self
powered gauges and speed sensors.
3.12.3
Remote Control and Surveillance

a.
b.
The Gearbox shall normally be operated under remote control with surveillance
from the Main Propulsion Plant Control System, supplied by a controls contractor.
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;
(b) Transmission Brakes;
(c) Reversing mechanisms;
(2) Output Signals Required for Control Purposes:
(a) Clutch state;
(b) Brake position and availability;
(c) Reversing mechanism state;
(d) Output shaft speed and direction (see Clause 3.12.1a.(6));
(e) Turning Gear state (see Section 3.8);
(3) Alarm Signals:
(a) LO supply pressure;
(4) Warning Signals:
(a) Bearing temperatures;
(b) Seal temperatures;
(c) Input line vibration;
(d) Drain Tank oil temperature;
40

(NES 305 )
(5)
3.12.4
Surveillance and Health Monitoring Signals:

(a) Bearing Cap vibration;
(b) Bearing temperatures;
(c) Input shaft speeds.
Design Constraints
a.
b.
c.
d.
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, 2, 3, 5, 6, 7, 8,
10, 11, 12 and 13, as applicable.
All cables shall be led through the Gearcase structure via sealed glands and not to
pass through covers or inspection doors. Glands shall be selected from the range in
DEF STAN 02-514 and shall, where practical, pierce the Gearbox horizontally or in
a downward direction from external to internal. One cable only shall be fed through
each gland.
The electrotechnical equipment on the Gearbox shall be designed in accordance
with DEF STAN 08-107. Unless specified otherwise in the SRD, the following
supplies shall be available:
(1) 440 V ac, 60 Hz, 3-Phase;
(2) 115 V ac, 60 Hz, Single Phase;
(3) 24 V dc.
3.13
Gearcase Manufacture
3.13.1
General
a.
b.
All welding carried out on Gearcase fabrications shall satisfy the requirements of
DG Ships/PS/9023.
The contractor shall classify all welds as Level 1, 2, 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, e.g. loss of LO, risk of Bearing
failure;
Failure of the weld could lead to serious disruption of the
Main Propulsion machinery, e.g. loss of control, damage to
Clutches or Couplings;
Failure of the weld does not constitute an immediately
significant hazard;
Failure of the weld does not constitute a hazard.
NOTE: 1. The above definitions are based on DEF STAN 02-773;

2. 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.
c.
The extent and nature of Non-destructive Examination (NDE) required by each

level of weld is defined in DEF STAN 02-773. The NDE methods that shall be used
are defined in DEF STAN 02-729 Parts 2, 4 and 5. The acceptance standard
applicable to the various methods of examination are defined in DEF STAN
02-773.
41

(NES 305 )
d.
Handwork (e.g. scraping and/or filing) to correct misalignment between Bearing

housings and Bearing bores shall not be conducted. Such components shall be
machined by precision jig borers or other similar machine tools.
e.
The fit of a standard Bearing Shell in its housing bore or liner bore, as appropriate,
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. The nip of the Shell in the housing or
liner and circularity of the bearing bore, shall be checked and recorded in the
Gearbox Inspection Record.
3.14
Balancing and Vibration
3.14.1
Balancing
a.
All components operating above 200 rpm, including Main Wheels where
appropriate, shall be dynamically balanced in accordance with BS 6861-1. 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 a
minimum requirement, the balance quality grade shall meet or exceed the
requirements of BS 6861-1.
b.
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. If in the opinion of the manufacturer, application of the above criteria to
particular equipments is likely to lead to excessive penalties in time or cost, the
circumstances shall be reported to the Prime Contractor who shall advise on the
acceptability of a reduced standard.
c.
Main Wheels operating up to 200 rpm shall be statically balanced. After correction
for any imbalance has been made, the residual imbalance shall not exceed 0.23
kgm/tonne.
d.
Bolts used in any Coupling assembly shall be of a uniform mass within the
tolerance specified in the following table:
e.
Coupling maximum
rotational speed
Bolt weight
tolerance
below 1000 rpm
4 grammes
1000 to 5000 rpm
1 gramme
above 5000 rpm
0.2 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;
(2) Balance machine or rig to be used (alternatives may be quoted);
(3) Concentricity requirements;
(4) Position of supports when balancing;
(5) Method of correction;
42

(NES 305 )
3.14.2
(6)
Position and radius of correction planes;
(7)
Whether any drive adaptors, mandrels or temporary stub shafts are required
and, if so, the balance limits and concentricity tolerances for these items;
(8)
Particulars of any separate parts to be attached to the component in service,

whether these shall be in place for balancing and methods of ensuring their
concentricity during subsequent reassembly.
f.
A claw piece or Coupling portion of a Flexible Coupling, bolted, keyed or

shrunk-on to a Quill Shaft, Torque Tube, Turbine Rotor or Pinion shall be balanced
with the item in question after being fitted to it. When an individual member of a
gear tooth type Coupling is balanced it shall be balanced with the teeth running
concentric, as measured by rollers, within 10 m Total Indicator Reading (TIR)
(run-out).
g.
When a Coupling, Torque Tube or Quill Shaft running at Turbine speed is balanced
as a separate stem, it shall be set up in the balancing machine to its reference band
and balanced in this condition. When it is assembled, it shall be set up to its
reference band within the limits of run-out specified. Actual run-outs shall be
recorded on assembly (see Clause 3.20.1a.).
h.
Main input Flexible Coupling assemblies shall be balanced with their reference
bands running true within the limits of Clause 3.9.1b. 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.
Vibrations
a.
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.
b.
When installed in HM Surface Ships or Submarines, the level of vibration on the

high speed (input) line(s) Bearing Caps shall not exceed 3.8 mm/s peak velocity at
1x shaft rotational frequency (known as the fundamental). The Gearbox
manufacturer shall quote the following in mm/s peak velocity at 1x fundamental:
c.
(1)
The maximum allowable vibration at each Bearing Cap if less than 3.8 mm/s;
(2)
The vibration level that is expected at each Bearing Cap.
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.
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, i.e.:
Vibration level (mm/s)
Shaft rotational frequency
d.
Shaft displacement (mm)

Time taken for one rev of the shaft
During Shop and Sea Trials, records of Bearing Cap and Gearcase structural
vibration shall be taken in accordance with Clauses 3.18.3a. and 3.19.2. The results
achieved shall be provided to the MOD.
43

(NES 305 )
3.15
Inspection
3.15.1
General
a.
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.
The minimum requirement is that record sheets shall be completed for each element
of the Gearbox as detailed in Clause 3.21. The MOD reserves the right to have
additional inspections carried out; the liability for the cost of such additional
inspections shall be negotiated at that time.
b.
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. The Prime Contractor shall be informed immediately of any departures
from allowable tolerance.
c.
On completion of the finishing process, the meshing of each pair of Gears shall be
checked and the results recorded. The Gears shall be supported on rollers or, in
no-clearance bearings, in a meshing frame. With the gear element axis parallel,
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, due allowance being made where end relief, helix or
profile correction has been applied.
d.
When the Gears are installed in the Gearcase, a further meshing check shall be made
and the results recorded. If acceptable meshing is not achieved with the normal
Journal Bearings in place, the test may be repeated at the Gear manufacturers
discretion, using special no-clearance Bearings to locate the Gears in their Full
Power running positions. The use of packing materials to position the shafts within
Bearings is not acceptable. 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.
NOTE
The Contractor may offer alternative methods for achieving these
requirements, particularly by using strain gauging techniques or by using
data from accurate modern Gear measuring machines.
e.
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.g.
Sellotape).
f.
A band of Talbot Blue Lacquer, or other suitable semi-permanent marking, shall be
applied to every Gear to facilitate examination of meshing marks during Shop and
Sea Trials. This marking shall cover at least four teeth across their full face width.
g.
Gear alignment during Shop Trials and Contractors Sea Trials under load shall be
checked as in Clauses 3.18.5a. and 3.19.2a.
h.
NDE of the Main Transmission Gear elements and shafts shall be carried out in
i.
All Bearings shall be thoroughly examined for cracks, porosity, depressions,
inclusions, mechanical damage and apparent lack of bond along the White Metal to
Steel interface. No cracks are acceptable and any other visual defects shall also be a
cause for rejection, unless subsequent ultrasonic or liquid penetrant examination
can demonstrate that the defect is within the acceptance level for those techniques
(see Clause 3.15.2a.(3)).
j.
NDE of thin walled Journal Bearings shall be carried out in accordance with
BS 7585-1 and/or BS 7585-3, as required.
44

(NES 305 )
3.15.2
Acceptance Standards
a.
The following standards shall be applied when assessing the acceptability of test
results:
(1)
(2)
(3)
Forgings: Forgings containing defects, as defined below, may be a cause for

rejection and shall be reported:
(a)
Magnetic Particle Examination: All cracks or crackline indications;
(b)
Ultrasonic Examination:
(i)
In outer 50 mm: All flaws giving echoes equal to or greater than

that from an ideal reflector of 1.0 mm diameter and closely
grouped defects, i.e. within 25 mm in any direction of each other
which would individually give echoes in excess of 12 dB below
an ideal reflector of 1.0 mm diameter;
(ii)
At depth greater than 50 mm: All flaws giving echoes equal to or

greater than that from an ideal reflector of 4.5 mm diameter;
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;
(b)
Liquid Penetrant Test: All defects greater than 1.5 mm in length;
(c)
Ultrasonic Examination from Tip: All defects greater than 1.0 mm in

length;
(d)
Surface Temper Etch Examination (Nital Etch), which shall be in

accordance with BS 7862, or an alternative technique for identifying
the presence of grinding burns. Any indication of grinding burns shall
be a cause for rejection;
Bearings: This standard applies to the Bearing in the final machined

condition. 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). Any indication of bad bonding in a White Metal
Bearing is undesirable and zero defect bonding is considered to
be the normal production standard. If this cannot be achieved, it
shall be reported to the Prime Contractor. As a minimum
standard, Bearings shall not be accepted if they contain defects
above the levels defined in BS 7585-1;
Liquid Penetrant Examination:

(i)
Liquid Penetrant Examination of a Bearing surface shall be in

accordance with BS 7585-3 acceptance criteria, which is
considered to be the normal production standard. If this cannot
be achieved, it shall be reported to the Prime Contractor. As a
minimum standard, bearings shall not be accepted if they do not
satisfy the requirements of BS 7585-3 acceptance criteria.
45

(NES 305 )
3.16
Shop Flushing
3.16.1
General
a.
The Main Gearing and its associated LO pipework shall be thoroughly flushed
before shop testing, in accordance with DEF STAN 02-303, 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. Drain Tanks, ledges and other horizontal
surfaces shall be wiped clean;
(2) Supply pipework used in the Gearbox and the shop service unit shall be
cleaned to Grade C Standard before installation;
(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 3.6.1i.) and each group of Gear Sprays;
(4) A certificate shall be provided to the Prime Contractors Quality Assurance
Representative stating that the required standard of cleanliness has been
achieved.
3.17
Cleanliness and Preservation
3.17.1
During Manufacture
3.17.2
a.
Cleanliness and preservation of all components during manufacture shall be in

b.
After completion of the flush, 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.
After Shop Trials

a.
On completion of shop trials and any subsequent opening up for inspection and
reassembly, equipments shall be preserved and protected to BS 11336.1 and/or BS
1133-6.2, as applicable. Additional the following shall be observed:
(1) All parts of the Gearbox shall be completely drained;
(2) All parts of the Gearbox which have been in contact with water shall be dried;
(3) All Gearbox openings shall be blanked;
(4) All external unpainted Ferrous surfaces and the Gearbox internals shall be
coated with an approved preservative oil;
(5) Where practicable, the Gearbox and ancillary equipments shall be
completely enclosed in either a self-sealing thick plastic bag or sealed
polythene envelope. Basic desiccant shall be used with each enclosure. If in
the manufacturers opinion a complete enclosure is not practicable, proposals
for preservation for a minimum period of six months shall be submitted to the
Prime Contractor for approval.
b.
The Gearbox shall be internally examined for signs of corrosion, in the presence of
the Prime Contractors Quality Assurance Representative, at intervals not
exceeding six months. The preservative oil film shall be repeated and the desiccant
trays renewed. A report on each examination shall be submitted to the Prime
Contractor. The MOD reserves the right to inspect the Gearbox for internal
corrosion at any stage during the construction of the vessel.
46

(NES 305 )
3.17.3
3.17.4
Cleanliness and Preservation After Delivery

a.
Maintaining the cleanliness and condition of the Gearbox after delivery is the
responsibility of the Shipbuilder or other Receiving Authority, who shall be held
liable for any degradation allowed to occur.
b.
On receipt at the Shipyard and in the presence of the Prime Contractors Quality
Assurance Representative, the Gearbox shall be internally examined. Any
corrosion found or other deficiencies shall be reported in writing to the MOD. 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 3.17.2b.
c.
When a Gearbox is opened for internal work or inspections, the Gearbox shall be
treated as a Clean Area and a polythene tent shall be constructed around any
openings. Clean Area protocol shall be strictly adhered to (see Clause 3.17.1b.).
Access to the Gearbox shall be controlled and limited to necessary personnel only.
A log shall be maintained of all tools and equipments taken into and removed from
the Clean Area.
d.
When metal-removing activities have to be performed within the Gearbox (e.g.

drilling, filing, grinding, etc.), a local clean area shall be established around the
work area to minimize the spread of debris. A vacuum cleaner shall be used to
remove the debris. The Prime Contractors Quality Assurance Representative shall
be advised, in advance, of any such work.
e.
The need for flushing or lancing prior to installation in the ship, shall depend upon
the amount of work done on the Gearbox and the care with which it was controlled.
The Prime Contractors Quality Assurance Representative shall decide on the need
for and extent of such additional cleaning measures.
Cleanliness During Installation

a.
Particular care shall be taken to avoid the ingress of dirt during installation. The
following instructions shall be followed:
(1)
When equipment openings are unplugged or blanks are removed for the
purpose of making pipe connections, no burning, grinding, chipping, or
welding shall take place in the vicinity. 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;
(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;
(3)
Each plug or blank shall be retained in position until immediately before the
relevant joint is made;
(4)
Should any items of equipment or pipework be contaminated by the ingress

of dirt or foreign matter, it shall be thoroughly cleaned before continuing with
the installation. If this is not possible on board, the items shall be removed for
cleaning ashore.
47

(NES 305 )
3.17.5
3.17.6
3.18
3.18.1
3.18.2
Preservation and Cleanliness up to Acceptance

a.
Immediately prior to the system being filled, the desiccant trays (see Clause
3.17.2a.) shall be removed from the Gearcase and the Dehumidifier shall be proved
operational. From this time onward the Dehumidifier shall be operated
continuously whenever the LO supply to the Gearbox is isolated. Failure to use the
Dehumidifier will result in condensation forming on exposed bare metal surfaces,
leading to corrosion of the Gearcase and Gear elements.
Preservation During Setting to Work
a.
Gearbox internal corrosion is a particular hazard during the period of LO system
flushing. The preservative oil film is removed prior to system flushing when the
Gearbox is internally washed down by lance flushing. 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. During this period, 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;
(2) The Dehumidifier shall be brought into operation whenever LO is not being
supplied to the Gearbox.
Testing
Shop Testing
a.
Prior to the commencement of any Shop Testing, the Gearcase alignment shall be
accurately checked using the reference surfaces (see Clause 3.5.1b.) and the results
recorded along with the tolerance allowed when the Gearbox is fitted in the Vessel.
Performance Testing of a New Gearbox Design
a.
Each new design of Gearing shall be performance tested in accordance with the
requirements of the SRD. The MOD shall specify which type of test shall be
adopted (depending on the class of vessel), which shall be one of the following:
(1) Shore Test Facility: Gearbox testing at Full Load and Full Speed, in
association with the rest of the propulsion machinery;
(2) Back-to-Back testing of the first two production Gearboxes, at Full Load and
Full Speed;
(3) Spin-testing at Full Speed and Part Load.
b.
The Contractor shall provide a detailed performance testing procedure for the
specified type of test. The procedure shall include, but is not limited to:
(1) Running-in and part load trials;
(2) Proving and calibrating instruments (this may be achieved by sighting copies
of valid test certificates issued by the instrument supplier);
(3) Demonstration of Clutches, Couplings and controls;
(4) Overspeed tests;
(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, including a determination of gear efficiency;
(b) Astern running tests (where applicable);
(c) Overload and/or endurance tests.
c.
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 3.18.4a.).
48

(NES 305 )
3.18.3
Production Test
a.
3.18.4
Every set of Gearing shall be subjected to a production test as specified below,

together with any additional requirements specified in the SRD, and shall be
inspected after testing in accordance with Clause 3.18.4a:
(1)
The equipment tested shall be that which shall be supplied. The Prime
Contractor shall be notified in advance of any intended substitutions or
temporary fittings used to facilitate testing, which shall be replaced or
modified prior to delivery. 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;
(3)
Before commencing production tests the Gearbox shall have been

successfully flushed in accordance with Clause 3.16;
(4)
The Gearing shall be operated at the maximum continuous specified speed

until Bearing and LO temperatures have stabilized. 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;
(5)
Where Clutches and Couplings are fitted, tests shall be carried out to
demonstrate their satisfactory operation;
(6)
All warning, protective and control devices, shall be functionally tested and
adjustments made as required;
(7)
During the test the Gearcase shall be thoroughly checked for oil leaks,
especially at joints and seals. Any leaks found shall be corrected;
(8)
All vibration monitoring and position indicating equipment, which shall be

permanently fitted in the Gearbox installation, shall be in use during the tests.
Sufficient additional equipment shall be provided to enable a positive
readout to be obtained from each item of equipment under test;
(9)
During the production test at maximum steady speed, accelerometers shall be

attached to all Gearbox Bearing Caps and the level of vibration at the
once/rev frequency recorded. In addition, a sweep shall be made for
vibrations at other frequencies. 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.
Post Test Inspections

a.
The following assessments and/or inspections shall be carried out (and recorded)
during, or immediately after, the production test:
(1)
Gear Alignment:
(a)
Gear alignment shall be assessed during the test using strain gauge data,
as specified by the MOD;
49

(NES 305 )
(2)
3.18.5
(b)
On completion of the mechanical running tests, the Gear unit shall be

opened for visual inspection of the Gear meshes. Meshing shall be
checked by noting the removal of Talbot Blue Lacquer or other
marking;
(c)
The contact marking shall be recorded by taking of records of the

transfer of blue marking by means of transparent adhesive tape (e.g.
Sellotape). The Talbot Blue Lacquer or other marking should be
reapplied for use during Sea Trials.
Bearings:
(a)
Although full inspection of Journals, Bearings and Thrust Collars shall

not normally be required, the manufacturer shall open for inspection
such Bearings as the Prime Contractors Quality Assurance
Representative may select. 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. The MOD shall be consulted in cases of dispute or
uncertainty;
(b)
The MOD reserves the right to call for a complete strip and inspection
of the Gearing.
(3)
Drain Tank: The sump and/or Drain Tank shall be emptied, wiped clean and
searched for foreign matter. The Prime Contractors Quality Assurance
Representative shall be informed if anything unusual is found;
(4)
Gearcase Alignment: On completion of all Shop Tests the Gearcase

alignment shall be accurately checked using the reference surfaces (see
Clause 3.5.1b.) and the results recorded.
Records Required During Tests

a.
b.
The manufacturer shall keep a detailed log of the following during production
testing, making entries every 15 minutes of the first hour and every 30 minutes
thereafter, until stabilization of temperatures and vibration levels:
(1)
Inlet LO pressure and temperature;
(2)
LO flow rate;
(3)
LO outlet (drain) temperature;
(4)
Bearing temperatures;
(5)
Bearing Cap vibration levels (where fitted) at once per rev frequency;
(6)
Shaft speed;
(7)
Input power;
(8)
Strain gauge results (if fitted);
(9)
The reasons for any unprogrammed stoppages.
These records shall be included in the formal Gearbox Inspection Record

(see Clause 3.20).
50

(NES 305 )
c.
If improvements are required as a result of deficiencies noted during tests or

inspections, the initial production test shall not be acceptable and a repeat test shall
be carried out after the replacements or corrections are made.
d.
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.
On completion of all tests and inspections the Gearing shall be reassembled,

preserved and closed in accordance with Clause 3.17.
3.19
Contractor Sea Trials
3.19.1
General
a.
Shipboard trials and inspections shall be carried out in accordance with the
requirements of DEF STAN 02-350, DEF STAN 02-351, DEF STAN 02-352, DEF
STAN 02-353, DEF STAN 02-354 and with the procedures given in DEF STAN
02-32. The Prime Contractor shall provide a representative, to attend throughout
the trials, to assist with inspections and to supervise any work carried out on the
Gearbox. The Gearbox manufacturer shall obtain from the Shipbuilder a contract
to cover the cost of such attendance. The Gearbox manufacture shall confirm that
his representative is able to authorize priority work at the manufacturers Works,
including at weekends or other quiet periods, should this be required to maintain to
the trials programme.
b.
The extent and timing of Gearing inspections during trials shall be defined in the
Trials Programme for each vessel. 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. Particular attention should be paid to the final reduction
Gears. Examine Bearings and other components only if there is reason to
suspect malfunction;
(2)
After First Run at Full Power: Examine Gear meshes as above and any
Bearings which show higher than expected temperatures;
(3)
After Full Power Trial: Examine Gear meshes and take records of tooth
contact marking (see Clause 3.19.2a.);
(4)
On Completion of Contractors Sea Trials:

(a) Examine all Pinion and Wheel Teeth;
(b) Examine top and bottom halves of selected Bearings.
NOTE On vessel other than First of Class, unless there is a reason to suspect
damage, the Bearing examinations should be limited to two per
Gearbox.
(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;
(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. Any
movement of fasteners shall be reported to the MOD;
(e) Check the security of selected internal instrumentation including the
associated cabling and carry out random check of terminal screws,
taper pins, etc.;
51

(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

(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
5.
CORPORATE EXPERIENCE & KNOWLEDGE

53

(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

purposes. Nonalloy and alloy steels with specified elevated
temperatures
BS EN 100283

purposes. Weldable fine grain steels, normalised
BS EN 100284

purposes. Nickel alloy steels with specified low temperature
properties
BS EN 100285

purposes. Weldable fine grain steels, thermomechanically rolled
BS EN 100286

purposes. Weldable fine grain steels, quenched and tempered
BS EN 100287

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

(NES 305 )
BS 4365
Spur and Helical Gears. Definitions and allowable values of

deviations relevant to radial composite deviations and runout
information
BS 11336.1
Packaging code. Protection of metal surfaces against corrosion

during transport and storage. Cleaning and drying of metal
surfaces
BS 11336.2
Packaging code. Protection of metal surfaces against corrosion

during transport and storage. Temporary protectives and their
application
BS 3332
Specification for white metal bearing alloy ingots
BS 36431
ISO metric screw threads. Principles and basic data
BS 36432
ISO metric screw threads. Specification for selected limits of size
BS 4439
Specification for screwed studs for general purposes. Metric series
BS 4800
Schedule of paint colours for building purposes
BS 49291
Specification for steel hexagon prevailing-torque type nuts.

Metric series
BS 68611
Mechanical vibration. Balance quality requirements of rigid

rotors. 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. 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, 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, RFA's
and other Naval Auxiliary Vessels.
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

(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, 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, 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, Electrical Silicon Rubber Insulated, Limited
Fire Hazard (LFH) or Chlorosulphonated Polyethylene
(CSP) Sheathed for General Service
Part 3:
Cables, Electrical, Ethylene Propylene (EP) Rubber
Insulated and Halogen Free Rubber Insulated, Limited
Fire Hazard (LFH) or Chlorosulphonated Polyethylene
(CSP) Sheathed for General Service
Part 5:
Cables, Electrical, Radio Frequency
Part 6:
Cables, Electrical, Miniature and SubMinature and
Equipment Wires
Part 7:
Cables and Wires, Electrical, Miscellaneous for Special
Services
Part 8:
Cables, Electrical, ThinWall insulated Limited Fire
Hazard (LFH) for General Services
Part 10:
Terminations and Connectors
Part 11:
Glands, 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, Termination and Junction Components for

Equipment
DEF STAN 02520

(NES 520)
Guide to Design Procedures for Versatile Console Systems
56

(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, 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, 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

(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, Cords and Cables, ElectricalMetric Units:

Part 8:
PTFE Insulated Equipment/Wires
DEF STAN 662
Gauges, Pressure, Dial Indicating (Bourdon Tube Type)
BR 8470
Shock and Vibration Manual
BGA:
DUCOP.01,
DUCOP.02 and
DUCOP.03
British Gear Association Codes of Practice for Gear Accuracy:

BGA, Suite 43, IMEX Business Park, Shobnall Road,
BurtononTrent, DE 14 2AU.
ANNEX B.
B.
ABBREVIATIONS AND DEFINITIONS
B1.
For the purpose of this Standard the following abbreviations and definitions apply.
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

(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.
C.
PROCUREMENT CHECK LIST
Notes:
1.
This Check List is to ensure that certain aspects of this Defence Standard are consulted
when preparing a procurement specification for a particular application.
2.
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.
t
3
3.
Each item is to be marked either:
Check
No.
1.
included
NA
not applicable
Check
Clause No.
Specifying auxiliary drives required.
59
Scope
or NA

(NES 305 )
2.
Specifying the responsibility for the Main Thrust Bearing. Scope
3.
Specifying the responsibility for all other Gearbox Scope

auxiliaries.
4.
Stating the date for holding down arrangement proposal. Scope
5.
Specifying Gear accuracy requirements.
3.1.3.1a.(4)
6.
Number of copies of tender submission required.
3.1.4a.
7.
Stating the date for submission of the preliminary design. Table 3.1
8.
Specifying the format required for supplying drawings and Table 3.1;
setting to work procedures.
3.1.6.2a.
9.
Specifying the requirements of the preliminary design.
3.1.5.1b.
10.
Defining targets for reliability.
1.1.1a.(1)
11.
Defining periods for maintenance.
1.1.1a.(2)
12.
Giving noise and vibration targets.
1.1.1a.(4),
3.14.2b.
13.
Giving weight and size limitations.
1.1.1a.(8)
14.
What design instructions shall be given?
1.1.2a.
15.
Defining the frequency and times allowed for manoeuvres. 1.1.2a.(9)
16.
Is there a requirement for operation in other than ahead 1.1.2a.

and astern modes?
17.
Specifying the depth at which the Gearbox shall continue to 1.1.2a.

run and for the minimum duration required.
18.
Specifying the type of LO to be used.
3.6.1b.
19.
Specifying the Drain Tank requirement.
3.6.1j.
20.
Specifying other fasteners required.
3.11.1k.
21.
Specifying the control requirement and responsibility for 3.12.2c

the supply of actuators.
22.
Requirements for local surveillance other than self 3.12.2e.

powered guages and speed sensors.
Note
23.
Specifying electrical supply available.
24.
Specifying the requirements for performance testing of a 3.18.2

new Gearbox design.
60
3.12.4d.

(NES 305 )
Clutches requiring remote control and

surveillance, 40
Cold start, 9
Components of main gearing, 2
Comprehensive drawing schedule and index, 17
Contractor sea trials, 51
Control of design, 11, 12
Control of design changes, 19
ALPHABETICAL INDEX
A
Acceptance Standards, 45
Access provisions within gearcase, 25
Accessibility, 8
Accuracy, 24
Adjustable bearing housing, 26
Datum pack, 19
Dehumidifier required for gearbox, 28
Design change control, 19
Design competition, information required, 13
Design constraints, 41
Design full power, 9
Design justification process, 12
Design objectives, 8
Design reviews, 13
Distribution of records, 53
Drain tank instrumentation, 38
Drain tank requirement, 27
Drainage of gearcase, 25
Drawings required in support of a tender, 13, 15
Astern operation, 9
Auxiliary drives, 2
B
Balancing, dynamic and general requirements,
42, 43
Bearing design and analysis, 29
Bearings, general, 28, 29
Bearings, material, 21
Bearings, thin walled, NDE requirement, 44
Brakes requiring remote control and
surveillance, 40
Cable terminals, 26
Earthing of gearcase, 27
Electrical equipment fitted to the gearbox, 21,
26
Electrical indicating instruments, 38
Electrical requirements for dehumidifier, 28
Electrotechnical definition, 2
Electrotechnical requirements for gearbox, 21
Environmental conditions, 9
Estimates of timescales, 13
External loads and movements imposed, 17
Cabling, removal without disturbing other

fittings, 26
Cabling, support of, 26
Caps to be fitted to bearings, 31
Cleanliness and preservation after delivery, 47
Cleanliness and preservation after shop trials,
46
Cleanliness during installation, 47
Cleanliness procedures during manufacture, 46
Clutch securing in engaged and disengaged
positions, 32
Clutches, 36
Clutches for turning gear and main engines, 32
Fasteners, 37, 38
61

(NES 305 )
Final design approval and drawing standards,

17
J
Jigs and special equipment, 17
Final design justification and drawing

standards, 17
Junction boxes and cable terminals, 26
Flange connections to prime movers, 32
Flexible couplings, 24, 32

Flushing procedure before shop tests, 46
Life expectancy period, 9
Forgings, 45
Limitations on use of materials, 21
Functional block diagram, 17
Liquid Penetrant Test, 45

Local control, 40
Local plant control unit, 2

Locking device to hold gearing and shafting
stationary, 32
Gear construction, 24, 25

Gear tooth alignment, 44
Long lead items, 13
Gear tooth design, 22
Loose couplings, 33
Gearcase design, 25, 26, 27
Lubricating and venting, 27, 28
Gearcase manufacture, 41
Gearcase materials, 21
Lubricating Oil, 11, 14, 15, 21, 26, 27, 30, 38,
40, 41, 46, 48, 49, 50, 52
Grinding burns, 45
Lubricating oil distribution system, 2
H
Health monitoring signals, 40
Magnetic particle examination, forgings, 45
Holding down arrangements,gearboxes, 25
Maintenance envelope, 17
Housings for bearings, check during design, 30
Maintenance schedule, 17
Manoeuvring, 9
Manufacturing requirements for gearcase, 41,
42
I
Identification plates to gearcase, 26
Marking to identify gear elements, 25
Information to go to the shipbuilder, 19
Materials for components, 21
Inspection doors to gearbox, 26
Materials for gearcase design, 25
Inspection record sheets, 44
Materials, limitation on use, 21
Inspection, general requirements, 44
Meshing Marks, 44, 49, 52
Installation instructions shipbuilders

responsibility, 19
Modification plate fixed to gearcase, 26
Instrumentation for drain tank, 38

Instrumentation for gearbox, 38
Noise, 8, 13, 24
Instruments, provision for in bearing caps, 31
Nondestructive examination of main

transmission items, 44
Interlocks required for turning gear, 31

62

(NES 305 )
Nondestructive examination of thin walled

bearings, 44
Reliability and maintainability, 8
Nondestructive examination of welding, 41
Reversing mechanisms requiring remote

control, 40
Representatives of manufacturer at trials, 51
O
S
Oil inlets for bearings, 30

Overload capability, 9
Safety, 8
Scuffing operating gearing with negative
effect, 24
Sea trials, 51, 52
Pads offsets, 30
Seating plan, 2
Paint to be used, 21
Security of inspection plates, 26
Painting of external surface of gearboxes, 26

Performance tests, 48
Sensors for bearing temperature measurement,

31
Phantom tones, 24
Shaft materials, 21
Physical interface drawings, 17
Shaft speeds and gear ratios, 9
Pipework materials, 21
Shipbuilders responsibility for writing

alignment procedures and installation
instructions, 19
Pitch for gear tooth design, 22

Post test inspections, 49, 50, 51
Shock, 8
Preliminary design preparation, 15
Shock loads, 9
Preservation and cleaning up to acceptance, 48
Shop testing, 48, 49, 50, 51
Preservation during setting to work, 48
Space and weight limitations, 8
Preservation procedures during manufacture, 46
Spares recommendations, 17
Pressure gauges for gearbox, 38
Standardization of Components, 8
Production backup spares, 17
Starting and control gear for turning gear, 32
Production test, 49
Steel backing for bearings, 29

Stress calculations basis, 9
Submergence precautions, 32
Quality and format for tender, 14
Submersibility, 9
Quality Assurance for the design, 20
Supply of drawings by the Prime Contractor, 11
Quillshaft materials, 21
Supply of programmes by the Prime Contractor,

11
Records of spare components, elements and

gearboxes, 53
Temperature measuring, for bearings, 31
Records required during tests, 50
Temperature monitoring, for bearings, 29, 30
Records to be kept by manufacturer , 52
Tenders, information required, 13, 14

63

(NES 305 )
Thermosensors for gearbox, 38
Thrusts, 9
Ultrasonic testing requirements, 45
Tooth bending stresses, 23
Upkeep support, 12
Tooth load analysis, 23
Tooth load distribution, 22
Valve isolating to gearbox supply pipes, 28
Tooth loading, 22, 23
Ventilation from drain tank, 27
Torque tubes, 32
Vibration levels to be met and recorded, 24, 43
Torque, maximum, full power, 9
Vibration monitoring, 31, 38, 43, 52
Torque, overload, ahead, nontransient, 9
Transducers, noncontacting displacement type,

38
Weight and space limitations, 8
Trials programme, timing for ship or

submarine, 51
Welding on gearcase fabrications, 41
Turning gear, 31, 32
White metal linings, for bearings, 29
Wheels and pinions, materials, 21
64
Inside Rear Cover
Crown Copyright 2003

Copying Only as Agreed with DStan
Defence Standards are Published by and Obtainable from:

An Executive Agency of The Ministry of Defence
Kentigern House
65 Brown Street
GLASGOW G2 8EX
DStan Helpdesk
Tel 0141 224 2531/2
Fax 0141 224 2503
Internet e-mail enquiries@dstan.mod.uk
File Reference
The DStan file reference relating to work on this standard is D/DStan/69/02/305.
Contract Requirements
When Defence Standards are incorporated into contracts users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with
a Defence Standard does not in itself confer immunity from legal obligations.
Revision of Defence Standards
Defence Standards are revised as necessary by up issue or amendment. It is important that
users of Defence Standards should ascertain that they are in possession of the latest issue or
amendment. Information on all Defence Standards is contained in Def Stan 00-00 Standards
for Defence Part 3 , Index of Standards for Defence Procurement Section 4 Index of Defence
Standards and Defence Specifications published annually and supplemented regularly by
Standards in Defence News (SID News). Any person who, when making use of a Defence
Standard encounters an inaccuracy or ambiguity is requested to notify the Directorate of
Standardization (DStan) without delay in order that the matter may be investigated and
appropriate action taken.

NES 305 Requirements For Gearing - Main Propulsion

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

NES 305 Requirements For Gearing - Main Propulsion

Încărcat de

Drepturi de autor:

Formate disponibile

Ministry of Defence

Defence Standard 02-305

Requirements for Gearing

AMENDMENTS ISSUED SINCE PUBLICATION

DEFENCE STANDARD 02305 (NES 305)

REQUIREMENTS FOR GEARING MAIN PROPULSION

This Defence Standard is

DEF STAN 02305 / ISSUE 2

The extent of the equipment covered by this Standard is as follows:

The Main Gearing, which comprises:

Gearbox Atmospheric Control:

Auxiliary drives required by the System Requirement Document (SRD) as follows:

For driven units mounted remotely, e.g. on the Vessels structure.

Gearbox seating arrangements.

DEF STAN 02305 / ISSUE 2

If it is found to be unsuitable for any particular requirement MOD is to be informed in writing of

No alteration is to be made to this Standard except by the issue of an authorized amendment.

DEF STAN 02305 / ISSUE 2

Categories of Defence Standard

Operational performance of the vessel, its systems or equipment.

Category 3. If not applied may have a Minor affect on the following:

Current support practice.

British Standards Institution,

DEF STAN 02305 / ISSUE 2

DEF STAN 02305 / ISSUE 2

DEF STAN 02305 / ISSUE 2

CORPORATE EXPERIENCE & KNOWLEDGE . . . . . 53

ABBREVIATIONS AND DEFINITIONS . . . . . . . . . . . . 58

PROCUREMENT CHECK LIST . . . . . . . . . . . . . . . . . . . 59

DEF STAN 02305 / ISSUE 2

DEF STAN 02-304 Part 1; DEF STAN 08-123; BR 8470;

The design shall be based upon the following principles:

Reliability: The achievement of adequate reliability is of overriding

Maintainability: The Gearbox shall be designed for minimum maintenance

Noise: Airborne and structure borne noise shall be minimized by adherence

DEF STAN 02305 / ISSUE 2

Arrangements shall be made for access for examination and

Standardization: The Gearbox shall be subject to refit/repair/overhaul by

Moving parts of gearing such as Clutches, Brakes, Couplings, Gear

Hand operating gear shall be interlocked or arranged to disengage

Initial loads on spring assemblies shall be fully released before the

The design shall be based on the following requirements unless specific

To Specifying Authority: It is essential that the requirements listed below, which

DEF STAN 02305 / ISSUE 2

Basis for Stress Calculations: Calculations of transmission loadings and

Astern Operation: The Gearing shall be capable of transmitting 30 per cent

Thrusts: The Gearing shall be capable of withstanding such thrusts and

Overload Capability: The design shall be capable of accepting the

Torque: A non-transient ahead torque overload (duration of more than

Thrust: See DEF STAN 02-304 Part 1;

Speed: An overspeed 15 per cent above the specified input speed;

Reversing Gearboxes the frequency and times allowed for any

Non-reversing Gearboxes (i.e. those associated with Controllable

(10) Emergency Operation: The requirements for operation in other than

DEF STAN 02305 / ISSUE 2

(12) Environmental Conditions: The gearing shall meet the requirements of

Design Justification, Drawings and Information Required

Design Justification Process:

Information Required (see Clauses 3.1.2.1a. 3.1.2.1d.);

Drawings and Information Required in Support of a Gearbox Tender:

Information Required (see Clause 3.1.3.1a.);

Quality and Format (see Clause 3.1.4a.);

Drawings and Information Required for a Design Contract or Gearbox