0903_A_PROPELLER_SHAFT_AND_STERN_TUBE_INSPECTION_REV_A(6Apr17).docx

USNS CESAR CHAVEZ

(T-AKE 14)

PROPELLER SHAFT AND STERN TUBE INSPECTION

1.0 ABSTRACT

1.1 This work item describes the requirements to of removing the existing/installed tailshaft and crating for overhaul under a separate contract and installing a refurbished shore based spare tailshaft. Also to be accomplish are the following:

2.0 REFERENCES/ENCLOSURES

2.1 References:

2.1.1 NAVSEA Drawing No. 243-7488962 Revision G, Shaft Arrangement

2.1.2 T/M T9243-AZ-MMC-010 Fixed Pitch Propeller and Shafting with Bearings Model W084836780

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

2.1.4 Wartsila Drawing W084837233 Revision E, Ass Stern Tube

2.1.5 Bot Groningen Drawing 1.1262/1/1 A1, Rudder Project Arrangement

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

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

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

2.1.9 Wartsila Drawing WLP001616-001, Assembly Propeller Cap

2.1.10 Wartsila Drawing W084836779, Propeller Boss

2.1.11 Wartsila Drawing W084838596, Assembly Propeller Hydraulic Nut

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

2.1.13 Wartsila Drawing W084837232, Arrangement Shafting; Spare Parts

2.1.14 Wartsila Drawing W007420313, Round Nut Locking

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

2.1.16 MIL-STD-2199A Department of Defense Standard Practice: Coverings for Waterborne Main Propulsion Shafting on U.S. Naval Surface Ships and Submarines (26 July 2010)

2.2 Enclosures

2.2.1 Rudder Pull-up Cone Coupling Protocol Sheet

2.2.2 Propeller Push-up Data Conversion Table

2.2.3 Shaft Coupling Super-Bolts

3.0 ITEM LOCATION/DESCRIPTION

2.3 Location/Quantity

2.3.1 Location

2.3.2 Quantity

3.1 Description of Equipment/Systems

Component Weights

3.2 Bill of Materials (Contractor Furnished Materials)

Contractor Furnished Materials (CFM)

NASSCO Drawing 471-351-4984; Pc 2

NASSCO P/N LMCH-1002;

Shipyard may fabricate based on reference 2.1.12 details.

4 each

NASSCO Drawing 471-351-4984; Pc 5 Bolt 3/8" X 1-3/4 Long, SST 304 8 each

NASSCO Drawing 471-351-4984; Pc 6 Nut hex Self Locking 3/8-16, SST 304 8 each

NASSCO Drawing 471-351-4984

4 each

Hempadur Mastic 45880 12170 Grey;

Hempadur Mastic 45880 Haze Gray FSC 26270 As Required

Enecon DurAlloy

1-2 kg units Approx.

CeramAlloy CL+AC

6 sq. ft.

Approx.

1x1 kg units

Rudder Hydraulic Nut O-Ring (Between the Fitting Disc and Nut) *Included in T-AKE Rudder O-Ring OEM Kit, P/N WLP001326-006 Wartsila Rep to Provide- Ref 2.1.8 Bot-Groningen Drawing 2.1264/2.1 Hydraulic Nut Parts List Part No. 2 6mm Diameter Thick NBR 65º SH 1 each

Rudder Hydraulic Nut O-Ring (O.D Piston Ring O-Ring) *Included in T-AKE Rudder O-Ring OEM Kit, P/N WLP001326-006 Wartsila Rep to Provide- Ref 2.1.8 Bot Groningen Drawing 2.1264/2.1 Hydraulic Nut Parts List Part No. 4 6mm Diameter Thick

NBR 65º SH

1 each

Rudder Hydraulic Nut O-Ring (O.D Piston Ring O-Ring) *Included in T-AKE Rudder O-Ring OEM Kit, P/N WLP001326-006 Wartsila Rep to Provide- Ref 2.1.8 Bot-Groningen Drawing 2.1264/2.1 Hydraulic Nut Parts List Part No. 5 6mm Diameter Thick

NBR 65º SH

1 each

Rudder Hydraulic Nut O-Ring (O.D Piston Ring O-Ring) *Included in T-AKE Rudder O-Ring OEM Kit, P/N WLP001326-006 Wartsila Rep to Provide- Ref 2.1.8 Bot-Groningen Drawing 2.1264/2.1 Hydraulic Nut Parts List Part No. 7 6mm Diameter Thick

NBR 65º SH

1 each

Rudder Hydraulic Nut O-Ring (Between the Fitting Disc and Rudder Blade) *Included in T-AKE Rudder O-Ring OEM Kit, P/N WLP001326-006 Wartsila Rep to Provide- Ref 2.1.8 Bot-Groningen Drawing 2.1264/2.1 Hydraulic Nut Parts List Part No. 9 6mm Diameter Thick

NBR 65º SH

1 each

Rudder Seal Ring O-Ring (Between Lower Segmented Seal Ring and Rudder Blade) *Included in T-AKE Rudder O-Ring OEM Kit, P/N WLP001326-006 Wartsila Rep to Provide- Ref 2.1.7 Bot-Groningen Drawing 2.1263/1.1 Cone Coupling Part No. 4 6mm Diameter Thick

NBR 65º SH

1 each

Rudder Seal Ring O-Ring (Between Lower Segmented Seal Ring and Rudder Stock) *Included in T-AKE Rudder O-Ring OEM Kit, P/N WLP001326-006 Wartsila Rep to Provide- Ref 2.1.7 Bot-Groningen Drawing 2.1263/1.1 Cone Coupling Part No. 7 12mm Diameter Thick

NBR 65º SH

1 each

Rudder Seal Ring O-Ring (Between Upper Segmented Seal Ring and Rudder Trunk) *Included in T-AKE Rudder O-Ring OEM Kit, P/N WLP001326-006 Wartsila Rep to Provide- Ref 2.1.6 Bot-Groningen Drawing 3.1265/1.1 Rudder Trunk Summary Part No. 6 12mm Diameter Thick

NBR 65º SH

1 each

Wartsila Drawing W084827066 Pc 3 NBR 70 Shore

ID 932.5 X7

Wartsila Detail Drawing W007040014 1 each

Wartsila Drawing W084827066 Pc 8, NBR 70 Shore, ID 932.5 X7 Wartsila Detail Drawing M713000290 2 each

Ref 2.1.11 Wartsila Drawing W084838596 Pc 3 Cord ring with Vulcan Joint NBR90 Shore Ø 650 X 3.53 Wartsila Detail Drawing W007058061 1 each

Ref 2.1.11 Wartsila Drawing W084838596 Pc 4 Cord ring with Vulcan Joint NBR90 Shore Ø 745 X 3.53 Wartsila Detail Drawing W007058062 1 each

Ref 2.1.13 Wartsila Drawing W084837232 Pc 57 NBR 70 Shore

ID 730.5 X7

Wartsila Detail Drawing W084838703 1 each

Wartsila Drawing W084827066, Pc 2, M24 x 70mm A4-80 SS, M713001637

12 each

Wartsila Drawing W084827066, Pc 4, M24 Locking Washer Nord-Lock, W084820302 12 each

Ref 2.1.13, Wartsila Drawing W084837232 Pc 81, M24 x 50 Hex Socket head cap screw A4-80 SS, M712041484 12 each

Reference 2.1.15 Piece 4 O-ring Ø721X6,99 Nitril 70 Shore A Cage OEYA6 Part No. N000737973 1 each

Ref 2.1.15 Pc 5 O-ring Ø587X3,53 Nitril 70 Shore A Cage OEYA6 Part No. N000737882 1 each

Ref 2.1.15 Pc 8 O-ring Ø799X6,99 Nitril 70 Shore A Cage OEYA6 Part No. N000738096 1 each

Wartsila Drawing W84837233 Pc 7 M10 x 35mm Hex Head Cap Screw A4-80 SS 12 each

P/N M712085430 1 each

P/N W006564007

2 each

3.2.1 Listing of Equipment/Tooling (Contractor Furnished Special Tools)

Contractor Furnished Special Tools (CFT)

3.2.2 Listing of Services (Contractor Furnished Services)

Contractor Furnished Services (CFS)

Wartsila Technical Representatives

Thordon Bearing Technical Representatives

Diehl Engineering/Maritech Technical Representatives

ENECON Technical Representatives

3.2.3 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.

4.0 GOVERNMENT-FURNISHED EQUIPMENT/MATERIAL/SERVICES

4.1 Government Furnished Equipment:

Government Furnished Equipment (GFE)

Wartsila Drawing W084827066 Pc 6 Wartsila Detail Drawing M713090039 C15 M20 1 each

42CrMo4 80M Ø135 L=225 Wartsila Detail Drawing W084813619 1 each

Wartsila Drawing W08483677 Pc 6 42CrMo4 64M Ø110 L=190 Wartsila Detail Drawing W084813618 4 each

Wartsila Drawing W006040130 1 each

Shipyard to Provided 2 each

Reference 2.1.1 Pc 9 1 each

Reference 2.1.1 Pc 31 1 each

Reference 2.1.1 Pc 32 1 each

Reference 2.1.1 Pc 33 1 each

Reference 2.1.1 Piece 34 1 each

Reference 2.1.1 Piece 35 1 each

Thordon COMPAC Standard Key Installation Kit -Consisting of Hydraulic Cylinder, Threaded Rod, Installation Plate, Rubber Mallet, Key Extraction Tool, Johnson Bar, and Hex Wrench 1 each, Kit

4.2 Government Furnished Material:

Government Furnished Material (GFM)

4.3 Government Furnished Services: None additional.

5.0 NOTES

5.1 The Contractor and all subcontractors, regardless of tier must 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 GTR’s.

5.2 The Contractor and all Subcontractors, regardless of tier shall 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 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 without proper authorization.

5.4 THE USNS 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 ENERGIZED UNTIL TESTED AND PROVEN OTHERWISE. THE CONTRACTOR SHALL TEST ALL ELECTRICAL CABLES TO ENSURE THEY ARE DE-ENERGIZED 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.

5.7 SHIPPING OF CRATED TAIL SHAFT WILL BE COVERED UNDER A SEPARATE CONTRACT

6.0 QUALITY ASSURANCE REQUIREMENTS: None Additional.

7.0 STATEMENT OF WORK REQUIRED

7.1 Arrangements/Outfitting: None additional.

7.2 Structural: None additional.

7.3 Mechanical/Fluid

7.3.1 General Work Requirements

a. Provide Wartsila, Diehl Engineering / Maritech, Thordon, and ENECON Technical Representatives to oversee and/or perform all work described by this work item.

b. Provide industrial support for all work described by this work item performed and/or overseen by the Wartsila, Diehl Engineering / Maritech, Thordon, and ENECON Technical Representatives.

c. Fabricate and install all necessary hull mounted and rudder mounted pad eyes required to perform rigging operations described by this work item. Rigging pads shall be placed a minimum of two (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.

d. Fabricate and install all necessary pad eyes in shaft alley to rig the hydraulic coupling and tail shaft while performing operations described by this work item. Any pad eyes installed shall be removed upon completion of work.

e. Perform a load test of all pad eyes and rigging equipment, regardless of if they are new or previously installed, prior to use. Load test shall be a minimum of 110% of load.

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

g. Receive and store OEM provided material and tools from Wartsila, Diehl Engineering/Maritech, Thordon, and ENECON as per OEM specifications and/or recommendation.

h. Remove and reinstall all interferences necessary to perform this work item. 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

· Stern tube seal

· Stern tube reference cells

· Shaft grounding brush rigging

· Proximity probes and foundations

7.3.2 INITIAL AND RE-INSTALLED TAIL SHAFT BEARING WEAR DOWN READINGS

a. Prior to any disassembly the tail shaft bearing wear down readings shall be taken.

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

c. The tail shaft bearing wear down reading shall be taken using the feeler gauge method. The rope guard shall be removed prior to taking wear down measurements. The max thickness feeler gauge shall be inserted between the tail shaft liner and tail shaft bearing at the top, Stbd (two locations: 50 mm above and below the key), bottom, and port (two locations: 50 mm above and below the bearing split).

d. Reference 2.1.4, stern tube drawing shows the arrangement of the tail shaft and bearing.

e. The tail shaft wear down readings shall be recorded and submitted to the MSCREP via Condition Found Report.

f. ABS, Chief Engineer, and MSCREP shall witness the tail shaft bearing wear down readings.

7.3.3 INITIAL AND RE-INSTALLED RUDDER WEAR DOWN READINGS

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

b. The rudder wear down readings shall be taken again after the re-assembly of all components.

c. Remove the upper rudder seal ring (bolted in two segments). Upper rudder seal ring to be abrasive grit blasted, painted, and stored for re-assembly.

d. Rudder wear down reading shall be taken using the feeler gauge method. The max thickness feeler gauge shall be inserted between the rudder stock and rudder stock bearing at the Fwd., Aft, Port and Stbd positions.

e. See References 2.1.5 and 2.1.6 for rudder bearing arrangement.

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

g. 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.

h. The rudders wear down and as found readings shall be recorded and submitted to the MSCREP via Condition Found Report.

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

7.3.4 UNSHIP & SHIP THE RUDDER BLADE. (RUDDER STOCK TO REMAIN IN PLACE)

a. The baseline must be one thousand two hundred (1200) mm minimum above the Dry Dock.

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

c. Unship the rudder in accordance with Reference 2.1.1, Sheet 5.

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

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

f. Scribe/mark the rudder stock to the rudder blade for reference when re-installing the rudder blade on the rudder stock.

g. 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.

h. Provide hydraulic pump and tooling to remove rudder hydraulic nut, and pump up rudder blade hub.

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

j. Connect hydraulic pump to the rudder hydraulic nut.

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

l. Connect hydraulic pump to the blade hub. There are three connection points. See Reference 2.1.7, Rudder Cone Coupling Drawing.

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

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

o. Support the Rudder with Chain Falls using Reference 2.1.1 as guidance. Rudder blade weighs approximately 28,000 kg.

p. Remove the rudder nut. Rudder nut weighs approx. 790 kg.

q. 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.

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

s. All rudder hydraulic nut O-rings shall be renewed. See Reference 2.1.8.

t. 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.

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

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

w. Apply hydraulic oil to the conical parts.

x. Rig the rudder blade onto the rudder stock per Reference 2.1.1.

y. Reinstall the rudder hydraulic nut and fitting disc assembly 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.

z. Re-install the Contractor provided hydraulic pumps to the rudder hydraulic nut and the rudder blade hub. There is one connection for the nut and three connections on the rudder hub.

aa. Pump the rudder hydraulic nut to 50 bars. This is the starting position.

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

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

ad. The cone coupling pull up pressures must be recorded on the Protocol Pull-up Sheet provided in the back of Reference 2.1.3 tech manual and shown in Enclosure (1).

ae. ABS is to witness cone pull up pressures and dimension.

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

ag. When the rudder blade is in position, slowly release the pressure from the rudder blade hub. Keep the pressure on the nut for twenty (20) minutes. Record rudder measurements as per Section 7.3.3. Measurements shall be provided to MSCREP.

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

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

aj. Put the cover on the rudder hydraulic nut. Fill the nut with grease. Use Lubriplate Super-lubrication 930-AAA or equal. Use new O-ring and Loctite 243 on the fasteners.

ak. Weld the rudder access plates back in place.

7.3.5 UNSHIP AND SHIP THE PROPELLER

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

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

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

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

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

f. Scribe/mark/measure the propeller hub to the tail shaft to be used for reference when reinstalling the propeller to the tail shaft in case reinstallation of original tail shaft is necessary.

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

h. Connect rigging in accordance with Reference 2.1.1, Sheet 6, using two (2) each 30 Ton air hoists.

i. Remove the rope guard. See reference 2.1.12 for details on how the rope guard is welded in place.

j. Disconnect the O-ring cover and O-ring from the propeller hub. It is held in place by twelve (12) socket head cap screws.

k. 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 Pcs 62 and 63.

l. Unscrew the propeller hydraulic nut to the amount of the axial drive up plus three (3) mm. 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.

m. 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.

n. 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.

o. 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.

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

q. Disconnect and remove pumps. Reinstall plugs on propeller.

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

s. Rig/transport main propeller to contractor’s designated lay-down area for inspection, cleaning, and polishing. Block main propeller to prevent damage to blades or hub.

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

u. Clean and polish/buff propeller blades, hub, and propeller cap to a Rupert “A” Finish (Surface Roughness of 0.65 microns) or better.

v. Wartsila Rep to inspect main propeller in accordance with Reference 2.1

w. CHECKPOINT: Examine all areas of propeller blades, hubs, and fairwater cap prior to NDT-Dye Penetrant Testing. Inspect for cracks and defects paying particular attention to hub, blade roots and blade edges. MSCREP and ABS Surveyor shall attend.

x. Accomplish NDT-Dye Penetrant Testing of all propeller blades, front and back; including propeller hub and fairwater cap.

y. CHECKPOINT: Examine all areas of propeller blades, hubs, and fairwater cap after NDT-Dye Penetrant Testing. Inspect for cracks and defects paying particular attention to hub, blade roots and blade edges. MSCREP, ABS Surveyor, and Wartsila rep will attend and shall inspect propeller.

z. Submit “As found" Condition Found Report along with NDT results to MSCREP.

aa. Upon completion of all work described in this section (polishing, inspection, NDT-Dye Penetrant Testing, etc.), and acceptance by MSCREP and ABS Surveyor, Contractor shall perform a final cleaning of propeller and fairwater cap. After final cleaning to remove all NDT-Dye Penetrant Testing residue and dirt, overspray, etc. that may have accumulated after polishing, Contractor shall protect propeller and fairwater cap from dirt, overspray, damage, etc. by covering/wrapping with heavy plastic or tarp and sealing all edges until just prior to installation.

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

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

ad. Re-install the propeller in accordance with procedures in References 2.1.1 and 2.1.2.

ae. The propeller is to be blue fit to the tail shaft taper with a minimum of 80% contact. The push-up procedure according to the mounting instructions for a new propeller to taper installation requires the propeller to be pushed up hydraulically and dismounted at least once before final push-up is achieved. This process insures the proper bedding of the propeller hub / cone to the tail shaft taper and press fit requirements by the OEM.

af. Lightly oil the propeller bore and tail shaft taper.

ag. Use a new O-ring for the tail shaft/propeller boss retaining ring.

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

ai. Replace the O-rings in the propeller hydraulic nut piston.

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

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

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

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

an. 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.

ao. Install a dial indicator on the hydraulic nut to measure the push up of the propeller.

ap. 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.

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

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

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

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

au. When the proper push up has been reached record the final dial indicator movement.

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

aw. Release the pressure on the propeller boss pump and let stand for thirty (30) minutes.

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

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

az. Re-install the tail shaft propeller hub O-ring seal.

ba. Re-install the hydraulic nut locking segment. Use Loctite 242. MSCREP to witness locking segment installation.

bb. Re-install the propeller cap using new O-ring. Torque the propeller cap bolts to 250 N-m. MSCREP to witness torque.

bc. Air tests the propeller cap at two (2) bars for thirty (30) min. ABS Surveyor and MSCREP to witness air test.

bd. Fill the propeller cap with 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 N-m and locked in place.

be. Clean out bolt recesses with solvent. Fill and fair the bolt recesses on the propeller boss cap fin with MIL-D-21631A latex concrete.

bf. After installation of propeller and fairwater cap, Contractor shall protect propeller and fairwater cap from dirt, overspray, damage, etc. by covering/wrapping with heavy plastic or tarp and sealing all edges.

bg. After all dry dock associated work on the vessel is complete and just prior to undocking of the vessel, Contractor shall remove protective covering/wrapping from propeller and fairwater cap.

bh. Install new 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.

7.3.6 UNSHIP INSTALLED/ORIGINAL AND SHIP GFM SHORE BASED SPARE TAIL SHAFT (PROPELLER SHAFT)

a. Unship installed/original and install GFM shore base spare tail shaft. Reference 2.1.1, Sheet 7.

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

c. Erect a platform/staging under the stern frame to allow for access during tail shaft removal and installation.

d. Disconnect the shaft turning gear and temporarily remove.

e. Stern tube seal and piping shall be disconnected in accordance with Work Item 904.

f. Shaft grounding device shall be disconnected in accordance with Work Item 0911.

g. Disconnect proximity probes and temporarily remove.

h. Disconnect reference cells and permanently remove. Reference cells shall be disconnected and removed from stern tube prior to shipping tail shaft.

i. Disconnect aft line shaft bearing RTD probe from line shaft oil sump and install temporary plug. Disconnect electrically and store in safe storage until reinstallation.

j. Prior to de-mounting the coupling, Wartsila Rep shall verify and document the following shaft coupling data as per ref 2.1.2 para 3.4.1. As found Condition Found Report shall be submitted to MSCREP.

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

l. “A” Dimension stamped on coupling.

m. 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.

n. GFM shore based spare Tail Shaft shall be installed. Mark tail shaft to coupling orientation with permanent marker to ensure proper shaft/propeller orientation in case reinstallation of original is necessary.

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

p. 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 in case reinstallation of original is necessary.

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

r. Remove the hydraulic coupling flange Super-Bolts from the tail shaft/line shaft coupling. Super-Bolt 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.

s. Loosen each Super-Bolt by loosening each jacking bolt ¼ turn in a circular pattern. When you get back to the first bolt repeat the circular pattern.

t. The Super-Bolts shall be cleaned and inspected for nicks and or burrs prior to re-installation. All metal to metal parts on the Super-Bolts are to be lubricated. Lubrication shall be as per the Wartsila Reps instructions. Do not use Molybdenum disulfide unless specifically instructed by the Wartsila Representative.

u. 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.

v. 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.

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

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

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

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

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

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

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

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

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

af. Remove ¾" injection plugs on hydraulic coupling.

ag. Install Contractor provided oil injections pumps on the hydraulic couplings and pump until oil leaks out.

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

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

aj. 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.

ak. Move the tail shaft aft to allow for installation of the tail shaft extension tool on the fwd. end of the tail shaft. See Reference 2.1.1, Sheet 12. Torque bolts to 1500 ft.-lbs.

al. Install roller jig or shaft extension tool bumper on shaft extension tool. See Reference 2.1.1.

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

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

ao. Remove the stern tube bearing retaining ring. Stern tube bearing retaining ring is shown by Reference 2.1.4 as Piece 7. It is held in place by twelve (12) each hex head bolts.

ap. Using 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, it can be pulled out to facilitate the removal of the stern tube bearing.

aq. Note: The lower key is bolted to the stern tube and the upper key is insertable/removable.

ar. Remove split stern tube bearing in accordance with reference 2.1.2 after tail shaft is removed.

as. Un-bolt and remove the lower key from the stern tube.

at. Note: Plans are to install new stern tube bearing (GFM) and stern tube bearing key parts (CFM). However, the stern tube bearing and key parts that are removed as part of this work item shall be thoroughly cleaned, presented to the Wartsila, MSCREP, and ABS for inspection, protected, and stored for re-installation if required.

au. Clean stern tube by means of high pressure washing to remove any dirt and marine growth.

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

aw. 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 measurements.

ax. Upon completion of the tail shaft and stern tube inspection/repairs install GFM shore based spare tail shaft in the opposite order of removal.

ay. Provide ABS recertification/repair documentation on GFM shore based spare Tail Shaft.

az. Perform NDT of GFM shore based spare Tail Shaft taper to the satisfaction of the attending ABS Surveyor. Record and submit to MSCREP via Condition Report.

ba. Install the stern tube seal section that must fit over the tail shaft per Work Item 904.

bb. Install the stern tube bearing key (bolted lower half).

bc. Install the lower bearing half first then the upper bearing half. Verify the bearing is in the same orientation as prior to removal and the lubricating water channels are correctly located.

bd. Install the stern tube bearing key (upper half) in accordance with Reference 2.1.2. The key is all the way in when the aft edge of the top and bottom halves are aligned. Do not force the key past the bottom key section.

be. Install the new retaining ring (CFM) and torque the fasteners to 33 ft-lbs (45 N-M). MSCREP to witness.

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

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

bh. Re-install the tail shaft hydraulic coupling to the tail shaft in accordance with Reference 2.1.2.

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

bj. Install new O-rings on the hydraulic coupling. Two (2) O-rings on the seal ring and one (1) on the flange face.

bk. Lubricate the tail shaft in way of the coupling with mineral oil SAE20/ISO VG 46.

NOTE: OILS WITH ANTI FRICTION ADDITIVES ARE STRICTLY FORBIDDEN.

bl. Verify the shaft orientation with removal marks so the shaft will be lined up with the coupling in the same position as before removal if reinstalling original shaft.

bm. 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 50 mm.

bn. 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.

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

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

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

br. 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 102.3 mm. 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.

bs. Release the coupling body pressure and wait fifteen (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 two (2) hrs. prior to reinstalling the plugs in the coupling.

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

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

bv. MSCREP and ABS shall witness hydraulic coupling drive up.

bw. Pull the tail shaft the remaining way into position. Verify the line shaft and tail shaft are aligned back to their original orientation relative to each other if reinstalling original shaft.

bx. Ensure that the O-ring on the hydraulic coupling flange has been renewed and is positioned correctly.

by. Re-install the hydraulic coupling flange Super-Bolts in accordance with Reference 2.1.2.

bz. Use a star pattern when tightening the flange Super-Bolts.

ca. Use a star pattern when tightening the Super-Bolt jack bolts.

cb. The hydraulic flange Super-Bolt jack bolts shall be torque to 220 Nm. MSCREP to witness jack bolt torque.

cc. Re-install the jacking gear removed as interference.

cd. Re-install shaft grounding removed as interference.

ce. Re-install proximity probes removed as interference.

cf. Re-install aft line shaft bearing RTD probe removed from line shaft oil sump as interference. Re-install electrical disconnected as interference.

cg. Reference cells removed as interference are not to be re-installed. Wiring for reference cells to be disconnected at each end and removed from the vessel. All hangers, stand-offs, studs, foundations, etc. associated with the reference cell wiring to be removed. All stuffing tubes to be removed and the openings inserted. Threaded inserts/weldolet in the stern tube high hat cofferdams for reference cells to be removed. The existing holes to be cleaned to white metal. Properly prepare the existing weldolet holes. Weldolets are recommended to be replaced by inserting a fitted solid plug to meet all OEM /Class material. Upon completion of welding, NDT test shall be accomplished to ensure water tight integrity of each existing repaired hole. QA verification and set check points of each repaired hole. Ground newly exposed welds, internal of stern tube wall areas to meet the specific contour of the surrounding stern tube wall area. Wartsila Technical Representative shall provide details of the insert and shall be approved by the MSCREP. Refer to paragraphs 7.3.9, all areas disturbed shall be surface prepared and coated to match the surrounding areas.

7.3.7 INSPECT THE STERN TUBE BEARING:

a. Present the stern-tube and stern tube bearing to MSCREP and ABS for a visual inspection. All items shall be cleaned and laid out/presented 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. The Contractor shall provide the following as found and as restored Condition Found Reports to MSC:

b. Stern Tube Bearing Measurements Prior to Removal From Stern Tube:

i. Bearing inner diameter readings; minimum of four (4) axial locations (each end of each bearing section) with four (4) readings at each location, top/bottom, Port/Stbd and both diagonals.

ii. Record bearing temperature at time of measurement.

iii. Allow measurement instruments to acclimate to bearing temperature.

c. Stern Tube Measurements:

i. Bearing fit length inner diameter readings; minimum of four (4) axial locations (each end of each bearing section) with four (4) readings at each location, Top/Bottom Port/Stbd, and both diagonals.

ii. Record tube temperature at the time of the measurements.

iii. Allow measurement instruments to acclimate to tube temperature.

iv. Surface roughness of bearing fit length.

d. GFM shore based spare Shaft (GFM) Measurements and as Restored Stern Tube and Stern Bearing Measurements:

i. FWD Liner: Wartsila shall provide data from refurbished GFM shore based spare tail shaft.

ii. AFT Liner: Wartsila shall provide data from refurbished GFM shore based spare tail shaft.

a. Stern Tube Measurements Prior to Bearing Installation:

i. Bearing fit length inner diameter readings; minimum of four (4) axial locations (each end of each bearing section) with four (4) readings at each location, top/bottom Port/Stbd, and both diagonals.

ii. Record tube temperature at the time of the measurements.

iii. Allow measurement instruments to acclimate to tube temperature.

iv. Surface roughness of bearing fit length.

b. Stern Bearing Measurements After Installation:

i. Bearing inner diameter readings; minimum of four (4) axial locations (each end of each bearing section) with four (4) readings at each location, top/bottom. Port/ Stbd and both diagonals.

ii. Record bearing temperature at time of measurement.

iii. Allow measurement instruments to acclimate to bearing temperature.

7.3.8 CRATE, PACKAGE, AND SHIP REMOVED TAIL SHAFT

a. Refurbishment, Polishing Tail Shaft Liners and renewal of Tail Shaft preservative coating shall be accomplished under a separate contract.

b. Under the guidance of Wartsila, Contractor shall preserve and crate/package removed tail shaft for refurbishment under separate contract.

i. Contractor shall crate/package shaft to prevent damage from weather and transporting.

Note

SHIPPING OF CRATED TAIL SHAFT WILL BE COVERED UNDER A SEPARATE CONTRACT

7.3.9 Stern Tube Coating

c. Provide an ENECON Technical Representative for the coating repair of the stern tube. ENECON Technical Representative shall witness all tests. ENECON Technical Representative will keep a log book of inspections and applications (final surface preparation, stripe coat, first and second coat). The ENECON Technical Representative will take pictures of each step. The ENECON Technical Representative shall submit a service report to MSCREP.

d. Repair, prep, fill, and coat damaged areas in the Shaft Tube and bearing areas. Assume repair to be approximately 10% of shaft tube and bearing area.

e. Provide containments required for proper working conditions and inspections.

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

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

h. 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.

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

j. Abrasive grit blast or mechanically clean damaged, flaking, blistering, etc. areas of the interior of stern tube and stern tube bearing housing area to an SSP-10 near white metal finish, achieving a minimum of 75 microns profile using an angular grit.

k. Enecon repair areas to include reference cells removed and plugged.

l. Enecon to include outer surface of stern tube seal Connecting Ring of Work Item 904.

m. 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.

n. Test for chlorides in the presence of the ENECON Technical Representative. If excess chlorides are found, repeat the cleaning procedures. Standard to achieve is less than 20mg/m2.

o. Perform sterilization of stern tube internals to kill any micro biological bacteria (only if required). Rinse and test for neutral PH.

p. Blast the repair area of the interior of the stern tube in the stern tube and bearing housing area to remove flash rust and maintain the minimum three (3) mil profiles.

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

r. Test blast profile using Testex tape. Look for a minimum three (3) mil profile and a dense blast pattern.

s. Degrease stern tube and bearing area.

t. Brush blast entire area to be coated.

u. Apply ENECON DurAlloy, to approximately a 15.0 mm thickness.