0909A_-_CRP_Propeller_Maintenance_and_15_Year_Tail_Shaft_Radius_Inspection_.doc

USNS LEROY GRUMMAN

T-AO 195

DRYDOCKING AND UNDOCKING N32205-14-R-1001

01 AUG 2011

ITEM NO. 909A CATEGORY "A" MSFSC/N43A/REC

CRP PROPELLER MAINTENANCE & 15 YEAR TAIL SHAFT INSPECTION

1.0

ABSTRACT

1.1 Replace the blade seals on the port and starboard CRP propellers. Inspect, clean, and polish the propellers and caps. Clean HOPM Tanks. Operationally test the port and starboard controllable pitch propeller systems.

2.0

REFERENCE/ENCLOSURES

2.1 References:

2.1.1 MIL-STD-271 (available onboard).

2.1.2 NAVSEA Technical Manual T9245-AE-MMC-010, Controllable Reversible Pitch

Propeller (available onboard).

2.2 Enclosures:

2.2.1 Sketch, Blade Port Assembly

3.0

ITEM LOCATION/DESCRIPTION

3.1 Location: Underwater hull, stern frame.

3.2 Quantity: Two (2) propellers (port & stbd.) to be dealt with.

3.3 Description: CRP Propellers: Four (4) Bladed, 21'-0" diameter, Ni-Al-Bronze, ABS TY4, Controllable Reversible Pitch. Mfr: Rolls-Royce Naval Marine, Inc. (Bird-Johnson).

4.0

GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICE:

4.1 Material:

Part No.

Description

Qty.

O-1-4-9 O-Ring, Blade Bolt

O-7-3-1 O-Ring, Dynamic

O-7-3-2 O-Ring, Static

K-8-3-32 Socket Cup Set Screw

J-12-1-22 Compression Spring, BSBR

115742018 Blade Seal Base Ring

115735006 Blade Dowel Pins

5.0

NOTES

5.1 This work item shall be worked on a minimum two (2) shift basis to maintain continuity, minimize impact on other drydock work items, and minimize time on drydock. A Manufacturer’s authorized technical field service representative shall be provided for both shifts.

5.2 No sandblasting, water blasting, painting or other debris generating work shall be accomplished whenever the propeller hubs are exposed. The contractor shall schedule other work items, including but not limited to items 902, 903, 910, and 912 to preclude any possibility of contamination of these components. Contractor shall provide adequate temporary coverings and protection of these components at all times, and in particular when the possibility of contamination exists.

5.3 This item must be accomplished in conjunction with all other drydock related work items.

6.0

QUALITY ASSURANCE REQUIREMENTS

6.1 All work shall be performed to the satisfaction of the ABS, Port Engineer, Chief Engineer, and the manufacturer’s technical field service representative(s).

7.0

STATEMENT OF WORK REQUIRED

7.1 All work on this item shall be accomplished under the direct supervision of manufacturer’s authorized technical field service representatives for the equipment described in paragraph 3.0, using reference 2.1.2 for guidance.

7.2 Remove the eight (8) propeller blades from the port and starboard CRP propellers to the contractor’s shop.

7.2.1 Accomplish the following propeller cleaning, inspection and repairs while they are removed.

7.2.1.1 Clean and buff propeller blades, hubs, and caps to bright metal. Thoroughly clean propeller blade bolts.

7.2.1.2 Visually inspect and accomplish NDT to check and examine all components for cracks and defects using reference 2.1.1 for guidance. Pay particular attention to hub, blade roots, and blade edges. Port Engineer, Chief Engineer, Manufacturer's Rep., and ABS Surveyor to witness inspection and testing. Submit condition report to the MSCREP detailing results of inspection and non-destructive testing.

7.2.2 Lay blades out on plywood to prevent scratching or damage.

7.2.3 Set up and machine the bases of the propeller blade flanges and clean up steps, removing a minimum amount of material.

7.2.4 Visually inspect and accomplish NDT on all blade bolts, blade pins and blade flanges in the presence of the Port Engineer and ABS. Submit report on results.

7.2.5 Repair all minor nicks, burrs, and cracks in accordance with ABS procedures and requirements. The contractor shall assume three (3) minor repairs (8in. long X 2in. wide) per propeller blade will have to be accomplished. Submit a copy of ABS approved repair procedures and welder's qualifications to the Port Engineer.

7.2.6 After repairs and dye check, grind and fair up blades to original contour. Polish to a "Rupert B" finish. Polishing shall include the forward and after surfaces of the propeller blade tips between 0.7 and 1.0 radius lines. The leading edge of the propeller blade over 0.2 of the blade width to a finish equal to the "B" specimen of the Rupert Comparator having a roughness average (Ra) of 76.8 micro inch. The remainder of the propeller blades shall be polished to a finish equal to the "C" specimen of the Rupert Comparator having a roughness average of (Ra) of 196.0 micro inch.

7.3 Reinstall propeller blades renewing all blade O-rings (static and dynamic), blade bolt O-rings, blade seal base rings, blade dowel pins, and blade seal base ring springs.

7.4 Remove and dispose of CRP system oil from the port and starboard hubs, shafts, and sumps (HOPM), for a total of approx. 2,524 gallons.

7.4.1 Open port and starboard HOPM tank covers.

7.4.2 Wipe out HOPM tanks, using lint-free rags, removing all oil, dirt, mud, and debris to the satisfaction of the Chief Engineer and the manufacturer’s rep.

7.4.3 After visual inspection by the Chief Engineer and the manufacturer’s rep., close up the port and starboard HOPM tanks, using new gaskets.

7.5 Perform 15 Fifteen Year Inspection of the Port and STBD Tail Shaft Radius’s.

7.5.1 Once Stern Tube seals have been removed per item 0910 Stern Tube Seal Maintenance. Unbolt the Dutch Men on the Port and STBD Shaft.

7.5.2 Once the Dutch Men has been Un-bolted move it FWD to gain access to the Tail-shaft Radius areas.

7.5.3 Perform a Visual Inspection and NDT of the Tail shaft Radius areas in the presence of the OEM representative, ABS attending Surveyor, Chief Engineer and Port Engineer. The method of NDT used shall be approved by the OEM Representative and ABS Attending Surveyor.

7.6 Inspections/Tests:

7.6.1 Make all required service adjustments to the port and starboard CRP systems.

7.6.2 Conduct one (1) complete cycling of propeller blades while vessel is in drydock. Port Engineer, Chief Engineer, Manufacturer's Rep., USCG and ABS to witness testing.

7.6.3 Pitch to be cycled from 0 pitch to full ahead pitch, to full astern pitch and then back to 0 pitch. Under no circumstances will more than one complete cycling of pitch be authorized.

7.6.4 Contractor to provide fire hoses to lubricate blades during cycling.

7.6.5 Conduct an operational test of the port and starboard CRP systems during dock trials. Port Engineer, Chief Engineer, Manufacturer’s Rep., and ABS to witness testing.

7.6.6 Manufacturer’s Rep. shall conduct an operational test and hot oil alignment of the port and starboard CRP systems during sea trials, to the satisfaction of the Port Engineer and the Chief Engineer.

7.7 Preparation of Drawing: None.

7.8 Manufacturer’s Representative:

7.8.1 The contractor shall provide the services of manufacturer’s authorized technical field service representatives throughout the performance of this work item, including multiple shifts, dock and sea trials.

7.8.2 Recommended source:

Rolls-Royce Marine North America Inc.

110 Norfolk Street

Walpole, MA 02081

POC: Mr. Tom Reinert

508-734-1352 e-mail: tom.reinert@rolls-royce.com

7.8.3 The manufacturer’s authorized technical field service representatives shall provide all special tools, equipment, and devices necessary for the accomplishment of this work item.

7.8.4 Upon completion of all work, field service representative(s) to provide service report noting all as found conditions, clearances, photos, and all repairs accomplished. Submit three (3) typewritten copies of the report to the Port Engineer.

8.0

GENERAL REQUIREMENTS

8.1 None additional.