0910_A_ Main Propulsion Shafting_ARCTICROH14R1.doc

USNS ARCTIC

(T-AOE 8)

DRYDOCKING AND UNDOCKING

RFP NO. N32205-14-R-2000

18 SEPTEMBER 2013

ITEM NO. 910

CATEGORY "A" MSC/PM1CM2/MJP/jb

MAIN PROPULSION SHAFTING

1.0 ABSTRACT:

1.1. This item describes the requirements to remove, inspect and refurbish and reinstall the port and starboard propeller shafts, propellers and components.

2.0 REFERENCES:

2.1. References:

2.1.1. NAVSEA Drawing 243-6360807 Rev E, Propulsion Shafting Coupling Guards-

2.1.2. NAVSEA Drawing 243-6360792 Rev F, Propulsion Shaft Arrangement, P/S.

2.1.3. NAVSEA Drawing 243-6360794 Rev H, Intermediate and Stern tube Shaft Details, Port and Starboard.

2.1.4. NAVSEA Drawing 243-6360793 Rev H, Propeller Shaft Details.

2.1.5. NAVSEA Drawing 243-6360803 Rev H, Propulsion Shafting Shipping and Unshipping.

2.1.6. NAVSEA Drawing 244-6360796 Rev H, Main Propulsion Shafting Water Lubricated Bearings.

2.1.7. NAVSEA Drawing 245-6361975 Rev F, Propeller.

2.1.8. NAVSEA Drawing 244-6360797 Rev C, Stern Tube Seal Assembly and Details, P/S.

2.1.9. Tech Manual S9243-BE-MMA-010/71724, Shaft Seal Assy; Operation and Maintenance (ETM12998).

2.1.10. NAVSEA Drawing 161-6361935 Rev E, Struts, Stern Tube Bearings and Stem Castings-

2.1.11. NAVSEA Drawing 161-6360800 Rev J, Propulsion Shafting Fairwaters and Rope Guard.

2.1.12. NAVSEA Drawings 243-6360795 Rev B, BHD Shaft Seal Assembly.

2.1.13. Crane Drawing US71686, GA OF 30.750” Type MX9 Seal, AOE-6 Class.

2.1.14. Crane Drawing WL P001281-001,MX-9 Overhaul Kit.

2.1.15. MSC Drawing 243-8390431, T-AOE 6 Class Main Propulsion Shaft Alignment Procedure

2.1.16. ABS approved GRP Coating Procedure SOP # 70-002, Rev 0 Dated 4/16/2003

2.1.17. Shaft Alignment Jacking Study, NAVSEA Drawing 835-6360595.

2.1.18. Pilgrim Propeller Nut Arrangement for AOE 6 Class MAPCO Drawing D-3051 Rev. D or C.

2.1.19. Lifting Padeye and Turning, Reusable, NASCCO Standard Drawings, NS-1001, Sheets 1-6, Rev D.

2.1.20. NAVSEA Drawing 562-6362023F Propeller and Rudder Stock Shipping and Unshipping Details.

2.1.21. NAVSEA Drawing 500-6360771M COMP ARR A2-031 A2-032 SKEG SIDE SHL.

NOTE:

All NAVSEA drawings are to be used as a reference throughout specification. There may be slightly differences between original drawings and existing conditions. Items such as stern tube seals use Wartsila - John Crane commercial Manuals, and Drawings along with Manufacturer Rep. for assistance.

3.0 ITEM LOCATION/DESCRIPTION:

3.1. Location/Quantity:

3.1.1. Location:

a. Stern of ship, shaft alley, and Main Machinery Room 1 (MMR1) and Main Machinery Room 2 (MMR2)

3.1.2. Quantity:

a. Two - (2) Main propulsion shafting systems, port and starboard, including propellers, propeller fairwaters caps, propeller shafts, intermediate shafts, stern tube shafts, main strut bearings, intermediate strut bearings, BHD Seals, stern tube bearings, stern tube seals, fairwaters, coupling guards, rope guards, line shaft bearings and bull gear bearings.

3.2. Item Description/Manufacturer's Data:

3.2.1. Water lubricated propeller shafts, QTY = 2; Material: Forged Steel, MIL-S-23284, Class II Diameter: Shafts are 28.313" in diameter with 30.125" diameter monel sleeves. Propeller shaft flange diameters are 45" Length: 54'-10 1/4" long Weight: Each propeller shaft (port and starboard) weighs 93,600 pounds

3.2.2. Intermediate shafts, QTY = 2; Material: Forged Steel, MIL-S-23284, Class II Diameter: Shafts are 28.500" in diameter with two 30.750" diameter sleeves. Forward and aft intermediate shaft flanges are 45.010" in diameter, Length: Port intermediate shaft is 25'-6" long and the starboard intermediate shaft is 25'-0" long Weight: Port intermediate shaft weighs 38,400 pounds and the starboard intermediate shaft weighs 35,100 pounds

3.2.3. Water lubricated stern tube shafts, QTY = 2; Material: Forged Steel, MIL-S-23284, Class IDiameter: Shafts are 28.500" in diameter withthree 30.750" diameter sleeves. Forward stern tube shaft flange diameters are 40" and aft stern tube shaft flange diameters are 45" Length: Port stern tube shaft is 59'-7 3/8" long and the starboard stern tube shaft is 36'-8" long Weight: Port stern tube shaft weighs 90,000 pounds and the starboard stern tube shaft weighs 57,600 pounds

4.0 GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

4.1. Government Furnished Material:

4.1.1. MX9 Major Overhaul Stern Tube seal Kit, US71686, QTY 2.

4.1.2. MX9 Stern Tube Seal Seat, Part No. H47954A03, Qty 2.

4.1.3. Emergency Stern Tube Seals Parts, QTY 2.

4.1.4. Pilgrim Nut Tire Tool Kit # A-6789, consisting of the following:

· Tire Assy. tool, A-2566 Qty: 2.

· Stem Nut Wrench, A-2567 Qty: 1.

· Stem Alignment tool, A-2568 qty: 1.

· Nitrile Washer Extractor, A-2569 qty: 2.

· Nylock plug, 9/16-18N Qty: 2.

· Stem plug, 3/8 NPTF green qty: 2.

4.1.5. Pilgrim Nut Tire 2” DIA, 22” ID x 26”OD Part # 22-26, Qty 2.

4.1.6. Paint: (Stern Tube, Propeller, Intermediate and Stern Tube Shaft and Rope Guard)

4.2. Government Furnished Equipment:

NOTE:

Contractor shall verify the list of equipment including quantity in Government inventory and request the delivery of necessary equipment for shafting removal and installation. Additional tools and equipment not available in Government inventory must be supplied by the Contractor.

4.2.1. Pad Eye & Roller Plate Assembly (DR7-10004),see Detail 34-A, SH 5, piece 64 – QTY available: 2 sets.

4.2.2. Roller Bracket Assembly Halves (DR7-10003),see Detail 23-A, SH 3, piece 63 – QTY available: 6 sets

4.2.3. Roller Bracket Spring Ring Halves (DR7-10052),see Detail 29-A, SH 4, piece 67 – QTY available: 4 sets

4.2.4. Shaft handling Through support 5 Hole, Piece 82, see detail 27-D, SH 4 QTY available: 2

4.2.5. Shaft handling Through support 4 Hole, Piece 83, see detail 27-D, SH 4, QTY available: 2

4.2.6. Shaft handling Through Halve ( DR7-10055), Piece 81, see elevation 53-A, SH 7, QTY available: 2

4.2.7. Shaft handling Through Halve ( DR7-10056), Piece 80, see elevation 53-A, SH 7, QTY available: 2

4.2.8. Bearing Land Protection Inner Plate (DR7-10006), piece 66, see section 29-G, SH 7, Qty available: 4

4.2.9. Bearing Land Protection Outer Plate (DR7-10005), piece 65, see section 29-G, SH 7, Qty available: 9

4.2.10. 1 ½ x 12” Turnbuckle (422-0562), piece 89, see detail 27-D, SH 4, Qty available: 5 each

4.2.11. 1 ½ x 18” Turnbuckle (422-0563), piece 89, see detail 27-D, SH 4, Qty available: 5 each,

4.2.12. 50-Ton Eye Bolt, Qty available: 4 each

4.2.13. 1 ½ Bolt, Qty available: 8 each

4.2.14. 1 ½ Nut, Qty available: 8 each

4.2.15. 1 ½ sleeve, Qty available: 4 each

4.2.16. Adapter Plate for Male End of Shaft to use Pad Eye & Roller Plate, Qty available: 2 each.

4.2.17. Shaft Support Strong Back, piece 62, see section 45-A & 42-A, SH 6, Qty available: 8 each

4.2.18. Dollar Plate for Propeller Removal, Qty available: 1

4.2.19. Propeller Removal Stud with Nut, Qty available: 6 each

5.0 NOTES:

5.1. The contractor and all subcontractors regardless of tier shall consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs including but not limited to GTRs 1 through 7.

5.2. The contractor and all subcontractors regardless of tier are advised to review ALL other work items under this contract, to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

5.3. Care is to be taken not to damage the bearing staves during the performance of this item. Flushing water is to be provided whenever shaft is rotated to protect staves.

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0 STATEMENT OF WORK REQUIRED:

7.1. Government Furnished Equipment Handling:

7.1.1. Immediately after contract award Contractor shall review Paragraph 4.2; list of Government Furnished Equipment. Contractor to request delivery of equipment in Government Furnished Equipment. Additional tools and equipment not available as Government Furnished must be supplied by the Contractor.

7.1.2. Upon receipt of Special Tool request from contractor the Government will ship to the shipyard requested equipment in the best conditions available. Upon receipt the contractor shall inventory, evaluate, and provide an “As-Found” condition report to MSCREP. Contractor shall verify suitability of all tools before use. Contractor shall estimate 100 hrs for unpacking, and equipment restoration prior to use.

7.1.3. After completion of work requiring use of GFE, all provided tooling shall be refurbished and an “As-Released” report forwarded to MSCREP describing condition of each piece of equipment Contractor and MSCREP shall jointly inspect equipment prior to crating of equipment for shipment to back to MSC Warehouse.

7.1.4. Upon approval of MSCREP contractor shall arrange crating and transportation from the shipyard to MSC warehouse in Cheatham Annex as requested by MSCREP.

7.2. Under the guidance of OEM certified manufacturer’s representative disassemble the stern tube inboard split shaft seal and remove to the shop for inspection and examination. Inspect the stern tube seal housings and distance rings. Machine or renew as directed by manufacturer. Inspect the inflatable seal and the standby flax packing overhaul as required by manufacturer. Disassembly and Inspection to be witnessed by MSCREP and Manufacturer Tech Rep. Submit as-found condition report with repair recommendations.

7.3. Clean the stern tubes inboard hull mounting flange for seal/water bearing internal and external face and inspect with MSCREP and ABS. Repairs if required will be subject to an RFP. Take note of all mating surfaces and sealants during disassembly, the port side shafting arrangement requires attention to detail due to multiple mechanical joints.

7.4. Temporary padeyes specified in Reference 2.1.5 and 2.1.21 shall be fabricated as required and installed to support the removal and reinstallation of shaft components under this item. The padeyes shall be tested for the working load required for removal of equipment using Reference 2.1.5 and 2.1.21. Temporary padeyes shall be removed after shaft installation is completed, unless approved by MSCREP.

7.4.1. NOTE: USNS ARCTIC has padeyes remaining from a previous availability. Athwartship facing padeyes were removed. No guarantees are made as to the quantity and condition of remaining padeyes. None shall be considered acceptable for service prior to inspection and weight testing.

7.5. Temporarily remove the port and starboard shaft fairwaters from propeller struts, intermediate struts, and stern tubes using References in 2.1 for guidance.

7.5.1. Shaft bearing wear down readings shall be accomplish prior to shafting and propeller removal bearing clearance readings shall be taken at each stave Submit "as found" condition reports for fairwater and bearing clearances, to MSCREP.

7.6. Provide rigging services and apparatus such as chain falls, straps, pendants, shackles, temp pad eyes and all other equipment not provided as GFE to allow for handling, removal and installation of port and starboard main propulsion shafting system and components, using Reference 2.1.5 and 2.1.21.

7.6.1. Additional equipment such as, 50 ton and 16 ton chain falls air operated, bolts, nuts, additional hull blanks, shaft support tower, straps, ropes, protective covers, propeller nut Intensifier/removal tools, and other equipment must be supplied by the Contractor.

7.7. Remove rope guards using Reference 2.1.11 for guidance, propeller rope guards have been welded in place.

7.8. Remove propeller lifting hole plugs and restore propeller lifting hole threads, restore lifting hole plugs.

7.9. Temporarily remove the port and starboard coupling fairwaters, propeller fairwater caps, propellers, strut bearing fairwaters, propeller shafts (tail shaft), intermediate shafts, stern tube shafts, main strut bearings, intermediate strut bearings, stern tube bearings, shaft seals, and stern tube seals using References in Paragraph 2.1 for guidance.

7.10. Measure and record as found condition for each water bearing as described and provide condition report to ABS and MSCREP:

7.10.1. Clean all debris from strut and stern tube measure inside diameters of shaft tubes and struts in way of water bearing lands at three equally spaced locations per land.

7.10.2. Measure outside diameters of water bearings housings at each bearing land in three equally spaced locations per land and in same relative area as 7.10.1. Perform after cleaning.

7.10.3. Measure shaft liner diameters for Stern Tube and Propeller shafts in bearing areas at three equally spaced locations around the liner and at four locations axially along the liner; a total of 12 readings per liner. Take after installing in lathe per 7.13, record shaft liner runout measurement at the same four locations as diameters.

7.10.4. Calculate shaft sleeve machining requirements and bearing clearances.

7.11. Size and procure new bearing staves. Staves to be sized to correspond to shaft liner measurements calculations after machining. The following information on the staves are available at this time:

Port Qty

STBD

Location

7.11.1. Standard thickness 0.981”, oversized staves in 1/16” increment are also available. The Contractor shall determine stave thickness after inspection and measurements. Due to long lead-time on staves The Contractor may consider discussing with DURAMAX a restocking fee charge for staves.

NOTE:

Port Stern Tube has FWD and AFT stern Tube Bearing. The only known Qualified Vendor is for staves is Duramax Marine tel.440-834-5400 For More information see item 2.1.6

7.12. Inspect nuts, bolts, studs, washers, and screws for port and starboard main propulsion shafting systems. Submit an "as found" condition report identifying materials that require replacement. It is anticipated that permanent Locktite used to install studs and bolts will be difficult in removal and some hardware will be damaged. Contractor shall estimate for the following replacement hardware:

7.13. Transport the propeller shafts, intermediate shafts, and stern tube shafts to the shop. Accomplish the requirements of Reference 2.1.16 and install in lathe.

7.13.1. Record shaft axial and radial runout measurements at flanges and propeller shaft nut and taper areas.

7.14. Temporarily remove water bearing shells and transport to shop. Remove staves from bearing shells. Thoroughly flush with clean water. After cleaning, bearing shells shall be assembled and measurements (O.D., I.D., and stave lands) taken to confirm that bearing shells follow the design sizes and are suitable for reinstallation in hull and for installation of staves. Submit readings to MSCREP.

7.15. Install new staves. Installation shall be performed according to manufacturer installation procedure. Do not use dry ice to shrink staves.

7.16. Painting:

7.16.1. Clean struts and stern tube of all debris, paint port and starboard stern tubes including high hats, and new rope guard.

a. Freshwater wash (2500 to 3000 PSIG) struts and stern tube to remove defective coatings and fouling. Degrease with suitable solvents prior to blasting. Wash down and dispose of solvents used. Monitor, contain, collect, process, filter, clean up, recycle, and dispose of all wash water, rinse water, and degreaser rinse fluids, generated by this work item. Dispose as found necessary or required, in accordance with any/all current local, county, state, or Federal Regulations.

b. Upon completion of all water washing chloride testing shall be performed on random areas of stern tube. If contamination is found, additional tests shall be made as necessary to determine the extent of contamination and to prove the success of remediation. The maximum allowable contamination concentrations shall be less than 10 ug/cm2 of chloride contaminants as determined by field or laboratory analysis using reliable, reproducible test equipment.

c. Inspect steel plates per Work Item 927 Perform any required repairs. Following repairs sweep blast and installation of stern tube tracks preserve tracks and stern tube.

d. Protect water bearing lands and other critical surfaces. Blast rope guards; and interior surfaces and appendages of stern tube to an SSPC-SP-10, Near White Metal finish.

e. Prior to the start of abrasive blasting the blast media shall be tested to ensure that it is not contaminated with chlorides, as determined by field or laboratory analysis using reliable, reproducible test equipment. Submit a report listing the results of the testing

f. Upon completion of exterior surface preparation and approval, apply the following coating system to blasted areas in accordance with the manufacturer's instructions:

PPG Paint System

* Amercoat 240 Haze Gray tie coat may be needed if application time between last coat of AC and first coat of AF are not within product guide lines

7.17. Renew stern tube zincs (Qty = 26, Type=ZHC-23)in high hats and reinstall high hats using new gaskets and fasteners. The gasket material must be DFM and seawater resistance. See Reference 2.1.21 for installation

7.18. Inspect propeller shafts, intermediate shafts, coupling bolts and stern tube shafts for pitting and corrosion and fit. Inspect the entire surface of the shafts including flanges, shaft taper, shaft key ways, and coupling bolts by magnetic particle or dye penetrant methods and submit an "as found" condition report to MSCREP. Explore all cracks to their full depth and remove by grinding or dressing with a rotary file only as approved by the MSCREP and ABS. Confirm by magnetic particle or dye penetrant method the complete removal of all cracks.

7.18.1. Install shafts in the lathe and remove fiberglass coating from propeller shafts, intermediate shafts, and stern tube shafts.

NOTE:

Max shaft weight is 96300 lbs so min. 50 tons overhead lift capability is required to perform this operation.

7.18.2. After approval by MSCREP machine outside diameter of propeller shafts and stern tube shaft liners to agreed upon diameter. Submit report if indications and surface irregularities remain.

7.18.3. Post machining, accomplish final measurements of shafts and shaft liners, provide final diameters and runouts after all work is accomplished as described in Paragraph 7.10.2 and 7.16. Submit report as released to ABS and MSCREP.

7.18.4. Apply new fiberglass protective coating on propeller shafts, intermediate shafts, and stern tube shaft in accordance with ABS approved procedure SOP # 70-002 (Rev-0) dated 4/16/2003.

7.18.5. (CHECKPOINT) Accomplish high frequency spark test of new fiberglass coating and record test results.

7.19. Disassemble propeller fairwaters / caps, clean, degrease and deburr surfaces and reassemble using new gaskets and monel hardware.

7.20. Transport the propeller shafts, intermediate shafts, and stern tube shafts from shop to ship and reinstall.

7.21. Reinstall lower stave bearing housings, propeller shafts, stern tube shafts, and intermediate shafts, main and intermediate strut bearing, stern tube bearings, BHD Seals and shaft seals.

NOTE:

All work with seals shall be accomplished under direction of Manufacturers Tech. Rep.

7.22. Reinstall upper water bearing housings in stern tube and struts. Reinstall stern tube seal. Stern tube seals must be installed under direction of Manufacturer Rep. Contractor shall ensure mechanical joints of shaft seal, port forward stern tube bearing upper and lower halves, and hull flange joints are water tight, apply sealant where required. Record sizes and clearances and submit an “as found” condition report to MSCREP.

7.23. Accomplish an air test on inflatable sealing rings at 35 PSI for ten minutes. Allowable leakage as per manufacturer requirements.

7.24. Assemble, install, align, adjust and connect the port and starboard main propulsion shafting using Reference 2.1.1 through 2.1.11 for guidance.

7.25. Check the shaft taper by blue fitting the shaft taper directly to the propeller. Blue fit contact is to be witnessed by ABS and MSCREP. Improve fit using hand tools in order to accomplish a minimum contact of 80% when checked with propeller.

7.26. Overhaul both pilgrim nuts, replace rubber tires, stems, and packing using GFM. These pilgrim nuts shall be overhauled at least every other dry-docking.

7.27. Reinstall propellers, measure propeller push up data in PSI vs. advance in inches at ambient temp as listed in NAVSEA Drawing 245-6361975. Reinstall propeller fairwater caps and seals using new gaskets and monel hardware.

7.28. Fill the propeller hub, fairwater cap, struts, stern tube bearings, and rotating fairwaters with corrosion preventative compound. Existing corrosion compound can be reused. Renew all outboard bearing zincs per Reference 2.1.6.

7.29. Renew 100 (100) feet of associated monel lacing wire. Drill holes in up to Fifty (50) fasteners to accept lacing

7.30. Reinstall the main strut, intermediate strut, and stern tube fairwaters using References 2.1.1 through 2.1.11 for guidance.

7.31. Fabricate and install new rope guards using Reference 2.1.11 and removed guards for guidance. Inspect and measure both rope guard clearances (max. 0.250”). Measurements are to be witnessed by MSCREP.

7.32. Measure and record final stern tube bearing clearances “as released”, intermediate strut bearing, main strut bearing, fairwater and rope guard clearances.

NOTE:

CARE IS TO BE TAKEN NOT TO DAMAGE BEARING STAVES. FLUSHING WATER FROM FIRE HOSES IS TO BE PROVIDED WHENEVER SHAFT IS ROTATED TO PROTECT STAVES.

7.33. Contractor shall accomplish five (5) sets of line shaft alignment readings for the port and starboard main propulsion shafting systems using strain gage method as follows, using Reference 2.1.15 as guidance:

7.33.1. First reading - Immediately on arrival to contractor’s facility (in water), and priors to pumping out the ship fuel and other liquids.

7.33.2. Second Reading – Prior to disturbing shaft system and after ship has settled on Dock Blocks for 24 hrs.

7.33.3. Third set – After reassembly of shaft system and prior to undocking.

7.33.4. Forth Reading – Waterborne after undocking and reintroduction of all liquids removed from the ship after her arrival, i.e. the ship loading condition shall be identical with the condition during the first readings.

7.33.5. Fifth Reading –At hot conditions during the sea trial with cargo fuel on board.

NOTE:

The contractor shall allocate sufficient time for the ship’s defueling and refueling and clearly indicate it in TPSN in the proposal. Assume that two (2) days will be required for each defueling and refueling.

The contractor shall submit the line shaft alignment procedure not later than two weeks after the contract award. After each set of readings is accomplished, calculate bearing loads for the bull gear, and lineshaft bearings, stern tube, intermediate strut and main strut bearings.

7.33.6. After taking the fourth set of readings and analyzing, recommend required adjustments. Take additional readings, as required, to prove adjustments.

7.33.7. Perform temporary removals as necessary to accomplish lineshaft alignment readings.

7.33.8. Paint all new and disturbed surfaces to match surrounding surfaces, This includes application of preservation system to fiber glassed propulsion shafts per requirements of Work Item 909.

7.34. Preparation of Drawings: None Additional

7.35. Manufacturer's Representative:

7.35.1. Provide the services of an authorized manufacturer's representative to provide on-site technical assistance, special tools, and guidance, during the disassembly, inspection, repairs, reassemble, testing and adjustments of the stern tube seals and BHD seals. Tech Rep to be present for the duration of work and present for dock/sea trials

Recommended Tech. Rep:

Wartsila Lips, Inc

3617 Koppens Way

Chesapeake, VA 23323

Attn: Wayne Williams

Tel. 757 558 3625

8.0 GENERAL REQUIREMENTS: None Additional

912-19