908_A_STBD Rudder and Rudder Stock Renewal Rev A.doc

USNS GRAPPLE

(T-ARS 53)

DRYDOCKING AND UNDOCKING

N32205-15-R-4008 April 15 2015

ITEM NO. 908

CATEGORY “A”

MSC/WTB

STARBOARD RUDDER AND RUDDER STOCK RENEWAL

1.0 ABSTRACT: This item describes the requirement to remove the starboard (STBD) rudder stock and install a new (GFM) rudder stock and rudder. Inspect the port rudder and rudder stock.

2.0 REFERENCE/ENCLOSURES

2.1 Reference

2.1.1 NAVSEA DWG 562-5763333, Rev G, Rudder Stock & Details

2.1.2 NAVSEA DWG 562-5763332, Rev C, Rudder

2.1.3 NAVSEA DWG 562-6584210, Rudder Post Seal Modification

2.1.4 NAVSEA DWG 562-6584211, Rudder Bearing Lubrication Modification

2.2 Enclosure: Wartsila Drawing US72718-01, Rev B, Upper Seal Drawings and Upper Seal O/H Kit details, ARS Installation 3.0

ITEM LOCATION/QUANTITY

3.1 Location: STBD Fantail, Frame 102, and Steering Gear Rm (2-100-0-E)

3.2 Quantity

3.2.1 One (ea) new rudder and rudder stock (GFM)

3.2.2 Two (2) sets, Busting keys and wedges

3.2.3 Gaskets, packing, lockwire, studs, bolts, cap screws, nuts, washers, pipe plugs, keys, cotters, grease fittings and locks, Permatex sealant, packing, quantities as required per Ref 2.1.1, List of Materials.

4.0 GOVERNMENT FURNISHED MATERIAL/SERVICE

4.1 New Rudder

4.2 New Rudder Stock

4.3 GFM: All oils, as required

4.4 2 ea, ARS ER Major O/H Kit, per Wartsila Dwg JCL001078-00C Rev C, see Encl 2.2

4.3 Rudder Seals ( see Ref 2.1.2)

a. 2 ea, LUP Seal, Johns-Manville p/n 18146 H1L5, 13.5”, Item 24,

b. 4 ea, LUP Seal, Johns-Manville p/n 16365 H1L5, 10.0”, Item 57

c. 4 ea, LUP Seal, Johns-Manville p/n 9030 H1L5, 14.0” , Item 43

4.3 ABS Surveyor

4.4 All paint.

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.

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 Maintain cleanliness of the job site to ensure components are not contaminated.

5.4 Coordinate with the Chief Engineer to designate a clean, dry area for safekeeping of removed seals, liners and fasteners.

5.5 All openings the ship and components subject to contamination shall be closed immediately using gaskets and blanks or mechanical plugs or caps.

a.

Cofferdams with covers (two sets) shall be constructed and installed over the openings resulting from removal of main deck rudder carrier bearing covers. Provide cofferdams and covers immediately upon unbolting the carrier bearing cover plates.

5.6 No contamination generating operations shall be performed in the area of the job site while system components are open and exposed.

5.7 All machined or finished surfaces subject to damage shall be masked and/or wrapped

6.0 QUALITY ASSURANCE REQUIREMENTS: None additional.

7.0 STATEMENT OF WORK REQUIRED

7.1 Arrangement and Outfitting

7.1.1 Coordinate with the Chief Engineer to tag-out/lock-out power to the rudder control system and motors.

7.1.2 Furnish and erect staging to facilitate access to the port and STBD rudder and rudder post.

7.1.3 Weld pad eyes to the hull, as required, for removal and reinstallation of rudder components.

7.1.4 Pad eyes shall be sized to accommodate anticipated loads.

7.1.5 All pad eyes shall be tested to 1-1/2 times the anticipated load.

7.1.6 Caution: All welding grounds to be made in such a way that ground current does not go through the Rudder or stock.

7.2 Mechanical/Fluids

7.2.1 Remove the STBD upper carrier bearing cover.at main deck aft.

a. Drill out all screw holes to remove Helicoil inserts and to enlarge to next screw size larger than Helicoil threads.

b. Re-drill countersink holes in both covers to match larger, approximately CRES 5/8”screws. Renew all fasteners with CFM.

c. Note: Contractor shall drill all holes using magnetic base drill press to insure quality work.

7.2.2 Remove the upper and lower rudder stock seal retainers and bearing retainers, seals and packing.

7.2.3 Measure and record rudder stock bearing clearances. Submit as-found condition report to the MSCREP.

7.2.4 Certify the rudder, stern area and after steering are safe for men and hot work by a Marine Chemist.

7.2.5 Remove (unship) the STBD rudder stock, sleeve and bearing.

a.

Manufacture two sets of busting keys and wedges for unshipping the rudders from its rudder stock in accordance with Ref 2.1.2.

b.

Clean exposed surfaces and parts free of oil and foreign matter leaving no residue on stock.

7.2.6 Convey the STBD stock to a machine shop lathe and perform run-out measurements on the stock. Inspect the stock for wear and defects. Measure and record sizes and clearances for wear and physical condition. Submit an as-found condition report to the MSCREP.

a. Remove burrs, high spots, nicks corrosion and foreign matter from wear and sealing surfaces.

b. Chase and tap exposed threads.

c. Clear and clean pockets and passages on the stern frame and rudders, free of obstructions and foreign matter.

d. Crate or palletize the stock for shipping. MSC will provide transportation to ship out.

Note: A contract modification will be issued to cover additional repair[s on the stock.

7.2.7 Mount the new rudder blade (GFM) vertically and blue-fit the new rudder stock (GFM) to the blade. Call-out the MSCREP to inspect contact area.

a.

Verify contact (fit) using bluing method. Contact shall be a minimum of 60 percent of total surface area, evenly distributed over 100 percent of the area.

7.2.8 Re-assemble, fit and install (ship) the STBD rudder assembly, components and disturbed steering equipment.

a. Fit and install new gaskets, square packing, lock wire, studs, bolts, screws, nuts, washers, plugs, keys, cotters, grease fittings, locks and the new GFM parts per Encl 2.2 and Para 4.3 & 4.4.

b. Measure final sized and clearances. Submit final condition report to the MSCREP.

a. Lubricate the new rudder stock bearing in accordance with Ref 2.1.2 with corrosion preventative compound conform to MIL-C-117976, Class 1A: Fill the angular groove between rudder and rudder stock sleeve

b. Coat rudder stock interior, key and keyway.

7.3.0 Rig and install the rudder blade in place. Fabricate and provide a new rudder pin/keeper key. Machine the stock keyway in accordance with reference 2.1.1. Final pin installation is to be witnessed by the ABS surveyor and MSC rep. prior to installing the keeper plates. Insure ABS and MSC rep. whiteness the installation of the keeper plates. Weld rudder access plates in place and test the welds in accordance with ABS requirements.

7.3.1 Port Rudder Inspection: Remove the two access plates in way of the rudder stock keeper pin; inspect the pin/keeper key and keeper plates holding the pin. Provide a condition survey of the existing rudder and keeper pin area. Reinstall the access plates after the inspection. Test welds in accordance with ABS requirements. Prime and paint the areas around the access plates. Build up three coats of AF paint around the access plates.

7.4 Painting: The new rudder and rudder stock will arrive at the yard with an epoxy primer coat installed. After the rudder and rudder stock are installed and after all testing; Apply one coat 5-6 mils DFT of AC to the entire rudder and a part of the rudder stock. Apply three (3) coats of AF as called for on the ship’s paint schedule. All paint is GFM.

7.3 Testing

7.3.1 Coordinate with the Chief Engineer to operationally test the rudder and associated equipment in conjunction with undocking, dock and sea trials.

a.

No seal leaking is allowed.

7.3.2 Submit final as-repaired/as-tested condition report to the MSCREP.

7.4 Technical Representative: Provide the services of a recognized Wartsila (John Crane) Company Technical Representative to provide on-site technical assistance and guidance for the removal, installation of the rudder seals.

8.0 GENERAL REQUIREMENTS: None Additional

Enclosure 2.2

EMBED AcroExch.Document.7

EMBED AcroExch.Document.7 908-4

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ITEM. DESCRIPTION GA DWG NO. QTY DETAIL PART NO. REVISION DATE

A Dwg created for proposed 5.6.2001

001 SCREW, HOUSING BUTT US72718-01-1-2 4 H44254-5-A05 installation refurbishment

002 DOWEL, HOUSING US72718-01-1-3 2 H44778-2-A05 B Removed spacer and updated 24.1.2003

003 SEAT (SPLIT) US72718-01-2-1 1 H72718-01/2 format.

004 SEALING STRIP, SEAT US72718-01-2-2 1 H41863-1277-F03 C 10.19.05

005 SCREW, CLAMP BUTT US72718-01-3-2 2 H80281-A05

006 DOWEL, CLAMP US72718-01-3-3 2 H42716-01-A05

007 FACE (SPLIT) US72718-01-4-1 1 H72718-01/4/H85064-G20

008 BODY (SPLIT) US72718-01-5-1 1 H72718-01/5

009 SCREW, SPACER US72718-01-6-2 2 H44254-4-A05

010 DOWEL, SPACER US72718-01-6-3 2 H42016-2-A05

011 O-CORD, SPACER US72718-01-6-4 1 H45112-3-1017-F03

012 SCREW, DRIVE CLAMP RING BUTT US72718-01-7-2 6 H44254-5-A05

013 COMPRESSION TOOL ASSY US72718-01-CT 1 H72718-01-CT

SEAL DWG. H72718-01 REV:A 1

OVERHAUL KIT PART NUMBER JCL001078-000 1

CONT. NO.

3617 Koppens Way, Chesapeake, VA 23323

DRN:KAR

CHK: AA ES RUDDERSTOCK SEAL

APP: ARS CLASS

Date:01/29/03 Size DWG. NO. REV.

JCL001078-000C C

MAJOR OVERHAUL KIT DWG US72718-01

Revised kit to standardize content

DESCRIPTION

Notes:

1. This kit contains the minimum OEM recommended parts for the complete overhaul of US 72718-01 ES type seal for the ARS class.

2. All Wartsila parts are covered under our standard Terms and Conditions and warranted against manufacturing defects. Available upon request.

3. A repair kit for face insert replacement or body assembly replacement can be supplied on request, if required.

4. The recommended normal duty operational life of the Bellows assembly is 5 to 7 years. The bellows assembly should be replaced at regular overhauls to insure this limit is not exceeded.

5. Rubber Body (5-1) assembly requires hot vulcanizing with the appropriate fixture for proper operation.

6. Contact Wartsila Service department for installation and warranty. Telephone 757-558-3625

Wartsila-Lips, Inc

P: 757- 558-3625 F: 757-558-3627

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