USCGC_Mackinaw_ABBWORKSTATEMNTDD_2015_Work_Specification__Rev_A.pdf

USCGC ”MACKINAW”

Drydock 2015

AZIPOD® Maintenance Works Specification

- Revision A – May 11, 2015

IMPORTANT NOTICE

This ABB Work Specification is preliminary and not final and as such non-binding. It is tendered for discussion only, does not constitute an offer to sell and/or term to contract and ABB can, without notice, make any change in ABB’s own discretion. Any contract to sell the subject matter of the proposal shall be subject to prior mutual agreement as to price (which may different than that shown herein), schedule, scope of works and terms.

The Works listed in this Work Specification have not been ordered in any specific sequence, and ABB reserves the right in changing the work phases, as deemed necessary, during the execution of the Project.

Azipod ® is a registered Trademark of ABB Oy.

Doc Kind: Work Instruction Title: USCGC Mackinaw DD 2015 – Work Specification

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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# of Pgs 21

Table of Contents

1 GENERAL

2 PROPOSED SCOPE OF SUPPLY

3 PROPELLER REMOVAL

3.1 PREPARATORY WORKS

3.2 EXTERNAL EARTHING

3.3 INTERNAL EARTHING

3.4 ROPE GUARDS DISMOUNTING

3.5 ROPE CUTTER REMOVAL

3.6 SERVICE HATCHES OPENING

3.7 PROPELLER CAP REMOVAL (if necessary)

3.8 PROPELLER NUT REMOVAL (If necessary)

3.9 PROPELLER REMOVAL (if necessary)

4 SHAFT SEAL DISMOUNTING ( if necessary)

5 POD CAP REMOVAL

6 SHAFT SEALS LUBE OIL SYSTEM CLEANING

7 OUTER SHAFT SEALS INSTALLATION (IF NECESSARY)

8 PROPELLER MOUNTING

8.1 PROPELLER MOUNTING

8.2 PROPELLER NUT MOUNTING

8.3 OUTER SHAFT SEALS ALIGNMENT AND

COMMISSIONING

8.4 PROPELLER CAP MOUNTING (IF NECESSARY)

8.5 FINISHING THE WORK

9 POD CAP INSTALLATION

10 BEARINGS LUBE OIL SYSTEMS FILLING (if needed)

Title: USCGC Mackinaw DD 2015 – Work Specification

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

En Rev

A

1 GENERAL

The below listed conditions shall be strictly followed at all times during the execution of the Project:

• Neglect of instructions may cause severe injury or even death!

• Neglect of instructions may cause severe damage or even destruction of the Azipod® product!

• ABB shall not be liable for any works, including but not limited to lifting, installation and maintenance that have been or will be done by anyone else than ABB’s own personnel, or ABB sub-contracted personnel!

• The Azipod® units are electrical machines. The windings are equipment that do not tolerate mechanical wear or impurities during the work they must be protected against moisture, dust, debris, paint or equivalent.

• Welding inside the Azipod is forbidden without explicit approval by ABB prior to the start of the work. To be addressed on a case by case basis.

• Azipods must be safely disconnected prior to commencing the works.

• Azipods (and relevant Void Spaces) must be gas-freed and air-quality tested prior entering.

• Working areas’ cleanliness and lighting shall be ensured throughout the execution of the Project.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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2 PROPOSED SCOPE OF SUPPLY

The purpose of the 2015 Drydock is to identify and correct the source of a water leak of the Port side Azipod. This leak was discovered in late March 2015 and resulted in significant water intrusion into the Port Azipod. The water level was approximately up to the center line of the propeller shaft before it was manually pumped out by ships crew.

The planned scope of supply in the option presented herein includes:

A. Port Side Azipod:

• Identify the source of the water leak. There are three possible sources of this leak. The propeller shaft seal, the Azipod hull cap, or one of the service hatches.

o First check and test the propeller shaft seal by removing only the rope guard and rope cutters allowing access to the seal. If it is determined that the shaft seal must be removed, then the propeller will also be removed in order to allow for the removal of the shaft seal package. It is not planned to remove the propeller unless the shaft seal package requires replacement.

o Next check the Azipod hull cap by removing the cap and checking for evidence that water had breached the o-ring which seals the cap.

o Finally, open all of the service hatches and investigate for signs that water had leaked through the seals of the hatch cover.

• Replace electrical components which had been submersed in the water inside the Azipod.

o Includes thrust bearing lube pump motors, propeller bearing lube pump motors, solenoid valves for the shaft sealing system, and possibly the drainage system level sensors

• Fully test the Azipod drainage system to verify correct operation. The system failed to remove the water in “automatic mode” and it must be determined why that happened and corrections to make the drainage system fully operational in “automatic mode”

B. Starboard Side Azipod:

• Open the service hatches and fully test the Azipod drainage system to verify correct operation.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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3 PROPELLER REMOVAL

Works are performed by the Yard

3.1 PREPARATORY WORKS

Preparatory works can be started as soon as the ship will be “High-and-dry”.

The preparatory work includes:

o Washing the work areas (Ship’s stern).

o Covering the workspace from external interferences (such as: welding spatters, rain, wind, etc.).

o Erecting the scaffolding by both ends of the Port side Azipod Unit (DE and

NDE).

3.2 EXTERNAL EARTHING

Besides the normal instructions of the shipyard, the earth connection to the welding machine must be secured:

1) A cable must lead from the ship hull to the strut or the motor housing of the Azipod (zero potential between Azipod and ship is secured). Earth connection is made by two copper cable, length 12 m, Cross-sectional area of one earth wire is 120 mm2.

2) The earth cable from the welding machine must be connected to the Azipod.

The maximum distance from welding machine earth connection point to the weld point should not be more then 1,5m.

3) The shortest route from the welding machine earth connection point to the weld must go through solid parts of the steel structure of the Azipod (NOT through other components or through the air).

Grounding cables shall be connected according to standards of local shipyard.

3.3 INTERNAL EARTHING

Earth connections for the Azipod shall be fitted immediately after mounting, before starting or continuing other out fitting or mounting works. Any earth connection cables must not be removed before the Azipod's own connection components are installed and checked and permission for removal is given.

o Earth connection is made by two copper cable, length 12 m, Cross-sectional area of one earth wire is 120 mm2.

Doc Kind: Work Instruction Title: USCGC Mackinaw DD 2015 – Work Specification

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

En Rev

A o One end of the cable is connected to stainless connection plate in the upper part of the Azipod, and the other to connection plate in the ship above the pod (see pictures below).

The connection cables are marked with signs:

GROUNDING CABLE. DO NOT REMOVE!

Name of Responsible Person phone number

Doc Kind: Work Instruction Title: USCGC Mackinaw DD 2015 – Work Specification

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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3.4 ROPE GUARDS DISMOUNTING

The removal of the shaft shield is compulsory for the service procedures at the propeller end. The removal and installation of the shield is described below.

3.4.1 REMOVAL OF THE ROPE GUARD

o Rope Guard’s fastening Bolts are covered by welded steel covers.

o The covers need to be gauged-off, to expose the fastening bolts.

o Hoisting tackles are attached to the Rope Guard.

o Fastening bolts of the Rope Guard are removed.

o The Rope Guard is removed and lowered down

The Covers after being opened

Covers

Title: USCGC Mackinaw DD 2015 – Work Specification

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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3.5 ROPE CUTTER REMOVAL

o Locking welds of the rope cutter’s bolts are removed o Bolts of the rope cutter are removed o The rope cutter is lowered down

Rope Cutter

Title: USCGC Mackinaw DD 2015 – Work Specification

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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3.6 SERVICE HATCHES OPENING

o The air space between the cover plate and the service hatch can trap gas. Drill a small venting hole to the plate. Check the correct position from a project specific drawing.

o The cover plate of the hatch is mounted with welds. Flame-cut the welds open and remove the cover plate.

o Open the bolts of the service hatch.

o Remove the service hatch and its sealing plate.

o Cover the hatch when it is not in use.

o Six (6) Hatches (3 per Azipod) will need to be opened.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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3.7 PROPELLER CAP REMOVAL (IF NECESSARY)

o The bolt Cover Band is removed.

o Bolts’ keepers are removed.

o A hoisting tackle is attached to the propeller cap.

o The bolts of the propeller cap are unscrewed and the cap is lowered down

The Cap after Cover Bands’ removal

3.8 PROPELLER NUT REMOVAL (IF NECESSARY)

o The Nut Lock is removed (cut by grinder or torch) o The Propeller Nut Wrench (provided by the Shipowner) is set on to the propeller nut so that hoisting tackle can be attached at its arm in order to unscrew the propeller nut.

o Rotation of the propeller is prevented by attaching a hoisting tackle to one of the propeller’s blades.

o Propeller nut is opened by unscrewing with hoisting tackle. Hoist needs to be done in a right angle in relation to the removal/fastening key. When the nut is loose it can be moved manually. The nut is unscrewed until the distance between the nut and the propeller is about 50 millimeters.

Doc Kind: Work Instruction Title: USCGC Mackinaw DD 2015 – Work Specification

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

En Rev

A o A cushion (wood) is put between the propeller and the propeller nut.

The propeller must be able to move about 20 millimeters outwards.

Nut Lock

Title: USCGC Mackinaw DD 2015 – Work Specification

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

En Rev

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3.9 PROPELLER REMOVAL (IF NECESSARY)

The dismounting of the propeller is done according to a project specific drawing “Propeller mounting and dismounting”.

Note! The work requires the use of hydraulic tools. The forces and working pressures are extreme. Thus, the work requires special caution and use of appropriate protection.

o The Outer Shaft Seal Liner is detached from the Propeller.

o A hydraulic pump connected to the Propeller Hub according to the

Propeller mounting and dismounting -drawing.

o The Hub is pressurized.

o When the propeller has moved against the cushion the Hub is depressurized..

o The Propeller Nut is unscrewed and lowered down. Usage of a proper Lifting Tool is recommended.

o The propeller is removed from the Shaft.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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4 SHAFT SEAL DISMOUNTING ( IF NECESSARY)

o The Propeller Bearing Lubrication System needs to be emptied before dismounting the Outer Shaft Seal package.

o Oil Collectors should be placed underneath the Seal Area, to collect eventual oil spillages during dismounting.

o The Seal Package is secured with the specific Transporting Clamps (provided by the Shipowner).

o The fastening bolts of the seal flanges are unscrewed and the flanges with seals are pulled out from the shaft in one piece.

.Unscrewing the bolts of the outer shaft seal

Removing and lowering down the outer seals.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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5 POD CAP REMOVAL

o The locking of the bolts are removed by chisel or flame cutting o A lifting lug is welded on the pod cap.

o The bolts are unscrewed and the pod cap is lowered down using three mounting points.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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6 SHAFT SEALS LUBE OIL SYSTEM CLEANING

o A waste oil container is placed under the shaft seal unit;

o Plastic hoses are connected the oil outlets;

o The seal tanks are emptied;

o Tanks are cleaned manually;

o The piping will be flushed (by gravity) with new oil;

o Blast the pipelines with industrial pressurized air. Check all the pipelines from project specific lubrication diagram.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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7 OUTER SHAFT SEALS INSTALLATION (IF

NECESSARY)

Works performed by the Yard o The new Shaft Seal is brought to the Dock Bottom, and mounted onto the Shaft;

o The assembled unit with the flanges and the liner is installed according to the manufacturer's instructions;

o The alignment of the lubrication oil bores between the hull and the seal body is checked.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

En Rev

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8 PROPELLER MOUNTING

Works performed by the Yard

8.1 PROPELLER MOUNTING

Mounting the propeller is done according to the project specific Propeller mounting and dismounting -drawing.

Note! The work requires use of hydraulic tools and the forces and working pressures are extreme. Thus, the work requires special extreme caution and use of appropriate protection.

o The temperatures of the propeller and the cone are measured prior mounting of the propeller. Requirements for the temperature meter is 0,1 °C for accuracy and tolerance for the measurement ± 0,1 °C. The mounting arrangements are presented in the below picture

Typical arrangement for Propeller push-up o The propeller is set on to the cone in the same position as it was prior dismounting.

o Hydraulic nut, hydraulic tools and dial gauges are set. Requirements for the pressure gauge is 0,1 bar for accuracy and tolerance for the measurement ± 4 %. Requirements for the dial indicator is 0,01 mm for accuracy and ± 0,05 mm for the measurement.

o The nut is pressurized to the starting pressure. The pressure is checked from the drawing “Propeller mounting and dismounting”.

o Measurement devices are set to zero. The dial gauge behind the propeller (closest to the Azipod) is the primary gauge.

Dial indicator

Pressure to hydraulic nut

Auxiliary oil between shaft and cone

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

En Rev

A o The nut and the cone are pressurized by turns, until the propeller has reached its final position. The final position, push up distance, is read from the drawing – Propeller mounting and dismounting. Primary gauge indicates the push distance.

Note! During the operation the pressure at the cone must not exceed the permissible value.

o When the propeller has reached its final position, the push up distance, the cone is depressurized. The hydraulic nut is kept pressurized at least 30 minutes after the cone has been depressurized so that the propeller sets properly on the cone.

o Hydraulic hoses are removed and the holes are plugged.

o The final position of the propeller is checked from the primary gauge.

8.2 PROPELLER NUT MOUNTING

o The Nut is refurbished in the Workshop prior its mounting (the Hydraulic Piston’s O-rings are renewed);

o Threads on the Shaft and on the Nut are treated with Molycote 1000;

o The Nut is lifted onto the Shaft and screwed in place;

o The tightening torque of the propeller nut is checked from the Azipod Unit assembly drawing.

o The specified tightening Torque for the Propeller Nut is verified;

o The Propeller Nut Wrench is mounted;

o One Dynamometer (0 to 5 Tons scale) is connected to the Wrench;

o The Nut is tightened with a chain hoist connected to the Wrench, and the

Force applied is constantly checked;

o The Nut will be tightened when the specific Force is reached;

o The Locking Bar (keeper) is welded back in place.

8.3 OUTER SHAFT SEALS ALIGNMENT AND COMMISSIONING.

Works performed by ABB.

o The Outer Seal Liner is connected to the Propeller Hub;

o The Propeller is slowly rotated, and the Liner’s alignment is checked in 4 points around the full revolution (0-90-180-270). Adjustments made as needed.

o Once the alignment is completed, the Seal can be filled and vented.

Doc Kind: Work Instruction Title: USCGC Mackinaw DD 2015 – Work Specification

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

En Rev

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8.4 PROPELLER CAP MOUNTING (IF NECESSARY)

o A new O-ring is mounted on the Cap.

o The tightening bolts are tightened up to the specified torque.

o The tightening bolts are locked by welding the locking pieces.

o The cover band is installed.

o The propeller cap is filled with rust protection grease or oil (10-30 l).

8.5 FINISHING THE WORK

o The sacrificial Anodes, the Rope Cutter and the Rope Guards are mounted;

o Service Hatches are closed and bolt covers are welded;

o The earthing arrangements are removed o The scaffoldings are removed.

o The painting can be done progressively as all the installation work outside the Azipod is finished.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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9 POD CAP INSTALLATION

o Gaskets and O-rings are renewed;

o The Pod Cap is lifted on its place using three mounting points;

o The pod cap is fastened to the hull. The tightening is done three times with one-hour intervals for securing the tightness of the flange;

o The bolts are tightened in crosswise sequence to a half of the specified torque;

o The bolts are tightened to the specified torque in ordinal sequence;

o Because the gasket can shrink, the bolts are tightened once more;

o Bolts’ keepers are welded; Note: if Nord-lock washers are used, then welded keepers are not necessary o The lifting lug is removed from the pod cap, see photo below.

Installation of the gasket and the o-ring.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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Removal of the lifting lugs.

10 BEARINGS LUBE OIL SYSTEMS FILLING (IF

NEEDED)

o Fill the systems with fresh Flushing Oil.

o Connect the LT water to the heat exchanger.

o Start oil circulation with an LO pump. Alternate the pump in use.

o Continue flushing until the required cleanliness class is reached.

o Take oil samples with the contamination analyser and a sample bottle.

o When the specified Cleanliness is reached, drain the systems from the used Flushing Oil.

o Fill the systems again, with the proper Lubrication Oil specified for the Vessel.

o Start oil circulation with an LO pump. Alternate the pump in use.

o Continue the Oil circulation until the Drydock will end.

o Take oil samples with the contamination analyser and a sample bottle.

Project:

USCGC Mackinaw Drydock 2015

ABB Inc, Marine and Ports Doc No. Lang.

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