Navsea s0600 Aa Pro 120
Navsea s0600 Aa Pro 120
Navsea s0600 Aa Pro 120
0910-LP-019-9270
REVISION 1
CHAPTER 12
CONTROLLABLE PITCH PROPELLERS
DISTRIBUTION STATEMENT A: This document has been approved for public release and sale; its
distribution is unlimited.
30 OCTOBER 1998
Change 1 Dated 15 November 1999
S0600-AA-PRO-120
* Change No.
Title, A, and B. . . . . . . . . . . . . . . . . . . . . . . . .1
Certification Sheet . . . . . . . . . . . . . . . . . . . . .1
blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
Flyleaf-1 (Flyleaf-2 blank) . . . . . . . . . . . . . . .1
i through v . . . . . . . . . . . . . . . . . . . . . . . . . . O
vi blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
vii through viii . . . . . . . . . . . . . . . . . . . . . . . . .1
ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
x through xiv. . . . . . . . . . . . . . . . . . . . . . . . . .1
12-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-2 through 12-6 . . . . . . . . . . . . . . . . . . . . O
12-6A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-6B blank . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-7 through 12-15 . . . . . . . . . . . . . . . . . . . O
12-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-17 through 12-46 . . . . . . . . . . . . . . . . . . O
12-46A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-46B blank . . . . . . . . . . . . . . . . . . . . . . . . .1
12-47 through 12-54 . . . . . . . . . . . . . . . . . . O
12-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-56 through 12-71 . . . . . . . . . . . . . . . . . . O
12-72 blank . . . . . . . . . . . . . . . . . . . . . . . . . O
12-73 through 12-81 . . . . . . . . . . . . . . . . . . O
12-82 blank . . . . . . . . . . . . . . . . . . . . . . . . . O
12-83 through 12-84 . . . . . . . . . . . . . . . . . . O
12-84A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-84B blank . . . . . . . . . . . . . . . . . . . . . . . . .1
12-85 through 12-90 . . . . . . . . . . . . . . . . . . O
12-91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-92 through 12-107 . . . . . . . . . . . . . . . . . O
12-108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12-110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
A-1 through A-13 . . . . . . . . . . . . . . . . . . . . . O
A-14 blank . . . . . . . . . . . . . . . . . . . . . . . . . . O
B-1 through B-22 . . . . . . . . . . . . . . . . . . . . . O
B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
B-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
B-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Page No.
* Change No.
Change 1
S0600-AA-PRO-120
Page No.
* Change No.
G-8 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-4 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
H-6 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
* O in this column indicates an original page.
Change 1
Page No.
* Change No.
I-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
I-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
J-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
J-2 blank. . . . . . . . . . . . . . . . . . . . . . . . . . . . O
K-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O
K-2 blank . . . . . . . . . . . . . . . . . . . . . . . . . . . O
S0600-AA-PRO-120
RECORD OF CHANGES
ACN/FORMAL
*CHANGE
ACN NO.
DATE
OF
CHANGE
11/15/99
ENTERED
BY
*When a formal change supersedes an ACN, draw a line through the ACN number
**Only message or letter reference need be cited for ACNs
Flyleaf-1/(Flyleaf-2 blank)
S0600-AA-PRO-120
TABLE OF CONTENTS
Paragraph
Page
SECTION 1 INTRODUCTION 1
12-1.1
12-1.2
PURPOSE.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-1.3
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-1.4
APPLICABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-1.5
REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12-2.2
12-2.3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
12-2.4
12-2.5
12-2.6
12-2.7
12-2.8
12-2.9
12-2.10
12-2.11
12-2.12
12-2.13
12-2.14
12-2.15
12-2.16
SECTION 3 FFG 7, DD 963, DDG 993, CG 47, AND DDG 51 CLASS PROPELLER HUB
PRAIRIE AIR CHECK VALVE REPAIR
12-3.1
12-3.2
12-3.3
REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-35
S0600-AA-PRO-120
12-4.2
12-4.3
REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-45
12-5.2
12-5.3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-46
12-5.4
12-5.5
12-5.6
12-5.7
12-5.8
12-5.9
12-5.10
12-5.11
12-5.12
12-5.13
12-5.14
12-5.15
12-5.16
SECTION 6 DD 963, DDG 993, AND CG 47 CLASS WATERBORNE BLADE PORT HUB SEAL
REPAIR
12-6.1
REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-73
12-6.2
12-6.3
REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-83
12-7.2
12-7.3
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-84
12-7.4
12-7.5
12-7.6
12-7.7
ii
S0600-AA-PRO-120
12-7.8
12-7.9
12-7.10
12-7.11
12-7.12
12-7.13
12-7.14
12-7.15
12-7.16
LIST OF APPENDICES
APPENDIX A MORGRIP BOLT ELONGATION MEASUREMENT PROCEDURE
A-1
A-1.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
A-1.2
A-1.3
A-1.4
A-1.5
A-1.6
A-2
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
A-3
A-4
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
A-4.1
DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
A-4.2
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
A-4.3
A-4.4
POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
A-5
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
A-5.1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
A-5.2
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
A-5.3
A-5.4
A-5.5
ELONGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12
A-6
EVALUATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12
iii
S0600-AA-PRO-120
A-6.1
EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12
A-7
A-8
B-1.1
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
B-1.2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
B-1.3
B-1.4
B-1.5
B-1.6
B-1.7
B-1.8
B-2
B-2.1
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
B-2.2
BACKGROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
B-2.3
REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
B-2.4
B-2.5
B-2.6
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11
B-2.7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-13
B-3
B-3.1
SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-15
B-3.2
B-3.3
B-3.4
B-3.5
B-3.6
iv
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S0600-AA-PRO-120
vi
S0600-AA-PRO-120
LIST OF ILLUSTRATIONS
Figure
Page
12-1
12-2
12-3
12-3A
12-4
12-5
12-6
12-7
12-8
12-9
12-10
12-11
12-12
12-13
12-14
12-14A
12-15
12-16
12-17
12-18
12-19
12-20
12-21
12-22
12-23
12-24
12-24A
12-25
12-26
12-27
12-28
12-29
12-30
12-31
12-32
12-33
12-34
12-35
A-1
A-2
A-3
B-1
B-2
B-3
B-4
B-5
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vii
S0600-AA-PRO-120
B-6
B-7
LIST OF TABLES
Table
Page
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-8
12-9
12-10
B-1
viii
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S0600-AA-PRO-120
SAFETY SUMMARY
GENERAL SAFETY PRECAUTIONS. The
following general safety precautions supplement the specific warnings and cautions
throughout this chapter. These general precautions are related to the task of underwater
Sonar Rubber Dome (SRD) repair. They are
precautions that must be understood and applied before and during work on the SRD. In
addition to the following precautions, personnel must be familiar with and observe safety
precautions set forth in the following publications:
a. Navy Occupational Safety and Health
Program Manual for Forces Afloat,
OPNAVINST 5000.19 (Series)
b. Naval Ships
(NSTM)
Technical
c. Technical/operating
equipment
Manual
manuals
Equipment in Motion.
Remain clear of equipment in motion. A safety
watch will be posted if equipment requires adjustment while in motion. The safety watch
shall have a full view of operations and immediate access to controls that are capable of
stopping equipment. If at any time the equipment appears to be moving out of control, stop
it immediately.
Limit Switches and Interlocks.
Limit switches and interlocks are provided to
protect personnel and equipm ent. They
should not be overridden or modified except
by an authorized person. Do not depend
solely upon limit switches for protection. Disconnect power at the power distribution
source before adjusting limit switches if possible.
for
First Aid.
Attend to all injuries, however slight, by obtaining first aid or medical attention immediately.
Resuscitation.
ix
S0600-AA-PRO-120
WARNINGS
All CPP blade bolt installation
operations require a NAVSEA
00C technical representative
on-site (page 12-1).
Rotating the propeller while
divers are in the vicinity may
result in serious injury to or
death of divers. Divers must be
clear of the propeller blades
and verify that dive hoses and
rigging lines are clear of the
propeller blades. Divers must
be warned when the propeller
will be rotating (pages 12-11,
12-17, 12-18, 12-23, 12-24, 1225, 12-49, 12-56, 12-57, 12-62,
12-63, 12-64, 12-87, 12-95, 1297, 12-99, 12-103).
The power head must have full
thread engagement with the
blade bolt to avoid catastrophic
failure and possible personnel
injury when the bolt is pressurized. Ensure seven full turns.
Record each power head pressurization in the log book provided (pages 12-12, 12-28, 1251, 12-67).
High pressure oil jets can penetr ate th e ski n. E nsu re tha t
divers are aware that the power
head is about to be pressurized. Divers should be clear of
the power head (pages 12-13,
12-54).
High pressure oil jets can penetrate the ski n. Di ver s must
ensure that topside personnel
Change 1
S0600-AA-PRO-120
over into the chain loops creating chain twist while deploying
and
rigging
the
chain
hoists/falls.
CAUTIONS
Change 1
xi
S0600-AA-PRO-120
1- To n
4- To n
Typical
R unning
B lock
Flip
3 To n
6 Ton
12-68).
Blade edges are easily damaged. Do not strike blade
edges with air cylinders, tools,
or other equipment (pages 1218, 12-56, 12-95).
Careless use of tools or equipment may nick or gouge the
shaft and propeller and cause
noise or cavitation problems.
Extreme care must be taken to
ensure that the propeller blade
and shaft are not damaged
(pages 12-18, 12-57, 12-95).
Ensure that new O-rings are
used for all installations (pages
12-20, 12-23, 12-59, 12-62, 1299, 12-102).
Divers must verify that the sus-
xii
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xiii
S0600-AA-PRO-120
xiv
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S0600-AA-PRO-120
CHAPTER 12
CONTROLLABLE PITCH PROPELLERS
SECTION 1 INTRODUCTION
12-1.1 GENERAL INFORMATION.
As in all underwater ship husbandry, there are
advantages to removing and replacing controllable pitch propeller (CPP) blades while the
ship is afloat. The most obvious advantage is
the elimination of costly dry-docking and the
expeditious return of the ship to operational
status. Another advantage is that the CPP
blade can be removed and replaced virtually
anywhere the ship is berthed.
12-1.2 PURPOSE.
This chapter provides commands with technical information and NAVSEA-approved procedures for the underwater replacement of CPP
blades. Strict adherence to the procedures in
this chapter will provide the best assurance
that all tasks, both underwater and topside,
are safely and efficiently completed and that
stringent quality control requirements are met.
12-1.3.2 The remaining sections of this chapter provide step-by-step procedures for specific CPP system repairs to specific classes of
ships.
12-1.4 APPLICABILITY.
Blade replacement and blade port hub seal
repair procedures are provided for FFG 7, CG
47, DDG 993, and DD 963 Class ships. A hub
prairie air check valve repair procedure is provided for FFG 7 Class ships. The prairie air
check valve procedure can easily be applied
to CG 47, DDG 993, DD 963, and DDG 51
Class ships. Blade replacement procedures
for DDG 51 Class ships with "Fleet" type
blades are also provided. The DDG 51 Class
blade bolt removal and installation procedures
are also applicable to CG 47 Class ships with
hull numbers CG 66 and higher.
12-1.5 CONTROLLABLE PITCH PROPELLERS.
WARNING
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12-1
S0600-AA-PRO-120
12-1.5.2 Purpose. The CPP propulsion system uses actuating mechanisms controlled
from the bridge or engine room to provide a
full range of ahead and astern thrust to the
vessel while the main propulsion machinery
operates at a constant speed. Maximum
ahead thrust is provided with blades in the full
ahead pitch position. By reversing the pitch
into the full astern pitch position, maximum
astern thrust is provided without reversing the
turning direction of the main propulsion
machinery, including the propeller shaft.
12-1.5.3 Terminology. Figures 12-1 and
12-2 are labeled illustrations of a typical CPP
12-2
hub/blade assembly. The terms shown in Figures 12-1 and 12-2 are defined below:
Hub. The center section of the propeller
bolted onto the propeller shaft.
Pressure Face. The aft face of the propeller
blade when the blade pitch is in the ahead
position.
Suction Face. The forward face of the propeller blade when the blade pitch is in the ahead
position.
S0600-AA-PRO-120
NOTE
The pressure face and suction
face are reversed when the
blade pitch is in the astern position.
Leading Edge. The blade edge adjacent to
the forward end of the propeller hub when the
blade pitch is in the ahead position.
Trailing Edge. The blade edge adjacent to
the aft end of the propeller hub when the blade
pitch is in the ahead position.
Blade Tip. The blade edge on the outermost
radius of the propeller.
Blade Palm. As shown in Figure 12-3.
12-3
S0600-AA-PRO-120
12-4
S0600-AA-PRO-120
12-5
S0600-AA-PRO-120
12-6
S0600-AA-PRO-120
CAUTION
1- To n
Typical
R unning
B lock
Flip
3 To n
4- To n
6 Ton
Fig. 12-3A Tugit Lever Hoists (Harrington PullChain Type have a two part Reeve)
Change 1
12-6A
S0600-AA-PRO-120
12-6B
Change 1
S0600-AA-PRO-120
.
Table 12-1. Material To Be Provided by the Repair Activity.
Item No.
Quantity
Component Description
Commercial
Commercial
Commercial
as required
Commercial
Commercial
Commercial
as required
Commercial
as required
Grease Pencils
Commercial
10
Commercial
11
as required
Chafing Material
Commercial
12
Degreaser/Carburetor Cleaner
Commercial
Technical Specification
hydraulic fluid in the chamber pushes the jacking body of the bolt down onto the blade palm.
Simultaneously, the threaded portion of the
bolt in the Morgrip bolt hole is pulled toward
the blade palm. This tension provides a tight
fit. Hydraulic temporary bolts can be connected in series with short quick-connect
hoses so that several bolts can be pressurized
at the same time (see Appendix E).
12-2.4.7 Lifting Assembly. The
lifting
assembly (FN 152) is attached to a propeller
blade so the blade can be lifted and lowered
with the hook of a lever hoist (see Appendix
F).
12-2.4.8 Righting Fixture. The righting fixture (FN 151) is installed onto the propeller
blade and connected to the pier crane hook.
The righting fixture is used to lift the propeller
blade out of its shipping container and to stand
the blade on its palm on wood timbers,
enabling the blade to be outfitted with the lifting assembly (see Appendix G).
12-2.4.9 Modified Channel Lock Pliers. The
rounded head of the channel lock pliers (FN
12-7
S0600-AA-PRO-120
2.
Inspect removed blade bolt caps and plugs for damage [12-2.7.5].
3.
Check Mapeco power head rupture disc torque at 100 ft.-lbs. [note prior to 12-2.8.2].
4.
5.
Clean blade bolts IAW Appendix A, [A-5.3.1], and conduct liquid penetrant inspection of
removed blade bolts [12-2.8.27].
6.
Ensure lifting fixture is installed with head clamp 64 inches from blade tip [12-2.9.11].
7.
Check forward lever hoist centered with respect to keel and the forward shackle in the head
clamp [12-2.9.16].
8.
9.
Blade Installation
1.
2.
Ensure edge guard material is used for lifting fixture clamps [12-2.11.5].
3.
4.
5.
6.
7.
8.
9.
Record serial numbers and initial lengths of blade bolts to be installed. Use Inspection
Report and Work Sheet, Figure A-3, Appendix A [12-2.12.1 and 12-2.12.3].
10. Apply thread lubricant to blade bolt shoulder and threads [12-2.12.15].
11. Dewater the blade bolt holes with Hydrolube [12-2.12.17].
12. Record final length and residual stretch when all eight bolts are installed. Residual stretch
must be between 0.006 and 0.0084 inches. Use Inspection Report and Work Sheet Figure
A-3 [12-2.13.1 and 12-2.13.2].
13. Ensure blade bolt cap seal is installed on blade bolt [12-2.14.5].
14. Torque blade bolt caps to 170 ft.-lbs. [12-2.14.7]
15. Dewater Morgrip bolt with Hydrolube [12-2.14.8].
16. Ensure blade bolt cap plugs are installed [12-2.14.9].
17. Test the CPP system performance [12-2.15].
12-8
Initials
Initials
S0600-AA-PRO-120
12) is ground off to a flat surface approximately -inch thick to allow for better access
to the Morgrip bolt Nylok pellet hole as
described in the note following step 12-2.14.2.
12-2.4.10 Spanner Wrench. The spanner
wrench (FN 23) is used to tighten or loosen
the Morgrip blade bolts, attached to the power
head assembly, into or out of the blade palm.
12-2.4.11 Dowel Pin Removal Tool. The
dowel pin removal tool (FN 13) is used to
remove stuck dowel pins that cannot be
removed by hand.
12-2.4.12 Blade Guide Pins.
The blade
guide pins (FN 14) are used to align the dowel
pins with the blade palm at installation.
12-2.4.13 Bolt Elongation Measurement
Tool. The bolt elongation measurement tool
(FN 43) is a transducer assembly and ultrasonic instrument specially designed to measure the elongation of the Morgrip bolts. The
tutorial in Appendix A allows any Intermediate
Maintenance Activity (IMA) Level II Ultrasonic
Testing (UT) inspector to perform measurements with this equipment.
12-2.4.14 Hydrolube. A heavier than water
hydraulic fluid used to dewater the blade bolt
holes.
12-2.5 RIG SHIPS HULL.
Rig the ships hull with forward and aft belly
bands and two 3-ton hoists in accordance with
Figure 12-4 and the following procedure.
12-2.5.1 Rig Forward Belly Band. (TOP)
Attach a line to one end of the belly band (FN
157). Lower the line from the ships outboard
aft deck to the diver.
12-2.5.2 (DV, TOP) Swim the line under the
ships hull to the inboard side and pass the bitter end of the line to topside personnel.
12-9
S0600-AA-PRO-120
12-10
S0600-AA-PRO-120
WARNING
NOTE
Morgrip blade bolt caps should
be installed at 170 ft.-lbs. (the
in sta lla tion tor que re quir ement) but they may be overtorqued and require a hydraulic
wrench to remove.
12-2.7.2 (DV) Remove the 1/8-27 NPTF pipe
plugs in the blade bolt caps using a 3/16-inch
Allen wrench (FN 7.1). Retain caps and plugs
for reinstallation.
12-2.7.3 (DV) Place the blade bolt cap
wrench (FN 5) in the blade bolt cap spanner
holes and tighten into the pipe plug hole.
NOTE
In some cases, the blade bolt
cap plugs are improperly
installed and cannot be
removed. If this occurs, the
blade bolt cap wrench may be
modified (by removing items 1,
2, 3, and 4 from drawing in
Appendix D) so that the wrench
will set on top of the blade bolt
cap and engage the locking pin
holes in the cap. Exercise care
when using the tool in this manner, because the blade bolt cap
wrench is not positively
secured on the blade bolt cap.
12-2.7.4 (DV) Using a breaker bar (FN 6.1)
and 1 1/8-inch socket (FN 6.2) attached to the
blade bolt cap wrench, remove the cap from
the blade bolt.
12-11
S0600-AA-PRO-120
WARNING
NOTE
12-12
NOTE
S0600-AA-PRO-120
WARNING
High pressure oil jets can penetr ate th e ski n. E nsu re tha t
divers are aware that the power
head is about to be pressurized. Divers should be clear of
the power head.
12-13
S0600-AA-PRO-120
12-14
S0600-AA-PRO-120
CAUTION
Hydraulic fluid pressure must
not exceed 37,500 psi. Exceeding 37,500 psi may damage
power head or intensifier.
12-2.8.11 (TOP) Increase the intensifier pressure to 35,000 psi by slowly opening the air
supply valve. Secure the air supply valve
when pressure is reached.
the
divers
when
High pressure oil jets can penetrate the ski n. Di ver s must
ensure that topside personnel
have depressurized the intensifier before disconnecting the
HP tube.
12-2.8.20 (DV) Disconnect the HP tube from
the power head. Reinstall the sealing plug into
the exposed tubing connection fitting.
12-2.8.21 (DV) Remove the blade bolt and
attached power head assembly from the
blade. Lift the entire assembly to the surface in
a diver tool bag. Do not loosen the power
head stop valve underwater.
WARNING
High pressure oil jets can penetrate the skin. Ensure that topside personnel are clear of the
valve opening when depressurizing the power head.
12-2.8.22 (TOP) Remove one of the sealing
plugs from a pressure connection port. Direct
the orifice of the power head stop valve away
from personnel into a proper waste oil con-
12-15
S0600-AA-PRO-120
12-2.8.26 (TOP) Remove the used Nylok pellet (see Figure 12-11) from each bolt. Use a
1/16-inch drill bit to center drill the pellet and
then stick a scribe into the hole to pry out the
pellet.
12-2.8.27 (TOP) Prior to use, all unthreaded,
polished, external bolt surfaces must be liquidpenetrant inspected in accordance with
NAVSEA Technical Publication 271. Group VII
(solvent-removable) and Group IV (waterwashable) fluorescent penetrant systems are
permitted for this application. Acceptance criteria shall be in accordance with MIL-STD2035A, paragraph 7.6. Surface blemishes or
scratches on the bolts polished surfaces may
be removed by rotating the bolt in a lathe while
polishing with a Scotch-Brite pad. Do NOT use
emery cloth or sand paper for polishing. All
polished bolts must be reinspected as detailed
above. The Morgrip blade bolts that pass inspection are to be reused with the replacement blades.
12-2.9 BLADE REMOVAL.
12-2.9.1 (TOP) Construct the lifting assembly
(FN 152) in accordance with Appendix F.
Ensure that the trailing edge clamp has the
FFG 7 delrin pads installed.
12-2.9.2 (TOP) Disconnect the trailing edge
clamp from the lifting assembly by removing
12-16
Change 1
S0600-AA-PRO-120
12-17
S0600-AA-PRO-120
12-18
S0600-AA-PRO-120
S0600-AA-PRO-120
12-2.10.3 (TOP) Inspect and clean the previously removed dowel pins and prairie air nipple with an emery cloth (FN 29). Dowel pins
must not be mushroomed or peened at either
end.
CAUTION
NOTE
12-2.10.4 (TOP) Lubricate the four new prairie air nipple O-rings (FN 16.2) with silicone
S0600-AA-PRO-120
12-21
S0600-AA-PRO-120
12-22
S0600-AA-PRO-120
WARNING
12-2.11.7 (TOP) Slack the crane and retighten the turnbuckles.
Rotating the propeller while
divers are in the vicinity may
result in serious injury to or
death of divers. Divers must be
clear of the propeller blades
and verify that dive hoses and
rigging lines are clear of the
propeller blades. Divers must
be warned when the propeller
will be rotating.
12-2.11.1 (DV, SF) Rotate the propeller hub
blade port targeted for installation into the 12
oclock position. Align the bench mark made
during the removal process to ease installation.
12-2.11.2 (TOP) Send the dowel pins (FN
19), prairie air nipple (FN 16.1), two tapered
blade guide pins (FN 14.2) and blade guide
pin turning bar (FN 14.1) down to the divers.
12-2.11.3 (TOP) Using the righting fixture,
stand the replacement blade to be installed
upright on the blade palm resting on two 4" x
4" wood timbers.
12-2.11.4 (TOP) Remove the righting fixture
from the blade.
12-23
S0600-AA-PRO-120
12-24
S0600-AA-PRO-120
12-25
S0600-AA-PRO-120
12-26
S0600-AA-PRO-120
WARNING
12-2.11.51 Check Blade Seating. (DV) Using a 0.002-inch feeler gauge (FN 22), check
the gap between the blade palm and the hub
at bolt holes #2, #3, #6, and #7. If the feeler
gauge penetrates at all, it should have a snug
(touching both sides) fit. Check the gap in two
places along the line of the bolt circle. The
purpose of this check is to determine the final
seating of the blade and that the O-ring installed between the blade palm and the blade
port cover has not been washed out of its
groove during the final seating of the blade.
12-27
S0600-AA-PRO-120
12-28
S0600-AA-PRO-120
NOTE
The HP tube end fitting is a
special design for extremely
high pressures. As illustrated in
Figure 12-6, an internally
threaded ferrule must be positioned on the threaded end of
the fitting so that 2 to 3 threads
are exposed at the end of the
fitting before the hose is
inserted into the power head
connection port. The ferrule
position must be checked prior
to each connection of the hose.
12-2.12.9 (TOP) Remove the pressure port
sealing plug and connect the HP tube from the
intensifier to the power head as shown in Figure 12-6.
12-2.12.10 (TOP) Pump the intensifier until a
steady stream of hydraulic fluid (no air) bleeds
from the loosened connection opposite the HP
tube in the power head. Fill the intensifier reservoir with hydraulic fluid as the tank level
drops. Tighten the bleeding connection with
the 5/8-inch wrench to seat firmly (DO NOT
OVERTIGHTEN).
WARNING
CAUTION
S0600-AA-PRO-120
NOTE
A one-minute delay is required
to allow hydraulic lock to relieve
itself. It is critical to repeat until
each bolt will no longer tighten.
12-2.12.22 (DV) Wait one minute, then
tighten the bolt again. Continue tightening the
bolt, with a one minute pause between efforts,
until the bolt stops advancing.
WARNING
High pressure oil jets can penetrate the skin. Ensure divers
are clear of the valve opening
when bleeding the power head.
12-2.12.23 (DV) Loosen one of the pressure
port sealing plugs. Open the power head stop
valve to depressurize the power head and the
Morgrip bolt.
12-2.12.24 (DV) Remove the depressurized
power head from the bolt using the spanner
wrench.
12-2.12.25 (DV) Remove the bullet rod from
the bolt. The special removal tool is provided if
suction makes the bullet rod removal difficult.
Send the power head and the bullet rod to the
surface.
12-2.12.26 (DV, TOP) Repeat the bolt installation procedure in the following bolt
sequence: #6, #3, and #7.
12-2.12.27 Remove Hydraulic Temporary
Bolts (DV) Remove the temporary bolts from
bolt holes #1, #5, #4, and #8 by reversing
steps 12-2.11.41 through 12-2.11.49.
12-2.12.28 Complete Morgrip Bolt Installation. (DV, TOP) Repeat bolt installation procedure (steps 12-2.12.1 through 12-2.12.25)
for the following bolt sequence: #1, #5, #4,
and #8.
12-30
12-2.13 MEASURE
LENGTH.
INSTALLED
BOLT
S0600-AA-PRO-120
12-31
S0600-AA-PRO-120
12-32
regarding any problems encountered, and recommendations for new or special tools
needed. The final report should be faxed or emailed to NAVSEA 00C54.
S0600-AA-PRO-120
SECTION 3 FFG 7, DD 963, DDG 993, CG 47, AND DDG 51 CLASS PROPELLER HUB PRAIRIE AIR CHECK VALVE REPAIR
12-3.1 FFG 7 CLASS REPAIR PROCEDURE.
12-3.1.1 NAVSEA 0941-LP-053-7010, FFG 7
Class CP Propeller and Propulsion Shafting
System, should be used by repair personnel
when accomplishing repairs to the FFG 7
Class propeller hub prairie air system. The following steps refer to sections of that manual.
12-3.1.2 Foldout 9 (Prairie Air Assembly) provides a diagram of the prairie air assembly.
Detail 14-A and View 17-B detail the configuration of the hub check valve.
12-3.1.3 Most often, the check valve spring
(item 16) fails before the check valve (item
10). When the spring fails, the check valve will
not reseat when air is secured and the prairie
air tubing is flooded. Replacement of the
spring is normally all that is required. If the
check valve is damaged and must be
replaced, the check valve may need to be fitted to the prairie air tube (item 8) because
each check valve and tube are matched pairs.
12-3.1.4 To access the check valve, the prairie air adapter plug (item 17) must be removed
from the aft end of the propeller hub. Remove
the retaining set screw (item 30) so the
adapter plug can be removed using a spanner
wrench.
12-3.1.5 Once the adapter plug is removed,
the check valve and spring can be pulled from
the cavity. Slide the spring off the check valve
stem and replace with a new spring.
12-3.1.6 Reinstall the check valve and the
adapter plug. Ensure that the O-ring (item 22)
on the adapter plug is checked. Replace if
necessary.
12-33
S0600-AA-PRO-120
12-34
S0600-AA-PRO-120
CAUTION
It is essential that all tools and
materials brought to the underwater job site are accounted for
and removed at the completion
of the job. Tools and materials
inadvertently left at the job site
can generate unacceptable
noise and possibly cause
severe damage to shipboard
components. Locally generated
work packages shall ensure
that a general tool and material
log sheet is prepared and maintained during all UWSH operations.
12-35
S0600-AA-PRO-120
Item
Name
Reference
1
2
3
4
5
6
7
8
9
10
11
12
13
14
FN 52.13
FN 54
FN 55
Item 24 of fold-out 2 in reference a
FN 60
FN 20
FN 56
Item 7 of fold-out 2 in reference a
FN 57
FN 53
Item 6 of fold-out 2 in reference a
Item 2 of fold-out 2 in reference a
FN 66 (FFG 7 set)
12-36
S0600-AA-PRO-120
Table12-3. FFG 7 Class Waterborne Blade Port Hub Seal Repair Quality Assurance Points.
Quality Assurance Point
Initial
1.
Check for cracked center post sleeve. If cracked, record OD measurement stamped on the
top of center post [12-4.3.3].
2.
Confirm final machined dimensions of the replacement center post sleeve [12-4.3.14d].
3.
4.
Verify replacement center post sleeve is flush with the center post and did not crack during
installation [12-4.3.14p].
5.
Measure blade port cover to bearing ring clearance and determine shim requirements [124.3.15].
6.
7.
8.
9.
Remove excess O-ring seating grease and ensure Mylar shim is flat [12-4.3.24].
10. Ensure stable oil/water interface is level with hub port opening [12-4.3.25].
11. Observe O-rings in proper position during final seating of blade port cover [12-4.3.26].
12. Check distance between blade port cover and crank pin ring with 0.002-inch feeler gauge
[12-4.3.29].
13. Check dowel pin fit and torque blade port cover cap screws to 33 ft.-lbs. [12-4.3.31].
14. Vent any air trapped in the hub [12-4.3.34].
15. Pressurize the system to check for leaks [12-4.3.36 and 12-4.3.40].
16. Final system test [12-4.3.39].
12-4.3.4 (DV) Install the second quick disconnect hub pressure test fitting (FN 51.2) into the
12-4.3.7 (TOP, DV) Rig staging to the propeller under the 6 o'clock blade port or an alterna-
12-37
S0600-AA-PRO-120
12-38
S0600-AA-PRO-120
j.
CAUTION
If the jack pressure increases
rapidly without movement of
the sleeve right at the start,
stop jacking and inspect for
misalignment. Retract the jack
and remove the sleeve from the
center post. If the sleeve
remains serviceable, align the
jacking assembly and restart.
o. Jack the sleeve into place. Do not stop
jacking until the sleeve is flush with the
center post.
p. Retract the jack and verify that the
sleeve is flush with the center post.
Verify that the new sleeve did not crack
during the press fit.
q. Remove the center post sleeve
replacement assembly from the hub
port. Leave four of the all-thread rods in
the crank pin ring.
r.
12-39
S0600-AA-PRO-120
12-40
able.
CAUTION
The reduction of shim thickness or removal of shim as
detailed above is at best an
interim method to regain a
blade port seal when bearing
ring wear has begun. Once
begun, bearing ring wear will
continue eventually causing
blade port leaking to resume.
Careful consideration of the
ships operational schedule and
drydock availabilities to perform
the eventual replacement of the
worn bearing ring is essential.
NOTE
Mylar shims are very delicate.
They are shipped with the CPP
equipment kit in a PVC tube for
protection (FN 66). Shims of
0.002, 0.003, 0.004, and 0.005inch thickness are included
S0600-AA-PRO-120
j.
a. Perform all measurements to the nearest 0.001 inch and with the blade port
at the 6 oclock position.
b. It is essential that the same diver experienced in the use of a depth micrometer perform all dimension A and B
measurements. This will ensure that
variation based on measurement technique will not effect the difference
between A and B.
c. Perform eight measurements around
both the blade port and blade port
cover, one adjacent to each Morgrip
bolt hole. Record the results. Because
of access limitations, dimension B is
more difficult to measure. It is most
important to be consistent with the
alignment and placement of the depth
micrometer at each location measured.
d. After the most repeatable measurements achievable have been recorded,
average the eight measurements taken
for B.
e. Average the
taken for A.
f.
eight
measurements
12-4.3.16 (DV) Install four 5/16-18 UNC, 4inch long jacking bolts 90 degrees apart into
the threaded through-holes provided in the
blade seal base ring (9). Note the depth of
insertion of the ring relative to the lip of the
hub blade port opening. This will allow the ring
to be reinstalled into the same position.
CAUTION
12-41
S0600-AA-PRO-120
12-42
NOTE
Ensure that items (3) and (8)
(dynamically loaded O-rings)
are replaced with fully molded
instead of spliced O-rings. Orings supplied by the stock system for items (3) and (8) are
often spliced instead of fully
molded.
12-4.3.24 (DV) Fill the empty O-ring grooves
on the blade port cover ID, the inner and outer
Morgrip bolt hole diameters on the crank pin
ring, and the blade seal base ring (four O-ring
grooves total) with grease and remove any
excess. Seat four new O-rings (3, 4, 7 and 8)
into their appropriate grooves and allow the
grease to hold them in place. Again, remove
any excess grease. If a Mylar shim is installed,
ensure that the shim lays flat against the crank
pin ring or blade port cover.
12-4.3.25 (SF, DV) Allow the oil/seawater
interface at the blade port to settle out and
have Ships Force release oil from the head
tank until all sea water is displaced from the
hub.
12-4.3.26 (DV) Raise the blade port cover
evenly with the handle nuts until it is carefully
seated into place. Be careful to ensure that all
the O-rings remain seated in their proper locations during the final seating of the blade port
cover.
12-4.3.27 (DV) Install four 5/8-inch cap
screws into the available holes to secure the
blade port cover in place.
12-4.3.28 (DV) Remove the four 5/8-inch allthread rods and install the remaining four 5/8inch cap screws. Tighten all cap screws
snugly.
12-4.3.29 (DV) Check the clearance between
the blade port cover and the crank pin ring in
all eight Morgrip holes with the 0.002-inch
feeler gauge. Confirm no fit or very tight fit of
feeler gauge between the blade port cover
and the crank pin ring. If the feeler gauge is
tight proceed with the next step. If the feeler
S0600-AA-PRO-120
NOTE
A value of 20 psig should be
low enough to not lift the cross
head chamber relief valve. In
cases where the pressure consistently drops to some lower
value (10 to 11 psig), use this
new value for the pressure test.
Hold pressure for 10 minutes
and have the divers confirm no
leaks. This will confirm that the
hub seal has been reestablished.
12-4.3.37 (TOP) If leakage is NOT observed,
proceed to the next step. If leakage is
observed, changes to the Mylar shim thickness based on measurements may not have
been enough to regain sufficient blade port
cover O-ring compression to get a seal. The
procedure may be repeated to confirm measurements and perhaps reduce shim thickness. However, if bearing ring wear is
indicated and the hub already has a long service life, the only alternative may be drydock
replacement of the worn bearing ring.
12-4.3.38 Replace the blade in accordance
with Section 12-2 of this manual.
12-4.3.39 (SF, DV) Remove out-of-service
tags. Cycle the blade pitch through normal
range of operation several times. Test and
purge the system in accordance with section
6-14 (Testing of the System) of reference a,
MRC 77 6WBM N (R-2W) and paragraph 124.3.40). Have divers check for leaks around
the blade palm and hub interface of all blades
during the testing.
12-4.3.40 In performing system test and
purge, supplement the procedure outlined in
MRC 77 6WBM N (R-2W) with the following.
Purge for approximately 15 to 30 minutes. To
open purge valve, (located in hub) take manual control (joystick) and slew pitch astern until
the main system relief valve lifts (1000 psi).
Slew pitch ahead just enough to reset the
12-43
S0600-AA-PRO-120
12-44
S0600-AA-PRO-120
NAVSEA T9074-AS-GIB-010/271, 30
April 1997, NAVSEA Technical Publication, Requirements for Nondestruc-
12-45
S0600-AA-PRO-120
NOTE
While the following procedure
requires that the topside personnel and the divers work
closely together, certain steps
must be carried out by particular personnel. To clarify these
steps, abbreviations are placed
at the beginning of each step
where the specific party needs
to be identified: (DV) represents diver, (TOP) represents
topside personnel, (SF) represents Ships Force personneland (UT) represents Level II
Ultrasonic Inspector.
12-5.3 PREPARATION.
12-5.3.1 Ships List and Trim. Ensure that
the ship has no more than one degree of list
and minimum possible trim during the actual
blade removal. Excessive list or trim will
adversely impact insertion of replacement
blades into the propeller hub port.
obtained and positioned on site before beginning the task. An inventory of the items in this
kit is available from NAVSEA 00C5. Table 124 identifies additional items that must be provided by the repair activity. Ensure the availability of all technical information, manuals,
and drawings.
12-5.3.3 Prepare Quality Assurance (QA)
Package. Prepare QA forms in accordance
with Table 12-5.
12-5.3.4 Review Bolt Elongation Measurement Procedure and Equipment. It is very
important that both the divers and the NDT
inspection personnel study and understand all
aspects of bolt elongation measurement as
detailed in Appendix A. Review of the tutorial
discussion provided in Appendix A first will
provide a good general understanding of the
responsibilities for the divers and NDT inspectors. See Appendix J for NAVSEA NDT equipment details.
12-5.4 SPECIAL TOOLS AND EQUIPMENT.
CAUTION
S0600-AA-PRO-120
CAUTION
1- To n
Typical
R unning
B lock
Flip
3 To n
4- To n
6 Ton
Fig. 12-14A Tugit Lever Hoists (Harrington PullChain Type have a two part Reeve)
Change 1
12-46A
S0600-AA-PRO-120
12-46B
Change 1
S0600-AA-PRO-120
Quantity
Component Description
Commercial
Commercial
Commercial
as required
Commercial
Commercial
Commercial
as required
Commercial
as required
Grease Pencils
Commercial
10
Commercial
11
as required
Chafing Material
Commercial
12
Degreaser/Carburetor Cleaner
Commercial
Technical Specifications
12-47
S0600-AA-PRO-120
2.
Inspect removed blade bolt caps and plugs for damage [12-5.7.5].
3.
Check Mapeco power head rupture disc torque at 100 ft.-lbs. [Note prior to 12-5.8.2].
4.
5.
Clean blade bolts IAW Appendix A [A-5.3.1] and conduct liquid penetrant inspection of
removed blade bolts [12-5.8.27].
6.
Ensure lifting fixture is installed with head clamp centered on the blade [12-5.9.8].
7.
8.
Blade Installation:
1.
2.
Ensure edge guard material is used for lifting fixture clamps [12-5.11.5].
3.
4.
5.
6.
7.
8.
9.
Record serial numbers and initial lengths of blade bolts to be installed. Use Inspection
Report and Work Sheet, Figure A-3, Appendix A [12-5.12.1 and 12-5.12.3].
10. Apply thread lubricant to blade bolt threads and shoulders [12-5.12.15].
11. Dewater the blade bolt holes with Hydrolube [12-5.12.17].
12. Record final length and residual stretch when all eight bolts are installed. Residual stretch
must be between 0.006-0.0084 inches. Use Inspection Report and Work Sheet Figure A-3
[12-5.13.1 and 12-5.13.2].
13. Ensure blade bolt cap seal is installed on blade bolt [12-5.14.5].
14. Torque blade bolt caps to 170 ft.-lbs. [12-5.14.7]
15. Dewater Morgrip bolt with Hydrolube [12-5.14.8].
16. Ensure blade bolt cap plugs are installed [12-5.14.9].
17. Test the CPP system performance [12-5.15].
12-48
Initials
Initials
S0600-AA-PRO-120
S0600-AA-PRO-120
NOTE
CAUTION
Before removing the blade bolt
caps, measures must be taken
for oil containment and abatement in accordance with local
Senior Officer Present Afloat
(SOPA) Manuals and reference
d. of section 12-5.1, Requirements.
12-50
S0600-AA-PRO-120
S0600-AA-PRO-120
NOTE
The HP tube end fitting is a
special design for extremely
high pressures. As illustrated in
Figure 12 -17, an i nter nally
threaded ferrule must be positioned on the threaded end of
12-52
S0600-AA-PRO-120
12-53
S0600-AA-PRO-120
WARNING
High pressure oil jets can penetr ate th e ski n. E nsu re tha t
divers are aware that the power
head is about to be pressurized. Divers should be clear of
the power head.
12-5.8.10 (DV) Swim clear of the power head
and inform topside that HP tube is purged and
connected securely.
CAUTION
12-5.8.18 (DV) When a blade bolt has been
loosened, close the power head stop valve to
isolate the pressure in the power head from
the pressure in the HP tube.
the
divers
when
12-54
High pressure oil jets can penetra te the skin. D ivers m ust
ensure that topside personnel
have depressurized the intensifier before disconnecting the
HP tube.
12-5.8.20 (DV) Disconnect the HP tube from
the power head. Reinstall the sealing plug into
the exposed tubing connection fitting.
12-5.8.21 (DV) Remove the blade bolt and
attached power head assembly from the
S0600-AA-PRO-120
High pressure oil jets can penetrate the skin. Ensure topside
personnel are clear of the valve
opening when depressurizing
the power head.
12-5.8.22 (TOP) Remove one of the sealing
plugs from a pressure connection port. Direct
the orifice of the power head stop valve away
from personnel into a proper waste oil container. Open the power head stop valve to
depressurize the power head.
12-5.8.23 (TOP) Remove the bolt from the
depressurized power head using the spanner
wrench (FN 23) and strap wrench (FN 25).
Sheet rubber wrapped around the shank of
the bolt may give a better grip with the strap
wrench.
12-5.8.24 (TOP) Remove the bullet rod from
the bolt. A special removal tool (FN 38.4) is
provided if suction makes bullet rod removal
difficult.
12-5.8.25 Repeat steps 12-5.8.2
12-5.8.24 for remaining blade bolts.
through
12-5.8.26 (TOP) Remove the used Nylok pellet (see Figure 12-22) from each bolt. Use a
1/16-inch drill bit to center drill the pellet and
then stick a scribe into the hole to pry out the
pellet.
12-5.8.27 (TOP) Prior to use, all unthreaded,
polished, external bolt surfaces must be liquidpenetrant inspected in accordance with
NAVSEA Technical Publication 271. Group VII
(solvent-removable) and Group IV (waterwashable) fluorescent penetrant systems are
permitted for this application. Acceptance criteria shall be in accordance with MIL-STD-
Change 1
12-55
S0600-AA-PRO-120
Pr o p e l l e r bl ad e e dg e s a r e
sharp. Avoid injury while handling blades.
CAUTION
Blade edges are easily damaged. Do not strike blade
edges with air cylinders, tools,
S0600-AA-PRO-120
or other equipment.
CAUTION
Careless use of tools or equipment may nick or gouge the
shaft and propeller and cause
noise or cavitation problems.
Extreme care must be taken to
ensure that the propeller blade
and shaft are not damaged.
12-5.9.21 (DV) If diver #2 reports that the
blade palm initially moved but that the blade
palm is no longer moving, then diver #1 needs
to shake the blade tip VIGOROUSLY while
diver #2 reports any upward travel of the blade
palm. As long as steady upward progress is
made, continue with the shake and pull
approach.
12-5.9.22 (DV/TOP) If diver #2 reports that
the blade palm did not initially move or the
shake and pull approach is not moving the
blade palm, the dowel pins are binding and the
binding must be relieved. The dowel pin binding may be caused by fore or aft misalignment
of the forward lifting tunnel with the center of
the propeller hub. If observation indicates that
fore or aft misalignment may be a problem,
lower the blade and try repositioning the head
clamp shackle to a more forward or aft position. If the above fore or aft adjustment does
not relieve the dowel pin binding, proceed with
the shaft rotation method. This is a trial-anderror process that may need to be repeated
several times to find the appropriate position.
If diver #2 reports that the blade palm did not
initially move, the direction of shaft rotation
must be selected arbitrarily.
12-5.9.23 Relieve Dowel Pin Binding. (DV)
If a good degree of upward movement was
encountered and ceased before the blade
became free, then divers are required to measure the spacing between the blade palm and
propeller hub to assist in determining the best
direction to rotate the shaft. Using a 1/16-inch
increment steel ruler (FN 15), record the dis-
12-57
S0600-AA-PRO-120
12-58
S0600-AA-PRO-120
S0600-AA-PRO-120
12-60
S0600-AA-PRO-120
12-61
S0600-AA-PRO-120
12-62
S0600-AA-PRO-120
12-63
S0600-AA-PRO-120
12-64
Pr o p e l l e r bl ad e e dg e s a r e
sharp. Avoid injury while handling blades.
12-5.11.32 (DV) When downward progress
has ceased, slack the forward lever hoist to a
light strain and have both divers commence
shaking the blade VIGOROUSLY at the tip.
12-5.11.33 (DV) If downward movement is
encountered, diver #2 continues shaking the
blade, while diver #1 slowly lets down on the
forward lever hoist.
S0600-AA-PRO-120
12-5.11.35 (DV, TOP) If no downward movement can be achieved by shaking the blade,
then from the measurements determine the
best direction for rotating the shaft. If the starboard side measurements are greater than the
port side, the starboard side of the hub may be
down and the shaft should be rotated to port. If
the port side measurements are greater, the
shaft should be rotated to starboard. If there is
no clear difference between port and starboard measurements, arbitrarily select the
direction of rotation. Record and keep all measurements for the duration of the installation
process in order to monitor progress.
12-5.11.36 (DV) Lift the blade until both dowel
pins are disengaged from the blade.
WARNING
12-65
S0600-AA-PRO-120
WARNING
12-5.11.51 Check Blade Seating. (DV) Using a 0.002-inch feeler gauge (FN 22), check
the gap between the blade palm and the hub
at bolt holes #2, #3, #6, and #7. If the feeler
gauge penetrates at all, it should have a snug
(touching both sides) fit. Check the gap in two
places along the line of the bolt circle. The
purpose of this check is to determine the final
seating of the blade and that the O-ring installed between the blade palm and the blade
port cover has not been washed out of its
groove during the final seating of the blade.
S0600-AA-PRO-120
CAUTION
Ultrasonic measurement procedures and equipment are
required to achieve the accuracy required in blade bolt measurement. Any ultrasonic blade
bolt measurement procedures
and equipment utilized must be
approved by NAVSEA or its
authorized representative in
a c c o r d a n c e w i t h N AV S E A
Technical Publication 271.
12-5.12.3 (UT) Using NAVSEA-approved
ultrasonic measurement procedures and
equipment, record baseline dimension measurements for all eight bolts on the Inspection
Report and Worksheet, Figure A-3. A sample
procedure using NAVSEA-developed equipment is provided in Appendix A.
12-67
S0600-AA-PRO-120
NOTE
The HP tube end fitting is a
special design for extremely
high pressures. As illustrated in
Figure 12 -17, an i nter nally
threaded ferrule must be positioned on the threaded end of
the fitting so that 2 to 3 threads
are exposed at the end of the
fitting before the hose is
inserted into the power head
connection port. The ferrule
position must be checked prior
to each connection of the hose.
12-5.12.9 (TOP) Remove a pressure port
sealing plug and connect the HP tube from the
intensifier to the power head as shown in Figure 12-17.
12-5.12.10 (TOP) Pump the intensifier until a
steady stream of hydraulic fluid (no air) bleeds
from the loosened connection opposite the HP
tube in the power head. Fill the intensifier reservoir with hydraulic fluid as tank level drops.
Tighten the bleeding connection with the 5/8inch wrench to seat firmly (DO NOT OVERTIGHTEN).
WARNING
S0600-AA-PRO-120
NOTE
A one minute delay is required
to allow hydraulic lock to relieve
itself. It is critical to repeat until
each bolt will no longer tighten.
WARNING
12-5.12.28 Complete Morgrip Bolt Installation. (DV, TOP) Repeat bolt installation procedure (steps 12-5.12.1 through 12-5.12.25)
for the following bolt sequence: #1, #5, #4,
and #8.
High pressure oil jets can penetrate the skin. Ensure divers
are clear of the valve opening
when bleeding the power head.
12-5.12.23 (DV) Loosen one of the pressure
port sealing plugs. Open the power head stop
valve to depressurize the power head and the
Morgrip bolt.
12-5.12.24 (DV) Remove the depressurized
power head from the bolt using the spanner
wrench.
12-5.12.25 (DV) Remove the bullet rod from
the bolt. The special removal tool is provided if
suction makes the bullet rod removal difficult.
12-5.13 MEASURE
LENGTH.
INSTALLED
BOLT
12-69
S0600-AA-PRO-120
NOTE
Because access to the Nylok
pellet hole is often partially
obscured by the bolt recess in
the blade palm, one installation
method is to grab the pellet
with needle nose pliers (FN 11)
in order to hold the pellet in line
with the hole and then squeeze
the pellet into the hole with
modified channel lock pliers
(FN 12).
12-5.14.3 (TOP) Apply silicone grease to the
blade bolt cap seals. (FN 8)
12-5.14.4 (TOP) Pass the blade bolt cap
seals and a flat-blade screw driver to the diver.
12-70
S0600-AA-PRO-120
12-5.16.4 Prepare Final Report. (TOP) Prepare a final report documenting the accomplished repair. Documentation which NAVSEA
00C54 needs to help improve the procedure
12-71
S0600-AA-PRO-120
12-72
S0600-AA-PRO-120
12-73
S0600-AA-PRO-120
Table 12-6. DD 963, DDG 993, and CG 47 Class Waterborne Blade Port Hub Seal Repair
Quality Assurance Points.
Quality Assurance Point
Initial
1.
Check for cracked center post sleeve. If cracked, record OD measurement stamped on the
top of center post [12-6.3.3].
2.
Confirm final machined dimensions of the replacement center post sleeve [12-6.3.14(d)].
3.
4.
Verify replacement center post sleeve is flush with the center post [12-6.3.14p].
5.
Measure blade port cover to bearing ring clearance and determine shim requirements [126.3.15].
6.
7.
8.
9.
Remove excess O-ring seating grease and ensure Mylar shim is flat [12-6.3.24].
10. Ensure stable oil/water interface is level with hub port opening [12-6.3.25].
11. Observe O-rings in proper position during final seating of blade port cover [12-6.3.26].
12. Check distance between blade port cover and crank pin ring with 0.002-inch feeler gauge
[12-6.3.29].
13. Check dowel pin fit and torque blade port cover cap screws to 33 ft.-lbs. [12-6.3.31].
14. Vent any air trapped in the hub [12-6.3.34].
15. Pressurize the system to check for leaks [12-6.3.36].
16. Final system test [12-6.3.39].
S0600-AA-PRO-120
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Name
Center Post Sleeve
Center Post
O-ring (dynamic)
O-ring (static)
Blade Port Cover
Capscrew
O-ring (static)
O-ring (dynamic)
Blade Seal Base Ring
O-ring (static)
Spring
Bearing Ring
Crank Pin Ring
Mylar Shim
Reference
FN 52.13
FN 54
FN 55
Item 24 of Figure 8-15a in reference a or FO2 in reference c
FN 60
FN 20, FN 120 for CG 66
FN 56
Item 7 of Figure 8-15a in reference a or FO2 in reference c
FN 57
FN 53
Item 6 of Figure 8-15a in reference a or FO2 in reference c
Item 2 of Figure 8-15a in reference a or FO2 in reference c
FN 67 (DD 963, DD 993, and CG 47 set)
12-6.3.7 (TOP, DV) Rig staging to the propeller under the 6 o'clock blade port or an alternative method for the diver(s) to work from a
stable position for hub component removal.
Wherever the stage is secured to the hub or
blade bases ensure adequate chafing gear is
used to prevent damage to any propeller sur-
12-6.3.9 (DV) Install a handle nut approximately four inches from the top on each of the
four 5/8-11 UNC 30-inch long, all-thread rods.
Make sure the handle on the handle nut is
angled downward. The top of the all-thread
12-75
S0600-AA-PRO-120
j.
S0600-AA-PRO-120
12-77
S0600-AA-PRO-120
a. Perform all measurements to the nearest 0.001 inch and with the blade port
at the 6 oclock position.
b. It is essential that the same diver,
experienced in the use of a depth
micrometer, perform all dimension A
an d B m e a su r e m en t s. Th i s w il l
ensure that variation based on measurement technique will not effect the
difference between A and B.
c. Perform eight measurements around
both the blade port and blade port
cover, one adjacent to each Morgrip
bolt hole. Record the results. Because
of access limitations, dimension B is
more difficult to measure. It is most
S0600-AA-PRO-120
eight
measurements
i.
j.
12-6.3.16 (DV) Install four 5/16-18 UNC, 4inch long jacking bolts 90 degrees apart into
the threaded through-holes provided in the
blade seal base ring (9). Note the depth of
insertion of the ring relative to the lip of the
12-79
S0600-AA-PRO-120
12-6.3.28 (DV) Remove the four 5/8-inch allthread rods and install the remaining four 5/8inch cap screws. Tighten all cap screws
snugly.
NOTE
Ensure that items (3) and (8)
(dynamically loaded O-rings)
are replaced with fully molded
instead of spliced O-rings. Orings supplied by the stock system for items (3) and (8) are
often spliced instead of fully
molded.
12-6.3.24 (DV) Fill the empty O-ring grooves
on the blade port cover ID, the inner and outer
Morgrip bolt hole diameters on the crank pin
ring, and the blade seal base ring (four O-ring
grooves total) with grease and remove any
excess. Seat four new O-rings (3, 4, 7 and 8)
into their appropriate grooves and allow the
grease to hold them in place. Again, remove
any excess grease. If a Mylar shim is installed,
ensure the shim lays flat against the crank pin
ring or blade port cover.
12-6.3.25 (SF, DV) Allow the oil/seawater
interface at the blade port to settle out and
have Ships Force release oil from the head
12-80
S0600-AA-PRO-120
surements and perhaps reduce shim thickness. However, if bearing ring wear is
indicated and the hub already has a long service life, the only alternative may be drydock
replacement of the worn bearing ring.
12-6.3.38. Replace blade in accordance with
Section 12-5 of this manual.
12-6.3.39. (SF, DV) Remove out-of-service
tags. Cycle the blade pitch through normal
range of operation several times. Test and
purge the system in accordance with section
6-7 of reference a for the DD 963 and DDG
993 Classes or Section 6-3d of reference c for
the CG 47 Class, MRC 77 6WBM N (R-2W)
and paragraph 12-4.3.40. Have divers check
for leaks around the blade palm and hub interface of all blades during the testing.
12-6.3.40. In performing system test and
purge, supplement the procedure outlined in
MRC 77 6WBM N (R-2W) with the following.
Purge for approximately 15 to 30 minutes. To
open purge valve, (located in hub) take manual control (joystick) and slew pitch astern until
the main system relief valve lifts (1000 psi).
Slew pitch ahead just enough to reset the
main relief valve. Purge valve is now open
allowing oil from the hub crosshead cavity to
be flushed out and returned to the sump for
purification. It should be noted that, if the main
shaft is rotated (turning gear) in conjunction
with the hub purge, this will improve the crosshead cavity flushing operation. Rotating the
shaft during a hub purge is not mandatory and
is left to the Chief Engineer/Main Propulsion
Assistant discretion. Recommend hub purge
be conducted upon each return to port prior to
securing the CPP system.
12-81
S0600-AA-PRO-120
12-82
S0600-AA-PRO-120
12-83
S0600-AA-PRO-120
installing remaining blade bolts into the lubricated holes, and fully tightening all bolts.
Measure the installed bolt lengths to determine the proper residual stretch, and install
fairing/sealing plug in blade bolt measurement
cavities.
NOTE
While the following procedure
requires that the topside personnel and the divers work
closely together, there are certain steps that must be carried
out by particular personnel. To
clarify these steps, abbreviations are placed at the beginning of each step where the
specific party needs to be identified: (DV) represents diver,
(TOP) represents topside personnel, (SF) represents Ships
Force personnel and (UT) represen ts L evel II Ul tra so ni c
Inspector.
12-7.3 PREPARATION.
12-7.3.1 Ships List and Trim. Ensure that
the ship has no more than one degree of list
and minimum possible trim during the actual
blade removal. Excessive list or trim will
adversely impact insertion of replacement
blades into the propeller hub port.
NOTE
It is essential that all tools and
materials brought to the underwater job site are accounted for
and removed at the completion
of the job. Tools and materials
inadvertently left at the job site
can generate unacceptable
noise and possibly cause
severe damage to shipboard
components. Locally generated work packages shall
ensure that a general tool and
material log sheet is prepared
12-84
S0600-AA-PRO-120
CAUTION
1- To n
Typical
R unning
B lock
Flip
3 To n
4- To n
6 Ton
Fig. 12-24A Tugit Lever Hoists (Harrington PullChain Type have a two part Reeve)
Change 1
12-84A
S0600-AA-PRO-120
12-84B
Change 1
S0600-AA-PRO-120
Quantity
Component Description
Technical Specifications
Commercial
Commercial
Commercial
as required
Commercial
as required
Commercial
as required
Grease Pencils
Commercial
Commercial
as required
Chafing Material
Commercial
Degreaser/Carburetor Cleaner
Commercial
12-7.4.1 Hydraulic Bolt Torquing Equipment. The hydraulic bolt torquing equipment
is used to tighten the blade bolts. The equipment must be operated in accordance with
manufacturer's instructions.
CAUTION
CAUTION
Careful attention must be paid
to connection of the hydraulic
hoses between topside pump
and
underwater
hydraulic
torque link. The hoses must be
connected in accordance with
manufacturer's instructions.
12-7.4.2 Lifting Assembly. The
lifting
assembly (See Appendix F) is attached to a
propeller blade so the blade can be lifted and
lowered with the hook of a lever hoist.
12-7.4.3 Righting Fixture. The righting fixture (See Appendix G) is installed onto the
12-85
S0600-AA-PRO-120
2.
3.
4.
5.
6.
Ensure lifting fixture is installed with head clamp 67" from blade tip[12-7.8.9]
7.
8.
9.
Blade Installation
1.
2.
Ensure edge guard material is used for lifting fixture clamps [12-7.10.6]
3.
4.
5.
6.
7.
8.
9.
Record serial numbers, hub position, and initial lengths of blade bolts to be installed.
Use Hex Socket Bolt Baseline and Post-Elongation Measurement Worksheet, Figure B4 [12-7.11.2]
10. Install new Teflon Blade Bolt O-Ring and apply lubricant to blade bolt threads and shoulder [12-7.11.4 and 12-7.11.11]
11. Record actual measured bolt elongation as each bolt is torqued. Use Hex Socket Bolt
Elongation Measurement During Installation Worksheet, Figure B-5 [12-7.11.15]
12. Record final length and residual stretch when all eight bolts are installed. Hex Socket
Bolt Baseline and Post-Elongation Measurement Worksheet on Figure B-4 [12-7.12.1]
13. Compare final with baseline and confirm proper residual stretch [12-7.12.2]
14. Ensure blade bolt 2-1/4-inch hex plug, rubber washer, and retaining screw are installed
[12-7.14.1]
15. Test the CPP system performance [12-7.15]
12-86
Initials
Initials
S0600-AA-PRO-120
12-7.5.5 Rig Forward Holdback Hoist. Fabricate a bridle to attach to the master links on
the forward (suction) face side of the trailing
and leading edge blade lifting fixture clamps.
As close as possible try to have the bridle center the pull approximately 3.5 inches outboard
of the port to starboard centerline of the blade
(blade CG location). The bridle may have to
be adjusted to find the sweet spot when the
blade is lifted. Choker rig a 10 ft synthetic
sling (6000 LB capacity) (FN 144) around the
inboard main bearing strut as the forward
attachment point for the holdback hoist. Position the choke point (hoist attachment point) of
the synthetic sling at the middle of the outboard side of the inboard strut. This position
will act to center the holdback hoist pull with
the port to starboard CG of the blade as much
as possible. Attach a 3 ton lever hoist (FN
153) between the special bridle and the synthetic sling.
WARNING
12-87
S0600-AA-PRO-120
12-88
S0600-AA-PRO-120
12-89
S0600-AA-PRO-120
NOTE
Pa ti e n ce i s re q u i r ed w h e n
using the Sweeney tool. The
recycle time is approximately
12 seconds and 12 full cycles
are required for one revolution
of the bolt.
12-7.7.5 (TOP/DV) Apply hydraulic pressure
to the link until #1 bolt is broken loose. Repeat
process in accordance with Table 12-9 or 1210 until all bolts are broke loose. In order to
avoid damaging the bolts, individually remove
each bolt and send it to the surface.
12-7.7.6 (TOP) Discard the used blade bolt
Teflon O-ring.
12-7.7.7 (TOP) Prior to use, all unthreaded,
polished, external bolt surfaces must be
12-90
S0600-AA-PRO-120
Change 1
12-91
S0600-AA-PRO-120
12-92
S0600-AA-PRO-120
Table 12-9 Sweeney Tool Fit-Up DDG 51: Right Hand Blade
LOOSEN
TIGHTEN
Bolt Position
Shim Size
React Against
Shim Size
React Against
1 inch
Hex in bolt 2
1 inch
Blade*
1 inch
Hex in bolt 3
1 inch
Hex in bolt 1
1 inch
Hex in bolt 4
1 inch
Hex in bolt 2
3 inch
Blade *
1 inch
Hex in bolt 3
1 inch
Hex in bolt 6
3 inch
Blade*
1 inch
Hex in bolt 7
1 inch
Hex in bolt 5
1 inch
Hex in bolt 8
1 inch
Hex in bolt 6
1 inch
Blade*
1 inch
Hex in bolt 7
*Reaction arm may be re-positioned on the hydraulic torque link to achieve a best fit against the blade palm.
TIGHTEN
Bolt Position
Shim Size
React Against
Shim Size
React Against
1 inch
Blade*
1 inch
Hex in bolt 2
1 inch
Hex in bolt 1
1 inch
Hex in bolt 3
1 inch
Hex in bolt 2
1 inch
Hex in bolt 4
1 inch
Hex in bolt 3
3 inch
Blade*
3 inch
Blade*
1 inch
Hex in bolt 6
1 inch
Hex in bolt 5
1 inch
Hex in bolt 7
1 inch
Hex in bolt 6
1 inch
Hex in bolt 8
1 inch
Hex in bolt 7
1 inch
Blade*
*Reaction arm may be re-positioned on the hydraulic torque link to achieve a best fit against the blade palm.
12-93
S0600-AA-PRO-120
Table 12-10. Sweeney Tool Fit-Up CG 66 and Higher: Right Hand Blade.
LOOSEN
TIGHTEN
Bolt Position
Shim Size
React Against
Shim Size
React Against
1 inch
Hex in bolt 2
1 inch
Blade*
1 inch
Hex in bolt 3
1 inch
Hex in bolt 1
1 inch
Hex in bolt 4
1 inch
Hex in bolt 2
3 inch
Blade*
1 inch
Hex in bolt 3
1 inch
Hex in bolt 6
3 inch
Blade*
1 inch
Hex in bolt 7
1 inch
Hex in bolt 5
1 inch
Hex in bolt 8
1 inch
Hex in bolt 6
3 inch
Blade*
1 inch
Hex in bolt 7
*Reaction arm may be re-positioned on the hydraulic torque link to achieve a best fit against the blade palm.
TIGHTEN
Bolt Position
Shim Size
React Against
Shim Size
React Against
1 inch
Blade*
1 inch
Hex in bolt 2
1 inch
Hex in bolt 1
1 inch
Hex in bolt 3
1 inch
Hex in bolt 2
1 inch
Hex in bolt 4
1 inch
Hex in bolt 3
3 inch
Blade*
3 inch
Blade*
1 inch
Hex in bolt 6
1 inch
Hex in bolt 5
1 inch
Hex in bolt 7
1 inch
Hex in bolt 6
1 inch
Hex in bolt 8
1 inch
Hex in bolt 7
3 inch
Blade*
*Reaction arm may be re-positioned on the hydraulic torque link to achieve a best fit against the blade palm.
12-94
S0600-AA-PRO-120
WARNING
S0600-AA-PRO-120
S0600-AA-PRO-120
S0600-AA-PRO-120
j.
S0600-AA-PRO-120
NOTE
If all removed blades are set
within reach of the crane
upright on timbers (step 127.8.20i) as they are removed,
topside will have plenty of time
to shift removed blades to the
special shipping pallets as new
blades are removed from the
shipping pallets for installation.
l.
S0600-AA-PRO-120
12-100
S0600-AA-PRO-120
12-101
S0600-AA-PRO-120
12-102
S0600-AA-PRO-120
NOTE
Guide pins need to be installed
through the holes after the
blade is positioned over the
hub. The rigging will not allow
the blade to clear the hub if the
guide pins are in place.
12-7.10.25 (DV) Detach the aft lever hoist.
WARNING
12-103
S0600-AA-PRO-120
12-7.10.36 (DV, TOP) If no downward movement can be achieved by shaking the blade, or
12-104
S0600-AA-PRO-120
CAUTION
S0600-AA-PRO-120
NOTE
For the Sweeney RSL-8 Link,
set the pump to 1100 psi to
obtain 800 ft-lbs.
12-7.11.7 (DV/TOP) Use the Sweeney Tool
(FN 78) to torque bolts #1, #4, #5, and #8 to
800 ft-lbs. Note that since not all bolts are in
place the tool will have to react against the
blade. The diver should position the tool
and/or adjust the reaction arm on the tool for a
"best fit".
12-7.11.8 (DV) Insert a .002 feeler gauge
(FN 122) into bolt holes #2, #3, #6, and #7
between the blade palm and port cover plate.
This step will verify that blade is, or is not
seated on the port cover. If the feeler gauge
can be inserted at all, it should be a snug
(touching both sides) fit. Any looser fit indicates that the blade is not seated and the
most probable cause is that the port cover Oring is not properly inserted. This problem will
have to be corrected before continuing with
the installation.
CAUTION
12-7.11.9 (TOP) Fill and cap lubricant dispensers (FN 163.1), one for each of the
remaining four blade bolt holes, with 200 cc of
Hydrolube (FN 163) each and pass to the
divers.
12-7.11.14 (DV/UT) As shown in Figure 1233 and 12-34, place the bolt elongation measurement assembly into bolt head #2. Screw
the transducer into the bolt head finger tight
until it comes to an abrupt halt. Using the correct shim and reaction arm location (see
12-106
S0600-AA-PRO-120
12-107
S0600-AA-PRO-120
12-108
Change 1
CAUTION
INSTALLED
BOLT
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APPENDIX A
MORGRIP BOLT ELONGATION MEASUREMENT PROCEDURE
A-1 TUTORIAL DISCUSSION
A-1.1 INTRODUCTION.
This procedure for measuring the elongation
of Controllable Reversible Pitch Propeller
Blade Bolts is a variation of standard ultrasonic thickness gauging. We assume that
inspectors using this procedure are already
proficient in ultrasonic thickness gauging, and
understand the underlying principles. This discussion is a "self-help" document which
explains some of the reasoning behind the
measurement procedure. It should take
approximately four hours of reading and practice to master the measurement procedure.
A-1.1.1 In this tutorial discussion we attempt
to highlight the similarities and differences
between conventional thickness gauging and
bolt elongation measurement. Discussion of
the differences will serve to deepen the
inspector's understanding of the measurement
process, and help avoid problems areas that
can arise from improper application of the procedure.
A-1.2 PRINCIPLES OF OPERATION.
The Bolt Elongation Measurement (BEM) process measures the waterpath that exists
between the face of the BEM transducer and
the bottom of a blade bolt cavity. By comparing this dimension before and after installation,
elongation can be detected and measured.
Velocity variations due to temperature and
salinity changes are compensated by use of a
reference bolt at each stage of the measurement process. When properly applied, the
measurement process is accurate to better
than half a thousandth of an inch.
A-1.2.1 When the Bolt Elongation Measurement tool is inserted into a blade bolt, the
small transducer at the tip of the tool is
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Thread lubrication
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explain that the transducer sends out ultrasonic pulses much like the fathometer or
depth finder on a boat.
A-1.6.3 Show the divers the reference bolt
and point out that the very bottom of the cavity
is milled flat, and serves as a reflector for the
ultrasound. Point out that the flat surface on
top of the bolt is a reference surface and that
the bolt's elongation is measured from that
surface to the bottom of the cavity.
A-1.6.4 Place the transducer in the reference
bolt, and as you do, explain that the transducer carrier puts the tip of the transducer
about a tenth of an inch away from the flat bottom of the cavity.
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reference bolt which undergoes the same temperature changes as the bolt being installed,
but is not stretched. This procedure also
establishes personnel qualification requirements, inspection material requirements, test
procedures, acceptance standards, and
reporting requirements. Hardware is defined
by NAVSEA Drawing 6698352. NAVSEA 00C
maintains a limited number of systems for use
by field activities.
Note
It is essential that all Ultrasonic
Technicians, especially those
with no bo lt measuremen t
experience carefully review all
of Appendix A and the applicable bolt installation portion of
the blade replacement procedure prior to commencing measurements. A good place to
start your review is Section A-1
of this appendix (Tutorial Discussion).
A-3 REFERENCED DOCUMENTS
a. NAVSEA T9074-AS-GIB-010/271, 30
April 1997, NAVSEA Technical Publication, Requirements for Nondestructive Testing Methods
b. ASTM E 1316-95a, Standard Terminology for Nondestructive Examination
c. NAVSEA Drawing #6698352, Bolt
Elongation M easurement Sys tem,
Assembly
A-4 GENERAL
A-4.2 PRECAUTIONS.
Safety precautions contained in the Installation and Removal procedure must be
observed at all times. Additionally, ground
fault interruption must be used with all underwater equipment requiring AC power.
A-4.3 EQUIPMENT AND MATERIALS.
A-4.3.1 Ultrasonic Instrument. A standard
A-scan type instrument conforming to the
requirements of NAVSEA Technical Publication 271 shall be used. Within six months prior
to use for bolt elongation measurements, the
instrument must be qualified in accordance
with NAVSEA Technical Publication 271 paragraph 6.5.1.1. Records of this instrument qualification must be retained with records of the
bolt installation.
A-4.3.2 Transducer Carrier (Bolt Elongation
Measurement Tool). Figure A-1 shows the
bolt elongation measurement tool which has
been designed for this application. NAVSEA
approval of transducers and associated fixtures is required.
A-4.3.3 Reference Bolt. A standard blade
bolt, modified in accordance with NAVSEA
drawing 6698352, (Appendix J) is supplied by
NAVSEA as part of the Bolt Elongation Measurement system. This bolt must be reserved
for use only as a calibration standard.
A-4.3.4 Calibration Standard. A reference
standard enabling the inspector to position the
transducer carrier in direct contact with the reference bolt (slot #1), 0.015 inch above the bolt
(slot #2). 0.020 inch above the bolt (slot #3), or
0.025 inch above the bolt (slot #4). See Figure
A-2.
A-4.1 DEFINITIONS.
Standard terminology (ASTM E 1316-95a)
related to ultrasonic examination is used
throughout this document.
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A-4.3.5 Couplant. Water is used as the couplant material. The reference bolt and the bolt
being measured must have the same kind of
water in them for valid readings to be taken.
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J.O.N.:
Ship:
Work Center:
Date:
Component: Blade
Port:
Project (Ship):
Blade Serial Number:
Ultrasonic Instrument:
Calibration Standard:
Reference Bolt:
Transducer:
Bolt Serial #
and
Position in Hub
NDT Inspector:
A-8
Installed Screen
Position
Date:
Initial Screen
Position
Length Change
(Difference x
0.005 "/div.)
Difference
(Screen div.)
Date:
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or smooth as the reference bolt. After correcting conditions of cleanliness and debris, make
note of bolts which remain "troublesome"
since they will also be "troublesome" when
installed. Note the position of the IFE and
record this screen position as the baseline
measurement for this bolt.
A-5.3.5 Repeat steps A-5.3.3 and A-5.3.4 for
each bolt. Note that each time the transducer
is placed in the reference bolt the IFE should
appear at 5 screen divisions. If adjustments
are required it is likely that the transducer has
not been properly aligned relative to the bolt
(see section A-5.1.3), or that the reference
bolt has not been properly cleaned (see section A-5.3.1).
A-5.4 UNDERWATER MEASUREMENTS
AFTER INSTALLATION.
A-5.4.1 Measurements will be taken with the
blade in the 12 o'clock position to ensure that
the bolt cavities are completely filled with
water. In this position, the transducer carrier
can be allowed to rest in the bolt without being
held by the diver. This helps ensure that it is
not tilted.
A-5.4.2 The diver ensures that each installed
bolt's cavity is clean, and free from oil. Immediately prior to placing the transducer carrier in
each bolt, the diver purges the bolt cavity with
air from the pneoumofathometer.
A-5.4.3 The diver places the transducer carrier in the reference bolt, and ensures proper
rotational alignment. The topside inspector
places the second IFE at 5 divisions on the
CRT using the FINE DELAY control only.
A-5.4.4 The diver moves the transducer carrier to the installed bolt specified by the topside inspector, and rotates it to the proper
position. The topside inspector records the
screen position of the second IFE.
A-5.4.5 Steps A-5.4.2 and A-5.4.3
repeated for each of the installed bolts.
are
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A-5.5 ELONGATION.
Underwater Measurements
A-5.5.1 Bolt elongation is determined by calculating the difference between the second
IFE's screen position prior to, and after installation of each bolt. Use Figure A-3 (Bolt Elongation Measurement Inspection Report and
Worksheet) to record data. Each major screen
division has been calibrated to represent
0.005 inch. See the example in paragraph A5.2.
A-6. EVALUATION
Bolts which show an elongation of 0.006 inch
to 0.0084 inch are acceptable. Bolts whose
elongation falls outside this range must be
reinstalled in accordance with NAVSEA procedures.
A-6.1 EXAMPLE.
Baseline Measurements
Place transducer carrier in reference bolt,
rotate to the proper position, and set IFE at 5
divisions on the CRT
..... inspector confirms IFE at 5 divisions.
Place transducer carrier in bolt number XXX,
rotate to the proper position, and read the
position of the IFE
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APPENDIX B
HEX SOCKET BOLT ELONGATION MEASUREMENT PROCEDURE
B-1. TUTORIAL DISCUSSION
B-1.1 SCOPE
B-1.1.1 This tutorial covers Controllable
Pitch Propeller (CPP) blade bolt measurement
for hex socket bolts used on the DDG 51
"Fleet" blade and CG 47 (CG 66 and higher)
class ships.
B-1.2 INTRODUCTION
B-1.2.1 This procedure for measuring the
elongation of Controllable Pitch Propeller
Blade Bolts is a variation of standard ultrasonic thickness gauging. We assume that
inspectors using this procedure are already
proficient in ultrasonic thickness gauging, and
understand the underlying principles. This
discussion is a "self-help" document which
explains some of the reasoning behind the
measurement procedure.
It should take
approximately four hours of reading and practice to master the measurement procedure.
B-1.2.2 In this tutorial discussion we attempt
to highlight the similarities and differences
between conventional thickness gauging and
bolt elongation measurement. Discussion of
the differences will serve to deepen the
inspector's understanding of the measurement
process, and help avoid problem areas that
can arise from improper application of the procedure.
B-1.3 PRINCIPLE OF OPERATION
B-1.3.1 The Bolt Elongation Measurement
(BEM) process measures the waterpath that
exists between the face of the BEM transducer and the bottom of a blade bolt cavity.
By comparing this dimension before and after
installation, elongation can be detected and
measured.
Elongation can be measured
directly, during the installation process. Veloc-
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REFERENCE
SURFACE
TRANSDUCER
ULTRASONIC INSTRUMENT
COAXIAL CABLE
WATER GAP
TRANSDUCER
FLAT BOTTOM
HOLE
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BENCHMARK
TRANSDUCER
PRECISION
LEAD SCREW
CALIBRATION
BASE
LEAD SCREW
CAP
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when the position of the second IFE is monitored, since the sound must travel from the
transducer to the reflecting surface, and back,
twice. Variations in cable length will visibly
affect the absolute position of the second IFE,
but this variable is removed by the measurement procedure.
B-1.5.2 For baseline measurements, the
same transducer and the same cable are used
to measure all of the blade bolts and the reference bolt, and the length of each blade bolt is
recorded after subtracting out the length of the
reference bolt. Absolute echo position is
immaterial, since any constant offset (due to
the transducer or cable's length) is subtracted
out. Similarly, when measurements are taken
after all the bolts are installed, the procedure
calls for the reference bolt to be measured insitu, with the same transducer and cable as is
used for the blade bolt measurements. Again,
subtracting the length of the reference bolt
from the length of each blade bolt eliminates
constant offsets. In the case of in-process
measurements, the transducer and cable
remain connected to the transducer during the
entire tightening process, and changes in the
second IFE's position are monitored, not the
absolute position of this echo.
B-1.6 POTENTIAL PROBLEM AREAS
B-1.6.1 Because the required measurement
accuracy is far smaller than an ultrasonic
wavelength, it is crucial that exactly the same
part of the ultrasonic waveform be used for all
measurements. The ultrasonic instrument's
receiver section performs a number of functions: amplification of the rf signal, rectification
(to produce the "video" signal), and filtering.
Reject is also available to clip low amplitude
portions of the signal. The point at which the
signal "breaks the baseline" depends on which
half cycle of the waveform is used, and that
depends on gain, reject, and filter choices. As
a general rule, all signals should be brought to
about full screen height using gain, and once a
filter has been selected it should not be
changed. To see the impact of filter choice,
set up on the reference bolt and compare the
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bolt
thread lubrication
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B-2.1 SCOPE
B-2.1.1 This section describes ultrasonic
measurement of bolt elongation during waterborne installation of controllable pitch propeller (CPP) blades, as required by reference (a)
for CG 47 (CG 66 and higher) class ships
(0.005-0.007 inch elongation) and reference
(b) for DDG 51 class ships with "Fleet" type
blades (0.005-0.007 inch elongation). Bolt
elongation must be measured within 0.0005
inches.
B-2.1.2 Program management for waterborne blade changes is under NAVSEA 00C5
cognizance (703-607-2761).
B-2.2 BACKGROUND
B-2.3 REFERENCES
a) S9245-AV-MMA-010/07309,
Technical Manual, Installation, Operation,
Maintenance and Repair Instructions
with Parts List, Controllable Reversible
Pitch Propeller for CG 66 and Follow
Ships, 30 APR 1991
b) S9245-AM-MMA-010/07309, System
Manual for Controllable Pitch Propeller
System, DDG 51 Class, Model 156,
Type S1/5, 15 AUG 1990
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B-2.6 PROCEDURE
B-2.6.1 A summary of the major procedural
elements is provided in this section. Details of
instrument set-up for calibration and measurement are included in an instrument-specific
addendum, Section B-3.
B-2.6.2 Exterior cleaning. Bolts removed
from an in-service propeller require cleaning to
remove all biofouling and corrosion prior to
penetrant testing. This cleaning may be performed with a soft wire brush (typically having
0.007" diameter wires) to avoid damage to the
bolt surface, threads or copper cladding. An
ordinary green ScotchBrite scouring pad may
also be used for exterior cleaning; however,
no form of sandpaper or abrasive cloth is permitted.
B-2.6.3 Penetrant testing. Bolts
are
inspected using a visible dye, solvent removable system. The inspection area is from the
top of the threads up to the head of the bolt,
including the underside of the head. Fluorescent systems (solvent removable, post emulsifiable, or water washable) can be used . No
linear indications in excess of 1/16" are
allowed.
B-2.6.4 INTERIOR CLEANING
B-2.6.4.1 Bolt elongation measurements are
made by reflecting ultrasound off the bottom of
a flat-bottomed hole approximately 5 inches
deep on the axis of the bolt. This surface must
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tion is required. To accomplish this, the difference in the lengths of each blade bolt and the
reference bolt are again measured, this time
with the blade bolt stretched but the reference
bolt in its original (unstretched) condition.
Accuracy is attained by measuring both bolts
side by side, underwater; this ensures that
they are under identical conditions of temperature and salinity.
B-2.6.8.2 Post-installation
measurements
are made by carrying the reference bolt underwater to the blade palm, where it will quickly
come to thermal equilibrium. The transducer
is first screwed into the reference bolt, then
the blade bolt, and the ZERO OFFSET is set
at a position for which both echoes are viewed
with no adjustments of any instrument settings.
The same echo feature chosen for baseline
measurements must be used for this measurement as well. As with the baseline measurements, the length of the blade bolt,
relative to the reference bolt, is determined by
the difference in their signal positions. Then,
subtracting the baseline difference from the
post-installation difference gives the blade bolt
elongation. These data are recorded in the
worksheet provided as Figure B-4.
B-2.7 MAINTENANCE
B-2.7.1 Maintenance is generally limited to a
freshwater rinse for all saltwater wetted and
sprayed components, other than the ultrasonic
instrument. Exterior surfaces and connectors
should be sprayed with a moisture displacing
anticorrosive spray prior to storage. The calibration standard should be thoroughly cleaned
and lubricated to prevent corrosion of the precision lead screw. Under normal use it is not
necessary to disassemble the transducer
assembly.
Should the transducer fail or
become damaged it is replaceable. Note that
in order to preserve high dimensional stability,
parts have been assembled with a thread
locking compound.
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Figure B-4. Hex Socket Bolt Baseline and Post-Elongation Measurement Worksheet
Blade Bolt
Position
Bolt
serial #
Baseline
Measurement
(NOTE)
Post Installation
Measurement
(NOTE)
Bolt
Elongation
Final Hydraulic
Torquing
Pressure
Final
Installation
Torque
Reference Bolt
Blade 1/Bolt #1
Blade 1/Bolt #2
Blade 1/Bolt #3
Blade 1/Bolt #4
Blade 1/Bolt #5
Blade 1/Bolt #6
Blade 1/Bolt #7
Blade 1/Bolt #8
Reference Bolt
Blade 2/Bolt #1
Blade 2/Bolt #2
Blade 2/Bolt #3
Blade 2/Bolt #4
Blade 2/Bolt #5
Blade 2/Bolt #6
Blade 2/Bolt #7
Blade 2/Bolt #8
Reference Bolt
Blade 3/Bolt #1
Blade 3/Bolt #2
Blade 3/Bolt #3
Blade 3/Bolt #4
Blade 3/Bolt #5
Blade 3/Bolt #6
Blade 3/Bolt #7
Blade 3/Bolt #8
Reference Bolt
Blade 4/Bolt #1
Blade 4/Bolt #2
Blade 4/Bolt #3
Blade 4/Bolt #4
Blade 4/Bolt #5
Blade 4/Bolt #6
Blade 4/Bolt #7
Blade 4/Bolt #8
Reference Bolt
Blade 5/Bolt #1
Blade 5/Bolt #2
Blade 5/Bolt #3
Blade 5/Bolt #4
Blade 5/Bolt #5
Blade 5/Bolt #6
Blade 5/Bolt #7
Blade 5/Bolt #8
Note: Enter ZERO Offset (in microseconds, msec.) required to place the second interface echo at 2 screen divisions
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NOTE:
Figure B-4, Hex Socket Bolt
baseline and Post-Elongation
Measurement Worksheet, is
also provided as a Windows
Office 97 EXCEL worksheet
(Elongation.xls) containing the
formulas required to calculate
bolt el ongation . Th is wo rksheet may be launched directly
from this CD-ROM or the file
may be copied to another computer directory for ease of use.
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B-3.1 SCOPE
B-3.1.1 This section presents a detailed
description of DDG 51 and CG 47 (CG 66 and
higher) class ships bolt elongation measure-
Figure B-5. Hex Socket Bolt Elongation Measurement During Installation Worksheet
NDT File #:
J.O.N.:
Ship:
Work Center:
Date:
Component: Blade
Port:
Project (Ship):
Blade Serial Number:
Ultrasonic Instrument:
Calibration Standard:
Reference Bolt:
Transducer:
Bolt Serial #
and
Position in Hub
NDT Inspector:
Installed Screen
Position
Date:
Initial Screen
Position
Difference
(Screen div.)
Level II Examiner
Length Change
(Difference x 0.0025/div.)
Date:
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Thickness: 0.000
Zero: 0.000 s.
FULL WAVE
PULSE-ECHO MODE
Angle: 0.0
* The published speed of sound in seawater is about 0.06 inches/microsecond, or about twice the recommended
set-up value. This discrepancy arises because the procedure calls for using the second interface echo, which
means that travel time for the ultrasonic pulse is twice as long as it would be for the first interface echo.
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200
180
Signal Amplitude
160
140
120
100
80
60
40
20
0
Time
100
90
Signal Amplitude
80
70
60
50
40
30
20
10
0
Time
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BOLT
MEASURE-
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EXAMPLE:
Reference bolt offset = 17.875 microseconds
Blade bolt offset = 16.975 microseconds
Velocity = 0.0300 inches/microsecond
Relative blade bolt length = -((17.875 16.975) * 0.0300) / 2 = -0.0135 inches
(The blade bolt is 13.5 thousandths of an inch
shorter than the reference bolt).
B-3.3.2.2 Save each bolt signal in memory.
Note bolts with unusual waveforms. Assuming that the flat-bottomed hole has been properly cleaned, an unusual waveform is the
result of the geometry of the hole bottom, and
can be expected to recur during all measurements on that bolt.
B-3.3.2.3 Print out each bolt waveform for
comparison with the signal obtained during inprocess and final measurements.
B-3.4 IN-PROCESS MEASUREMENTS
B-3.4.1 INITIAL CALIBRATION
B-3.4.1.1 The instrument calibration should
be checked on-site to account for minor variations in the speed of sound. To accomplish
this, immerse the calibration standard in local
seawater until thermally stabilized, then
recover it full of seawater. Install the calibration standard in its base and make minor
adjustments to RANGE and ZERO OFFSET
as required to achieve a calibrated screen.
Finally, set the gate to full screen width and
adjust VELOCITY to produce a GATE WIDTH
of 0.0250 inches. These adjustments should
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