0902_A__PROPELLER_SHAFT_AND_STERN_TUBE_INSPECTION_Rev_1.doc

USNS MEDGAR EVERS

(T-AKE 13)

DRYDOCKING AND UNDOCKING

N32205-14-R-3004

28 MARCH 2014

ITEM NO. 0902

Category "A"

MSC/PM1CM2/BVV

PROPELLER SHAFT AND STERN TUBE INSPECTION (ABS)REV 1

1.0 ABSTRACT:

This item describes:

Take initial and reinstalled tail shaft wear down readings.

Take strain gauge readings and optical alignment readings.

Take initial and reinstalled rudder wear down readings.

Unship and ship the rudder blade. (Rudder stock to remain in place)

Unship and ship the propeller.

Unship and ship, the tail shaft (propeller shaft).

Temporarily remove the intermediate shaft.

Inspect the tail shaft, and tail shaft bearing and stern tube internals.

Machine stern tube tail shaft bearing area.

Renew rope guard line cutters.

Preserve and coat the rudder.

2.0 REFERENCES/ENCLOSURES:

2.1 References

2.1.1 NAVSEA Dwg 243-7488962 Rev F, Shaft Arrangement

2.1.2 T/M T9243-BA-MMC-010 Fixed Pitch Propeller and Shafting with Bearings Model DAAK012887

2.1.3 T/M T9561-BR-MMC-010 Steering Gear Rotary Vane, Model # RV 2150-3, and Shorthorn Rudder

2.1.4 Wartsila Dwg W084837233 Rev E, Assy Stern tube

2.1.5 Bot Groningen Dwg 1.1262/1/1 A1, Rudder Project Arrangement.

2.1.6 Bot Groningen Dwg 3.1265/1.1 A3, Rudder Trunk Summary

2.1.7 Bot Groningen Dwg 2.1263/1.1 A3, Rudder Cone Coupling

2.1.8 Bot Groningen Dwg 2.1264/1.1 A3, Rudder Hydraulic Nut Summary

2.1.9 Wartsila Dwg W084827066, Assy Propeller Cap

2.1.10 Wartsila Dwg W084836779, Propeller Boss

2.1.11 Wartsila Dwg W084838596, Assy Propeller Hydraulic Nut

2.1.12 NASSCO Dwg 471-351-4984, Rope Guard Installation

2.1.13 Wartsila Dwg W084837232, Arrangement Shafting

2.1.14 Wartsila Dwg W007420313, Round Nut Locking

2.1.15 Wartsila Dwg 9AK30410AS3, Shaft Flange-9FC6-58 AS3

2.2 Enclosures

2.2.1 Enclosure (1) Rudder Pull-up Cone Coupling Protocol Sheet.

2.2.2 Enclosure (2) Propeller Push-up Data Conversion Table

2.2.3 Enclosure (3) Shaft Coupling Superbolts

3.0 ITEM LOCATION/DESCRIPTION:

3.1 Location/Quantity

3.1.1 Location

Rudder, Frame 95

Propeller, Frame 87 Tail Shaft, Frame 82-87 Hydraulic Coupling, Frame 87 Stern Tube Bearing, Frame 82

Bilge Keels, Frame 47-67

3.1.2 Quantity

Rudder, 1 each

Propeller, 1 each

Tail Shaft, 1 each

Hydraulic Coupling, 1 each

Stern Tube Bearing, 1 each (2 Segments) Bilge keels, 2 each

3.2 Item Description/Manufacturer’s Data

Component Weights

3.2.1 Quantities are considered estimates. The Contractor shall provide the exact quantities and additional material such as miscellaneous fittings, cable hangers, cable tags, etc, which are not included in the List of Materials, in order to install a fully functional system which meets the requirements of this specification.

3.3 Contractor Furnished Equipment/Material/Services

3.3.1 Bill of Materials: (Contractor Furnished)

Contractor Provided Materials (CFM)

Ref 2.1.8

Bot-Groningen

Dwg 2.1264/2.1 Hydraulic Nut Parts List

Part #2

6mm Dia thk

NBR 65º SH

1 ea

Ref 2.1.8

Bot-Groningen

Dwg 2.1264/2.1 Hydraulic Nut Parts List

Part #4

6mm Dia thk

NBR 65º SH

1 ea

Ref 2.1.8

Bot-Groningen

Dwg 2.1264/2.1 Hydraulic Nut Parts List

Part #5

6mm Dia thk

NBR 65º SH

1 ea

Ref 2.1.8

Bot-Groningen

Dwg 2.1264/2.1 Hydraulic Nut Parts List

Part #7

6mm Dia thk

NBR 65º SH

1 ea

Ref 2.1.8

Bot-Groningen

Dwg 2.1264/2.1 Hydraulic Nut Parts List

Part #9

6mm Dia thk

NBR 65º SH

1 ea

Ref 2.1.7

Bot-Groningen

Dwg 2.1263/1.1 Cone Coupling

Part #4

6mm Dia thk

NBR 65º SH

1 ea

Ref 2.1.7

Bot-Groningen

Dwg 2.1263/1.1 Cone Coupling

Part #7

12mm Dia thk

NBR 65º SH

1 ea

Ref 2.1.6

Bot-Groningen

Dwg 3.1265/1.1 Rudder Trunk Summary

Part #6

12mm Dia thk

NBR 65º SH

1 ea

Ref 2.1.9

Wartsila Dwg W084827066 pc 3

NBR 70 Shore

ID 932.5 X7

Wartsila Detail Dwg W007040014 1 ea

Ref 2.1.9

Wartsila Dwg W084827066 pc 8

NBR 70 Shore

ID 932.5 X7

Wartsila Detail Dwg M713000290 2 ea

Ref 2.1.11

Wartsila Dwg W084838596 pc 3

Cord ring with vulc joint

NBR90 Shore

Ø 650 X 3.53

Wartsila Detail Dwg W007058061 1 ea

Ref 2.1.11

Wartsila Dwg W084838596 pc 4

Cord ring with vulc joint

NBR90 Shore

Ø 745 X 3.53

Wartsila Detail Dwg W007058062 1 ea

Ref 2.1.13

Wartsila Dwg W084837232 pc 57

NBR 70 Shore

ID 730.5 X7

Wartsila Detail Dwg W084838703 1 ea

Ref 2.1.15 pc 4 o-Ring Ø721X6,99

Nitril 70 ShoreA

Cage OEYA6

Part # 737973 1 ea

Ref 2.1.15 pc 5 o-Ring Ø587X3,53

Nitril 70 ShoreA

Cage OEYA6

Part # 737882 1 ea

Ref 2.1.15 pc 8 o-Ring Ø799X6,99

Nitril 70 ShoreA

Cage OEYA6

Part # 738096 1 ea

NASSCO dwg 471-351-4984 pc 2

NASSCO part # LMCH-1002

Shipyard may fabricate based on reference 2.1.12 details 4 ea

NASSCO dwg 471-351-4984 pc 5

Bolt 3/8" X 1-3/4 Lg, SST 304 8 ea

NASSCO dwg 471-351-4984 pc 6

Nut hex Self Lkg 3/8-16, SST 304 8 ea

Hempadur Mastic 45880 12170 Grey

Hempadur Mastic 45880 Haze Gray FSC 26270 As Required

Contractor Provided Materials (CFM)

Contractor Provided Special Tools (CFT)

Propeller Rigging

30 Ton Air Hoists

Cap Screws, Flat Head, M12 x 50 LG, P/N F99M12X50S 15 Ea

Wartsila Dwg W084827066 pc 6

Wartsila Detail Dwg M713090039

C15

M20 1 ea

Wartsila Dwg W08483677 pc 4

42CrMo4

80M

Ø135 L=225

Wartsila Detail Dwg W084813619 1 ea

Wartsila Dwg W08483677 pc 6

42CrMo4

64M

Ø110 L=190

Wartsila Detail Dwg W084813618 4 ea

Wartsila Dwg W006040130 1 ea

Wartsila Dwg W0004000 and W006300563 and DMYI000059

1 ea assembly

or

Shipyard provided 2 ea

Reference 2.1.1 pc 9 1 ea

Reference 2.1.1 pc 31 1 ea

Reference 2.1.1 pc 32 1 ea

Reference 2.1.1 pc 33 1 ea

Reference 2.1.1 pc 34 1 ea

Reference 2.1.1 pc 35 1 ea

Or obtain from Thordon Bearing

Thordon COMPAC Standard Key Installation Kit

-Consists of Hydraulic cylinder, Threaded Rod, Installation Plate, Rubber mallet, Key Extraction tool, Johnson Bar, and Hex Wrench 1 ea kit

4.0 GOVERNMENT FURNISHED MATERIAL/EQUIPMENT/SERVICES:

4.1 Government Furnished Equipment (GFE): None

4.2 Government Furnished Material (GFM)

4.3 Government Furnished Services (GFS): None 5.0

NOTES:

5.1 The Contractor and all Subcontractors, regardless of tier, must consult the General Technical Requirements (GTRs) 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.

5.2 The Contractor and all Subcontractors, regardless of tier, are advised to review 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 This ship contains High Voltage (HV) electrical systems. The Contractor and all Subcontractors shall obey all posted and verbal instructions regarding safety and exclusion from High Voltage areas. At no time shall a Contractor or Subcontractor approach, work on, or enter a High Voltage area with out proper authorization.

5.4 THE T-AKE ELECTRICAL COLOR CODING DOES NOT FOLLOW CONSISTENT COLOR SCHEME. THE SHIP IS KNOWN TO HAVE CURRENT CARRYING CONDUCTORS COLORED GREEN, BLUE, BLACK AND WHITE. THE CONTRACTOR SHALL ASSUME ALL ELECTRICAL CABLES ARE HOT UNTIL TESTED OTHERWISE. THE CONTRACTOR SHALL TEST ALL ELECTRICAL CABLES TO ENSURE THEY ARE DEAD PRIOR TO WORKING ON THE ITEM.

5.5 All Welding shall be in accordance with ABS rules for building and classing steel ships.

5.6 All Electrical cables and components shall be installed in accordance with the IEEE STD 45 Latest Rev.

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional

7.0 STATEMENT OF WORK REQUIRED:

7.1 General Work Requirements

7.1.1 The Contractor shall provide the services of a Wartsila Technical Representative to oversee and perform all shafting and propeller work described by this work item.

7.1.2 The Contractor shall assist the Wartsila Technical Representative to oversee and perform work associated with evaluation, removal and reinstallation of the ship's rudder.

7.1.3 Contractor shall fabricate and install all necessary hull mounted and rudder mounted pads required to perform rigging operations described by this work item. Rigging pads shall be placed a minimum of 2 inches either side of existing weld seams. Under no circumstances shall pads be welded in way of existing rudder weld seams. Any pads installed shall be removed upon completion of work.

7.1.4 Contractor shall fabricate and install all necessary pads in the shaft alley to rig the hydraulic coupling and tail shaft while performing operations described by this work item. MSCREP will determine which installed pads shall be removed upon completion of work. For bidding purposes assume all pads will be removed.

7.1.5 All pads and rigging equipment regardless of if they are new or previously installed, shall be load tested to a minimum of 110% of load prior to use.

7.1.6 Clean, gas free, and certify safe for hot work the rudder and ship’s hull prior to welding.

7.1.7 The Contractor shall obtain OEM provided material and tools from Wartsila as required.

7.1.8 The Contractor shall remove and reinstall all interferences necessary to perform this work. This shall include but not be limited to the following:

· Bilge and dewatering piping

· Ships Service air piping

· Stern tube deck grating and foundations

· Turning gear assembly including gear ring.

7.2 INITIAL AND REINSTALLED TAIL SHAFT WEAR DOWN READINGS

7.2.1 Prior to any disassembly the shaft wear down readings shall be taken.

7.2.2 The shaft wear down readings shall be taken again after the reassembly of all components.

7.2.3 Shaft wear down reading shall be taken using the feeler gauge method. The rope guard shall be removed prior to taking wear down measurements. Refer to Paragraphs 7.5.10 and 7.5.11 for rope guard removal. The max thickness feeler gauge shall be inserted between the tail shaft and tail shaft bearing at the top, stbd (two locations: 50mm above and below the key), bottom, and port (two locations: 50mm above and below the bearing split).

7.2.4 Reference 2.1.4, Sterntube drawing shows the arrangement of the tailshaft and bearing.

7.2.5 The shaft wear down readings shall be recorded and submitted to the MSCREP via condition report.

7.2.6 ABS, the Chief Engineer and MSCREP shall witness the shaft wear down readings.

7.3 INITIAL AND REINSTALLED RUDDER WEAR DOWN READINGS

7.3.1 Prior to unshipping the rudder, rudder wear down readings shall be taken.

7.3.2 The rudder wear down readings shall be taken again after the reassembly of all components.

7.3.3 Remove the upper rudder seal ring (bolted in two segments) and store for reassembly.

7.3.4 Rudder wear down reading shall be taken using the feeler gauge method. Readings are best taken shortly after rudder is removed. The max thickness feeler gauge shall be inserted between the rudder stock and rudder stock bearing at the fwd, aft, port and stbd positions.

7.3.5 See References 2.1.5 and 2.1.6 for Rudder bearing arrangement.

7.3.6 Measure the gap between the rudder blade and rudder trunk seal ring segments prior to removing the rudder seal ring to verify a 3mm gap as per reference 2.1.7.

7.3.7 Measure the distance between the rudder blade and rudder trunk in both the forward and aft locations. See reference 2.1.5 Rudder Project Arrangement drawing for anticipated clearances.

7.3.8 The rudder weardown and as found readings shall be recorded and submitted to the MSCREP via condition report.

7.3.9 ABS, the Chief Engineer and MSCREP shall witness the rudder wear down readings.

7.4 UNSHIP AND SHIP THE RUDDER BLADE (RUDDER STOCK TO REMAIN IN PLACE)

7.4.1 The base line must be 1200 mm minimum above the dry dock.

7.4.2 The Rudder blade shall be unshipped from the rudder stock to facilitate tail shaft removal.

7.4.3 Unship the rudder in accordance with Reference 2.1.1 sheet 5 instructions.

7.4.4 Remove the rudder blade from the rudder stock in accordance with instructions outlined by Reference 2.1.2.

7.4.5 Cut and remove welded access plate on rudder blade to access the rudder nut.

7.4.6 Scribe mark the rudder stock to the rudder blade for reference when reinstalling the rudder blade on the rudder stock.

7.4.7 Remove the Rudder hydraulic nut cover and locking bar. Do not use excessive heat when removing the locking bar. The nut cover will be full of grease. Clean components, including the removal of grease. Dispose of grease.

7.4.8 Contractor to provide hydraulic pump and tooling to remove rudder hydraulic nut, and pump up rudder blade hub.

7.4.9 Unscrew the hydraulic nut 1-1/2 turns.

7.4.10 Connect hydraulic pump to the rudder hydraulic nut.

7.4.11 Pump up the hydraulic nut piston until it just touches the rudder.

7.4.12 Connect Hydraulic pump to the blade hub. There are three connection points. See Reference 2.1.7 Rudder Cone Coupling Drawing.

7.4.13 Apply pressure on the rudder blade hub until the rudder blade is dislodged from the rudder stock taper.

7.4.14 Slowly release the pressure on the rudder hydraulic nut. This should lower and unseat the rudder blade.

7.4.15 Support the rudder with Chain Falls as per Reference 2.1.1. Rudder blade weighs approximately 28,000 kg.

7.4.16 Remove the rudder nut. Rudder nut weighs approximately 790 kg.

7.4.17 Transport the rudder blade out of the way and set on blocks for temporary storage. Protective covers shall be installed to protect internal surfaces from any dirt or debris. Conical bore shall be protected with light film of hydraulic oil prior to installing temporary covers.

7.4.18 Provide temporary covering over the exposed rudder stock. Rudder stock shall be preserved with grease prior to installation of temporary covering.

7.4.19 All Rudder hydraulic nut o-rings shall be renewed. See Reference 2.1.8.

7.4.20 Renew rudder blade seal ring o-rings. See Reference 2.1.7. These are the seals that go between the rudder blade and the rudder trunk.

7.4.21 Upon completion of tail shaft installation reinstall the rudder blade.

7.4.22 The rudder stock and blade bores shall be cleaned. MSCREP and the Wartsila Representative to witness cleanliness just prior to installation.

7.4.23 Apply hydraulic oil to the conical parts.

7.4.24 Rig the rudder blade onto the rudder shaft per Reference 2.1.1.

7.4.25 Reinstall the rudder hydraulic nut and fitting disc assemble back on the rudder stock. Ensure all new o-rings have been installed. The rudder nut shall have the threads coated with Molycote. The nut shall be run all the way up.

7.4.26 Reinstall the Contractor provided hydraulic pumps to the rudder hydraulic nut and the blade hub. There is one connection for the nut and three connections on the rudder hub.

7.4.27 Pump the rudder hydraulic nut to 50 bar. This is the starting position.

7.4.28 Place a dial gauge on the stock and set it to zero.

7.4.29 Drive the rudder blade onto the rudder shaft while pumping oil into the nut and rudder blade hub. The blade should be driven up 9 mm as per Reference 2.1.5.

7.4.30 The Cone Coupling pull up pressures must be recorded on the Protocol Pull-up sheet provided in the back of Reference 2.1.3 Technical Manual and shown be Enclosure 1.

7.4.31 ABS is to witness Cone Pull up pressures and dimension.

7.4.32 Monitor the pressure on the blade hub and nut. Pressure will rise quickly.

7.4.33 When the rudder blade is in position, slowly release the pressure from the rudder blade hub. Keep the pressure on the nut for 20 minutes. Record rudder measurements as per Paragraph 7.3.6 and 7.3.7. Measurements shall be provided to the MSCREP.

7.4.34 Remove the pumps, tighten the nut and close the oil connections.

7.4.35 Lock the nut with the locking bar. Do not use excessive heat.

7.4.36 Put the cover on the rudder hydraulic nut. Fill the nut with grease. Use Lubriplate Superlubrication 930-AAA or equal. Use new o-ring and loctite 243 on the fasteners.

7.4.37 Weld the rudder access plates back in place. Perform a vacuum box test on rudder access plate welds.

7.5 UNSHIP AND SHIP THE PROPELLER

7.5.1 Ship and unship the propeller in accordance with Reference 2.1.1 Sheet 6.

7.5.2 Remove and reinstall the propeller from the tail shaft in accordance with Reference 2.1.2.

7.5.3 Locate the propeller shaft in the correct orientation to install lifting eyebolt in the propeller boss.

7.5.4 Remove the propeller cap. Reference 2.1.9 shows the propeller cap details. Use lifting 20M eyebolt, part number M713090039 provided by Wartsila.

7.5.5 The propeller cap is filled with grease. Capture and dispose of grease. Clean the propeller cap area.

7.5.6 Transport the propeller cap to the shop and hydrostatically test to 2 bar for ten minutes. MSCREP to witness the hydrostatic test.

7.5.7 Scribe mark the propeller hub to the tail shaft to be used for reference when reinstalling the propeller to the tail shaft.

7.5.8 Remove the plugs in the propeller boss and install the lifting eyebolts as per Reference 2.1.1. Eyebolt sizes are M80 and M64.

7.5.9 Connect rigging in accordance with Reference 2.1.1 Sheet 6 using two each 30 ton air hoists.

7.5.10 Remove the rope guard. See Reference 2.1.12 for details on how the rope guard is welded in place.

7.5.11 Transport the old rope guard to the shop to be refurbished per Paragraph 7.8.

7.5.12 Disconnect the o-ring cover and o-ring from the propeller hub. It is held in place by 12 socket head capscrews.

7.5.13 Remove the propeller hydraulic nut locking segment. It is held in by two hex bolts. See Reference 2.1.14 for details. Shown on Reference 2.1.13 as pieces 62 and 63.

7.5.14 Unscrew the propeller hydraulic nut to the amount of the axial drive up plus 3mm. The axial drive up is 16.8 mm at 0º C and 15 mm at 35º C. See Reference 2.1.10 for temperature correction chart. Do not exceed 20 mm which is the maximum protrusion of the piston of the hydraulic nut.

7.5.15 Unscrew the propeller hub oil connection plugs and install the hub intensifiers and holder per Reference 2.1.2 instructions. The center plug is used for venting the oil. Bleed hub of all air through the center hole.

7.5.16 Install the propeller hydraulic nut intensifiers per Reference 2.1.1 instructions. Bleed the air out of the hydraulic nut and pump the piston of the hydraulic nut just enough to regain contact with the aft face of the propeller boss.

7.5.17 Inject oil into the propeller boss in accordance with Reference 2.1.2 instructions. The propeller should start to move down the taper against the cushioning effect of the hydraulic nut. After the propeller has moved pressure can be relieved from the hydraulic nut and the propeller will slide down the taper. It is important to keep pressure on the propeller boss during loosening of the propeller.

7.5.18 Readjust the location of the propeller nut and repeat if required.

7.5.19 Disconnect and remove pumps. Reinstall plugs on propeller.

7.5.20 Remove propeller and propeller nut from tail shaft. Rig propeller off in accordance with Reference 2.1.1.

7.5.21 Transport propeller to an area for cleaning and polishing.

7.5.21.1 Rig main propeller to Contractor’s designated lay-down area. Block main propeller to prevent damage to blades or hub.

7.5.21.2 Cover main propeller with a heavy tarp. Install temporary blade tip protection on all blades to guard against impact damage.

7.5.21.3 Clean and buff propeller blades and propeller fairwater cap to bright metal.

7.5.21.4 Accomplish NDT-Dye Penetrant tests of all propeller blades, front and back, and including hub.

7.5.21.5 Wartsila Representative to inspect main propeller in accordance with Reference 2.1.

7.5.21.6 Submit “as found" condition report along with NDT results to MSCREP.

7.5.21.6.1 CHECKPOINT: Examine all areas of propeller blades, hubs, and fairwater cap. Inspect for cracks and defects paying particular attention to hub, blade roots and blade edges. MSCREP and ABS Surveyor will attend. Wartsila Representative shall be employed to inspect propeller.

7.5.22 Protect the tail shaft taper area and internals of the propeller hub.

7.5.23 The propeller, propeller hub and tail shaft taper shall be cleaned and presented to ABS for visual inspection.

7.5.24 Reinstall the propeller in accordance with Reference 2.1.1 and 2.1.2.

7.5.25 Lightly oil the propeller bore and tail shaft taper.

7.5.26 Use a new o-ring for the tail shaft /propeller boss retaining ring.

7.5.27 Rig the propeller up the tail shaft taper until no further movement is possible.

7.5.28 Replace the o-rings in the propeller hydraulic nut piston.

7.5.29 Install the propeller hydraulic nut. The position should be in the fully closed position.

7.5.30 Remove the propeller boss hydraulic connection plugs and install the propeller hydraulic boss pump assembly and holder tool.

7.5.31 Install the propeller hydraulic nut intensifier. Bleed air from the hydraulic nut.

7.5.32 Install thermometer on the propeller boss and shaft and let stabilize.

7.5.33 The initial start point load is 500 kN. The start point load is stamped on the propeller. The start point load should be placed on the hydraulic nut without oil injection into the propeller boss.

7.5.34 Install a dial micrometer on the hydraulic nut to measure the push up of the propeller.

7.5.35 Inject oil into the propeller boss with the center vent plug removed until all air is bleed from the propeller. Then reinstall the center plug.

7.5.36 Use Reference 2.1.10 push up diagram to correct for temperature to obtain push up value.

7.5.37 Continue pumping the propeller boss until oil bleeds from the forward end of the boss.

7.5.38 Increase the pressure on the hydraulic nut and propeller boss pumps at the same ratio.

7.5.39 Record the hydraulic nut and boss injector pressures in 1 mm increments as the propeller moves.

7.5.40 When the proper push up has been reached verify with the scribe marks made at disassembly. Required advance distance is determined at the time of installation. Record the final dial indicator movement and pump pressures.

7.5.41 MSCREP and ABS are to witness propeller push-up.

7.5.42 Release the pressure on the propeller boss pump and let stand for 30 minutes.

7.5.43 Release the pressure from the propeller hydraulic nut and screw the nut in until the nut piston is in the fully closed position.

7.5.44 Dye Penetrate (PT) test the propeller hub after the propeller is reinstalled. ABS and MSCREP to witness PT testing.

7.5.45 Reinstall the tail shaft propeller hub o-ring seal.

7.5.46 Reinstall the hydraulic nut locking segment. Use loctite 242. MSCREP to witness locking segment installation.

7.5.47 Reinstall the propeller cap using new o-ring. Torque the propeller cap bolts to 250 Nm. MSCREP to witness torque.

7.5.48 Air test the propeller cap at 2 bars for 30 min. MSCREP to witness air test.

7.5.49 Fill the propeller cap with new grease. Use Mobil Centaur Moly 2 Lubrication/preservative or equal. There are fill and vent holes in the propeller cap. When done filling the plugs shall be torqued to 235 Nm and locked in place.

7.5.50 Reinstall rope guard with new cutters in accordance with Reference 2.1.12. Verify net cutter clearance is in accordance with Reference 2.1.12. MSCREP to witness clearance.

7.5.51 Rope guard shall have new zincs installed.

7.6 UNSHIP AND SHIP THE TAIL SHAFT (PROPELLER SHAFT) AND TEMPORARILY REMOVE INTERMEDIATE SHAFT

7.6.1 Unship and reinstall the tail shaft in accordance with Reference 2.1.1 Sheet 7.

7.6.2 Rotate the shaft to have the lifting point on the hydraulic coupling on the top of the shaft.

7.6.3 Deleted.

7.6.4 Disconnect the shaft turning gear and temporarily move.

7.6.5 Stern tube seal and piping shall be disconnected in accordance with Work Item 0903.

7.6.6 Shaft Grounding device shall be disconnected and temporarily removed. Reinstall at completion of work.

7.6.7 Prior to de-mounting the coupling, Wartsila Representative shall verify and document the following shaft coupling data as per Reference 2.1.2, Paragraph 3.4.1. Submit an “as found” condition report to MSCREP.

7.6.7.1 “T” Mark stamp and distance from coupling sleeve. “T” Mark stamp is located on the tail shaft 50mm aft of coupling sleeve. Reference 2.1.2, Figure 3.2 provides guidance.

7.6.7.2 “A” Dimension stamped on coupling.

7.6.7.3 Coupling outside diameter shall be measured using an outside micrometer. This measurement will be used as an aid to verify coupling diametrical expansion during reassembly.

7.6.7.4 Mark tail shaft to coupling orientation with permanent marker to ensure proper shaft/propeller orientation during reassembly.

*Note: Care shall be taken to ensure permanent markings are not erased during tail shaft and coupling refurbishment.

7.6.8 Circumferentially mark tail shaft at coupling sleeve with permanent marker to aid in verifying the coupling has been drawn back to its original position on the tail shaft during reassembly.

*Note: Care shall be taken to ensure permanent markings are not erased during tail refurbishment.

7.6.9 Remove the hydraulic coupling flange super bolts from the tail shaft/line shaft coupling. Superbolt removal is detailed in Reference 2.1.2. The jacking bolts are to be unloaded in steps. Under no circumstances shall a single jacking bolt be unloaded completely at once.

7.6.10 Loosen each superbolt by loosening each jacking bolt ¼ turn in a circular pattern. When you get back to the first bolt repeat the circular pattern.

7.6.11 The super bolts shall be cleaned and inspected for nicks and or burrs prior to reinstallation. All metal to metal parts on the super bolts are to be lubricated. Lubrication shall be as per the Wartsila Representatives instructions. Do not use Molybdenum disulfide unless specifically instructed by the Wartsila Representative.

7.6.12 Support the tail shaft forward of the stern tube with the trolley rig as shown on Reference 2.1.1 Sheet 7. Detail of trolley rig is shown on Reference 2.1.1 Sheet 13.

7.6.13 Slide the tail shaft aft approximately 1300 mm using the trolley and rigging from outside the ship. Take extreme care not to damage the stern tube bearing during this operation.

7.6.14 Remove the hydraulic coupling from the tail shaft in accordance with Reference 2.1.2.

7.6.15 Contractor shall install lifting eye-bolts and rigging to secure hydraulic coupling in shaft alley.

7.6.16 The coupling shall always be dismounted complete as an assembly. The tapered sleeve and ring shall not be removed from the coupling assembly.

7.6.17 Clean the tail shaft in the area around the coupling.

7.6.18 Maintain a high degree of cleanliness in regards to the hydraulic areas of the coupling.

7.6.19 Use clean pure mineral oil SAE 20/ISO VG46 for hydraulic coupling.

7.6.20 Remove the ¼ inch hydraulic chamber plug shown on Reference 2.1.15 and install a Contractor provide hydraulic pump with pressure gauge and vent/drain valve. Vent hydraulic chamber.

7.6.21 Pump the hydraulic chamber to pressure specified by Wartsila Representative.

7.6.22 Remove ¼ inch vent plug on coupling flange shown on Reference 2.1.15.

7.6.23 Remove ¾" injection plugs on hydraulic coupling.

7.6.24 Install Contractor provide oil injection pumps on the hydraulic couplings and pump until oil leaks out.

7.6.25 Slowly open the drain valve to the coupling hydraulic chamber releasing pressure and slide the coupling back.

7.6.26 Once the coupling has been backed off release the pressure on the oil injection pumps.

7.6.27 Rig the hydraulic coupling to a secure location in the shaft alley. Clean and lubricate the hydraulic coupling. Reinstall injection and vent plugs to maintain cleanliness. Provide temporary protection for the coupling.

7.6.28 Temporarily remove intermediate shaft and rig in location in shaft alley to allow for optical alignment readings. The intermediate shaft is to be temporarily removed to allow for a clear line-of-sight from the aft end of the thrust shaft to the aft end of the stern tube. This process involves temporary removal of the line shaft bearing upper housing, and the temporary removal of the stern tube bulkhead seal between the Propulsion Motor Room and the Shaft Alley. Install pad eyes as necessary to accomplish the rigging and unrigging of the shaft for temporary storage. Use Reference 2.1.16 as guidance. Properly protect the line shaft bearing and bulkhead seal.

7.6.29 Upon completion of optical alignment, reinstall intermediate shaft. Reinstall line shaft bearing housing and bulkhead seal. Bulkhead seal will not be rebuilt at this time and deferred to the 5 year dry-dock.

7.6.30 Move the tail shaft aft to install the tail shaft extension tool on the fwd end of the tail shaft. Install shaft bumper tool to shaft extension tool. See Reference 2.1.1 Sheet 12. Torque bolts to 1500 ft-lbs.

7.6.31 The shaft is to be centered in the stern tube.

7.6.32 Continue to remove the tail shaft aft outside the ship until it can be rigged by a crane and transport to the shop for inspection.

7.6.33 Transport the tail shaft to a shipyard shop for inspection.

7.6.34 Remove split stern tube bearing in accordance with Reference 2.1.2 after tail shaft is removed.

7.6.35 Stern tube bearing retaining ring must be removed to remove the bearing. It is shown by Reference 2.1.4 as piece 7. It is held in place by twelve (12) each hex head bolts.

7.6.36 Renew the stern tube bearing retaining ring with thicker ring as per sample and drawing provided.

7.6.37 Use the key extraction tool to extract the stern tube key in accordance with Reference 2.1.2. When the tapered key has been extracted enough to be removed by hand pull out and store for reinstallation. Remove the lower key section that is bolted into the stern tube. Clean the bolt holes and protect bolt holes for stern tube machining and Belzona application.

7.6.38 The old bearing parts and the stern tube shall be keep for further investigation. Box the old bearing parts for shipment. MSC will provide shipping address.

7.6.39 MSCREP and ABS shall perform a visual inspection of the stern tube and old bearing.

7.6.40 Measure the inside diameter of the stern tube in way of the stern tube bearing. MSCREP and ABS shall perform a visual inspection of the stern tube.

7.6.41 Upon completion of the tail shaft and stern tube machining, coating and inspection, install the new stern tube bearing and reinstall the tail shaft in the opposite order of removal.

7.6.42 Machine and install the new stern tube bearing in accordance with paragraph 7.10.

7.6.43 Install the stern tube seal section that must fit over the tail shaft per Work Item 0903.

7.6.44 The tail shaft shall be centered in the stern tube.

7.6.45 Move the shaft forward and remove the shaft extension tool. Position the shaft as required allowing hydraulic coupling installation.

7.6.46 Reinstall the tail shaft hydraulic coupling to the tail shaft in accordance with Reference 2.1.2.

7.6.47 The tail shaft and hydraulic coupling shall be cleaned prior to reassembly. Clean the shaft and coupling bore with SHELLSOL 16.

7.6.48 Install new o-rings on the hydraulic coupling. Two o-rings on the seal ring and one on the flange face.

7.6.49 Lubricate the tail shaft in way of the coupling with mineral oil SAE20/ISO VG 46. OILS WITH ANTI FRICTION ADDITIVES ARE STRICTLY FORBIDDEN.

7.6.50 Verify the shaft orientation with removal marks so the shaft will be lined up with the coupling in the same position as before removal.

7.6.51 Rig the hydraulic coupling onto the tail shaft end. Slide the coupling into position so the distance between the "T" mark and the end of the coupling sleeve is 50mm.

7.6.52 Measure and record the hydraulic coupling outside diameter with an outside micrometer. This measurement will be used as the base number to calculate the coupling diametrical expansion.

7.6.53 Install the oil injection pumps and the oil chamber pump as per Reference 2.1.2.

7.6.54 Pressurize the injection pumps until oil comes out the mating surfaces.

7.6.55 Start to pressurize the oil chamber pump to drive up the flange.

7.6.56 Drive the coupling up until the distance from the coupling end to the sleeve is equal to "A" dimension stamped on coupling. The distance stamped on the coupling should be 102.3mm. NOTE: During new ship construction the piston pressure used was 2,800 PSI and the injection body pressure was 18,700 PSI to obtain the proper drive up.

7.6.57 Release the coupling body pressure and wait 15 minutes until releasing the pressure on the piston chamber. Measure and record coupling outside diameter with an outside micrometer. Reinstall the plug on the piston and wait 2 hours prior to reinstalling the plugs in the coupling.

7.6.58 Calculate hydraulic coupling diametrical expansion using base number recorded in 7.6.56. Diametrical expansion shall be 0.904 +0.04 /-0.0.

7.6.59 Seal the gap between the coupling sleeve and the shaft with Densyl tape.

7.6.60 MSCREP and ABS shall witness hydraulic coupling drive up.

7.6.61 Pull the tail shaft the remaining way into position. Verify the line shaft and tail shaft are aligned back to their original relative orientation.

7.6.62 Ensure that the 0-ring on the hydraulic coupling flange has been renewed and is still positioned correctly.

7.6.63 Reinstall the hydraulic coupling flange superbolts in accordance with Reference 2.1.2.

7.6.64 Use a star pattern when tightening the flange superbolts.

7.6.65 Use a star pattern when tightening the superbolt jackbolts.

7.6.66 The hydraulic flange superbolts jack bolts shall be torqued to 220 Nm. MSCREP to witness jackbolt torque.

7.6.67 Reinstall the jacking gear removed as interference.

7.6.68 Reinstall shaft grounding removed as interference.

7.7 INSPECT THE TAIL SHAFT AND STERN TUBE BEARING

7.7.1 Perform spark test on tail shaft coating. MSCREP and ABS shall witness spark test.

7.7.2 Present the stern-tube, stern tube bearing and tail shaft to MSCREP and ABS for a visual inspection. All items shall be cleaned and laid out for inspection. MSC is in a continuing investigation to determine root cause of recent stern tube bearing failures. Additional data is required to aid in their investigation.

7.7.3 The tail shaft shall be placed in shipyard lathe for run out readings and inspection. Shipyard shall be able to provide a lathe large enough to accommodate the tail shaft.

7.7.4 The tail shaft fwd and aft liners shall be cleaned/polishied. Based on inspection results below, MSCREP N7 will determine depth if any skim cuts required on existing liners. NOTE: It is not the intent to replace shaft liners at this time, therefore excessive material shall not be removed during liner clean up.

7.7.5 The Contractor shall provide the following as found and as restored condition reports to MSC:

7.7.6 As found Shaft Measurements and as found Stern Bearing and Stern Tube Measurements.

7.7.6.1 FWD Liner

7.7.6.1.1 Diameter, minimum of 3 axial locations, 2 orthogonal readings at each location.

7.7.6.1.2 Deleted

7.7.6.1.3 Deleted

7.7.6.1.4 Inform and allow MSC time to photograph as found condition of liner.

7.7.6.1.5 Deleted.

7.7.6.1.6 Radial run-out readings; minimum of 2 axial locations; shaft supported solely at the ends.

7.7.6.2 AFT Liner

7.7.6.2.1 Diameter, minimum of 3 axial locations, 2 orthogonal readings at each location.

7.7.6.2.2 Deleted.

7.7.6.2.3 Deleted.

7.7.6.2.4 Inform and allow MSC time to photograph as found condition of liner.

7.7.6.2.5 Provide MSC three samples of non-liner material surface growth or coating in clean plastic sample bottles. Cap the bottles once the sample is taken.

7.7.6.2.6 Radial run-out readings; minimum of 2 axial locations; shaft supported solely at the ends.

7.7.6.3 Propeller Taper

7.7.6.3.1 Radial run out readings; minimum of 3 axial locations; shaft supported solely at the ends.

7.7.6.3.2 MT NDT of taper surface, MSCREP and ABS to witness MT.

7.7.6.3.3 Allow opportunity for MSC to photograph as found condition of taper condition.

7.7.6.4 Stern Tube Bearing Measurements Prior to Removal From Stern Tube

7.7.6.4.1 Bearing inner diameter readings; Per Thordon measurement method which includes 7-8 axial locations.

7.7.6.4.2 Record bearing temperature at time of measurement.

7.7.6.4.3 Allow measurement instruments to acclimate to bearing temperature.

7.7.6.5 Stern Tube Measurements(coordinate with machining of stern tube)

7.7.6.5.1 Measurements taken under the direction of the Bearing OEM Representative

7.7.6.5.2 Record tube temperature at the time of the measurements.

7.7.6.5.3 Allow measurement instruments to acclimate to tube temperature.

7.7.6.5.4 Deleted

7.7.7 As Restored Shaft Measurements and as Restored Stern Tube and Stern Bearing Measurements (coordinate with machining of stern tube)

7.7.7.1 FWD Liner

7.7.7.1.1 Diameter, minimum of 3 axial locations, 2 orthogonal readings at each location.

7.7.7.1.2 Radial out readings; minimum of 2 axial locations; shaft supported solely at the ends.

7.7.7.1.3 Surface roughness of liner.

7.7.7.1.4 Deleted.

7.7.7.1.5 Contractor shall allow MSC time to photograph as restored condition of liner.

7.7.7.2 AFT Liner

7.7.7.2.1 Diameter, minimum of 3 axial locations, 2 orthogonal readings at each location.

7.7.7.2.2 Radial out readings; minimum of 2 axial locations; shaft supported solely at the ends.

7.7.7.2.3 Surface roughness of liner.

7.7.7.2.4 Deleted.

7.7.7.2.5 Contractor shall allow MSC time to photograph as restored condition of liner.

7.7.7.3 Stern Tube Measurements and Machining Prior to Bearing Installation

7.7.7.3.1 Bearing fit length inner diameter readings; Measure as per Thordon Rep, Typ 7 or 8 axial locations.

7.7.7.3.2 Record tube temperature at the time of the measurements.

7.7.7.3.3 Allow measurement instruments to acclimate to tube temperature.

7.7.7.3.4 Surface roughness of bearing fit length.(taken for coating application)

7.7.7.4 Stern Bearing Measurements After Installation

7.7.7.4.1 Bearing inner diameter readings; Measure as per Thordon Rep, Typ 7 to 8 axial locations.

7.7.7.4.2 Record bearing temperature at time of measurement.

7.7.7.4.3 Allow measurement instruments to acclimate to bearing temperature.

7.8 STERN TUBE COATING AND MACHINING IN STERN TUBE BEARING AREA

7.8.1 Provide a BELZONA Technical Representative to oversee the coating of the stern tube in the stern tube bearing area. BELZON Technical Representative shall witness all tests. BELZONA Technical Representative will keep a log book of inspections and applications (final surface preparation, stripe coat, 1st and second coat). The MSCREP will take pictures of each step. The BELZONA Technical Representative shall submit a service report to MSCREP.

NOTE

BLASTING, COATING, AND MACHINING THE STERN TUBE BEARING HOUSING AREA IS COVERED UNDER THIS WORK ITEM. STERN TUBE IS COATED WITH BELZON. THE REMAINDER OF THE STERN TUBE BELZONA REPAIRS ARE COVERED BY WORK ITEM 912.

7.8.2 Provide containments required for proper working conditions and inspections.

7.8.3 Provide and maintain adequate lighting of a suitable nature during the course of all surface preparation, coating and inspection activities.

7.8.4 Remove, store and re-install interferences as required to accomplish the work specified.

7.8.5 Temporarily install drop cloths, masking, division shields, seals, blanks and filtering materials to prevent abrasives and foreign substances from entering lights, machinery, piping, hatches, deck drains, ventilation systems, tank vents, motor shafts, seals and temporary openings during blasting and painting operations.

7.8.6 Pressure wash the interior of the stern tube to remove foreign materials.

7.8.7 Blast the interior of stern tube in the stern tube bearing housing area to an SSP-10 near white metal finish, achieving a minimum of 75 microns profile using an angular grit.

7.8.8 Pressure wash the interior of the stern tube in the stern tube bearing housing area to remove chloride contaminants and bacteria from the metal using 5 to 10kpsi equipment. Add “Salt Away” to the cleaning solution to assist with the removal of chlorides.

7.8.9 Test for chlorides and presence of BELZONA Technical Representative. If excess chlorides are found, repeat the cleaning procedures. Standard to achieve is less than 20mg/m2 (2μg/cm2).

7.8.10 Deleted.

7.8.11 Blast the interior of the stern tube in the stern tube bearing housing area a second time as in Paragraph 7.9.7 to remove flash rust and maintain the minimum 3 mil profile.

7.8.12 Remove dust and debris. Wipe surface with clean lint free rag using MEK, Acetone, or equivalent.

7.8.13 Test blast profile using Testex tape. Look for a minimum 3 mil profile and a dense blast pattern. A minimum of five test areas are required.

7.8.14 Measure and record the inner diameter of the stern tube bearing housing prior to coating. This is accomplished per the Thordon measurement method which includes 7-8 axial locations

7.8.15 Degrease Bearing tube Area

7.8.16 Brush Blast entire area to be coated

7.8.17 Apply a Belzona Super Metal Glide, p/n 1341, to a 175 to 250 micron thickness to mate with remainder of stern tube coating. Spark test Coated area; 120V sponge test (one pass only

7.9 STERN TUBE MACHINING

7.9.1 Provide the services of a firm specializing in in-place machining in a shipyard environment and accomplish offset machining of the coated stern tube bearing housing area to compensate for misalignment measured in 7.14 through 7.14.9.

7.9.2 Machine the stern tube bearing housing area to remove ovality and adjust alignment. Anticipated extent of ovality (difference between the vertical inner diameter and horizontal inner diameter) is 1.5mm. Anticipated extent of vertical and/or horizontal offset is 1.0mm. Actual machining and bar offset values will be provided by the MSC N7 technical representative through the MSC on-site Overhaul Management Team (OMT).

7.9.3 The tooling and equipment used to machine the stern tube shall have the following characteristics:

- Allow uninterrupted machining of the full length of the stern tube bearing housing.

- The boring bar shall be capable of being adjusted vertically and horizontally at each end to a resolution of 0.001”.

- The boring bar cutting tool shall be capable of being adjusted to a resolution of 0.001”.

7.9.4 The Contractor shall measure and record the inner diameter of the stern tube bearing housing after all machining. This is accomplished per the Thordon measurement method which includes 7-8 axial locations.

7.9.5 Deleted

7.9.6 The following notes and requirements pertain to the aforementioned machining and measurement actions:

7.9.6.1 All instruments used in acquiring bearing housing diameter, surface finish, and boring bar adjustment shall been in a valid state of calibration traceable to a NIST certified calibration standard.

7.9.6.2 All instruments used in acquiring bearing housing diameter measurements shall be thermally stabilized to the stern tube temperature prior to taking readings.

7.9.6.3 The surface finish of the stern tube bearing housing prior to bearing installation, either the stern tube metal or the filler material, shall be that required by the bearing OEM.

7.9.6.4 The Contractor shall provide one hard copy and one electronic copy of all measurements to the MSC on-site Overhaul Management Team (OMT) and MSC N7 technical representative within one day of taking the measurements.

7.10 RENEW STERN TUBE BEARING

7.10.1 Measure the GFM stern tube bearing’s I.D and O.D and compare to the as released stern tube measurements.

7.10.2 Machine the GFM bearing under the guidance of the Thordon Representative. The Thordon Representative shall verify measurements stated in 7.7 prior to machining the bearing.

NOTE: New stern tube bearing stock (GFM) provided in an un-machined condition. Machining consists of mounting on stern tube bearing (machining/turning) jig (GFE, turning ID and OD, Machining horizontal joints, grooves, and tapers.

7.10.3 Install the new bearing segments under the guidance of the Thordon Rep.

NOTE: Stern tube bearing OD to stern tube ID is an interference fit. Bearing shall be cooled under the direction of the Thordon Rep prior to installation of bearing segments and bearing key.

7.10.4 Install the new bearing retaining ring.

7.10.5 Extreme care shall be taken to ensure concentricity of the stern tube area throughout the entire length. Ensure the machined shoulder of the Fwd Stern Bearing Retainer is square. Ensure the area of the tube in way of the stern tube is concentric, no high spots.

7.10.6 The Contractor shall take a full set of ID measurements after the bearing is installed and temperatures have normalized. This is accomplished per the Thordon measurement method which includes 7-8 axial locations.

7.11 RENEW ROPE GUARD AND INSTALL NEW LINE CUTTERS

7.11.1 The new rope guard shall be grit blasted to bare metal and the weld prep area machined for reinstallation.

7.11.2 Cut 4 access holes 8” diameter at the 12, 6, 3 and 9 o’clock marks.

7.11.3 Install new rope guard anode studs, in accordance with Reference 2.1.12. Eight (8) each Bolts with heads removed, 3/8" X 1-3/4 304 SST.

7.11.4 New zinc anodes for the rope guard are to be provided by Work Item 0908.

7.11.5 Install new net cutters in accordance with Reference 2.1.12. Contractor may fabricate new rope cutters in accordance with Reference 2.1.12 details.

7.11.6 Coat rope guard in accordance with Reference 2.1.12 requirements with Hempel Shop primer 15280 and Hempadur Mastic 45880.

7.12 FLOAT COAT THE RUDDER AND BILGE KEELS

7.12.1 Accomplish an air test of the rudder and bilge keels at 1-1/2 psi for 10 minutes. Provide secondary relief to ensure rudder is not over pressurized. Inspect the rudder blade and bilge keels for any leaks. Any leaks will be weld repaired via condition report.

7.12.2 Preserve the rudder and bilge keels with penetrating marine preservative "Magnakote" manufactured by Drew Marine Division of Ashland Chemical Co or equal, applied in accordance with manufacturer's instructions. Preservative shall have the following characteristics:

-Forms a soft or semi-soft film.

-Is rust penetrating.

-Is not salt water soluble.

-is non-polluting (will not produce a sheen on water) and /or is self oxidizing

-Has a flash point of not less than 100 degrees F (38 degrees C)

7.13 STRAIN GAUGE READINGS AND OPTICAL ALIGNMENT MEASUREMENTS

7.13.1 Perform four (4) complete sets of strain gauge readings and one (1) set of optical alignment measurements.

7.13.2 For optical alignment measurements, the intermediate shaft will be temporarily removed from its installed position to allow a clear line-of-sight from the aft end of the thrust shaft to the aft end of the stern tube. The optical alignment measurements are to be taken of the stern tube bearing bore relative to the aft end of the thrust shaft. Alignment datum is to be a line-of-sight normal to the aft face of the thrust shaft and centered with rotation of the thrust shaft. Alignment readings are to be recorded at three (3) axial locations: a. Forward end of the stern tube bearing seating area, b. Aft end of the stern tube bearing seating area, c. Stern tube seal mounting flange. Record shaft alignment readings of the reduced three bearing shafting system comprised of the motor and thrust shafts at the time of the optical measurements.

7.13.3 Strain gauge readings and optical alignment measurements are to be taken as follows.

7.13.3.1 First Set of Strain Gauge Readings – Pier side, prior to entering dry dock.

7.13.3.2 Second Set of Stain Gauge Readings - In dry dock, prior to any propeller shaft work.

7.13.3.3 Optical Alignment Measurements – In dry dock, after tailshaft and intermediate shaft are temporarily removed.

7.13.3.4 Third Set…