2 × VSP28 Propeller Housings – 1,297mm Bore Machining & 2,006mm Flange Facing
Client: Voith
Industry: Marine & Shipbuilding
Location: UK
Duration: Completed within 7 days (24 working hours)
Services: Bore Machining & Flange Facing
Overview
Royce Onsite Machining was engaged to carry out a critical onsite flange facing and bore machining operation on two VSP28 propeller housings. The existing bores and flange faces had suffered significant corrosion, resulting in misalignment, sealing issues, and reduced operational efficiency. The client required both components to be restored to OEM specifications.
Our engineers removed the corroded material, installed precision-engineered marine steel replacement sleeves, and completed the final machining operations. A total of 53 mm was removed from the bore diameter and 8 mm from the flange face, restoring both components to the maximum allowable OEM limits while ensuring correct alignment, dimensional accuracy, and surface finish.
Work Carried Out
Damage Assessment
- Inspection confirmed that the existing sleeves were worn and damaged, affecting bore alignment and perpendicularity.
- Non-destructive testing confirmed that the parent material was suitable for repair.
- The low areas on the 2,006 mm flange face were built up prior to final machining.
Sleeve Replacement
- Precision-engineered marine steel replacement sleeves were manufactured, supplied, and installed.
Final Machining & Verification
- Bore machining removed 53 mm from the bore diameter, while flange facing removed 8 mm from the sealing face, restoring both surfaces to the maximum allowable OEM limits.
- Alignment was accurately checked and corrected to ensure full compliance with OEM specifications.
- Final dimensional inspections and surface finish checks confirmed that the components were restored to full operational integrity.
Technical Highlights
- Components: 2 × VSP28 Propeller Housings
- Bore Diameter: 1,297 mm
- Flange Face Diameter: 2,006 mm
- Repair Method: Onsite bore machining, flange facing, and marine steel sleeve replacement
- Sleeve Type: Precision-engineered marine steel replacement sleeves
- Material Removed: 53 mm from the bore diameter and 8 mm from the flange face
- Completion Time: 7 days (24 working hours)
- Accuracy: Alignment restored to OEM specification
- Verification: Final dimensions and surface finish confirmed within OEM tolerances
Outcome
The repair was successfully completed onsite within seven days, eliminating the need to cut out and replace the propeller housings. The bores, flange faces, and replacement sleeves were restored to OEM specifications, with alignment, dimensional accuracy, and surface finish all verified.
By carrying out the work onsite, Royce Onsite Machining significantly reduced downtime and avoided the cost and disruption associated with component removal, transportation, and workshop repairs.
This project demonstrates Royce Onsite Machining’s capability to deliver high-precision onsite bore machining, flange facing, and marine steel sleeve replacement on large marine propulsion components, even when working within strict OEM repair limits.
Frequently Asked Questions
Does Royce Onsite Machining offer all types of flange facing?
Royce Onsite Machining provides onsite flange facing solutions for a wide range of applications across the marine, energy, oil and gas, petrochemical and industrial sectors. Our specialist equipment allows large and complex flange faces to be machined accurately in situ, helping clients avoid the cost and downtime associated with removing components for workshop repair.
Does Royce Onsite Machining work to OEM specifications?
Yes. Royce Onsite Machining can work from OEM drawings, specifications, repair limits and technical requirements to ensure onsite machining is completed to the required standards. For critical components, our engineers work closely with the applicable OEM requirements to achieve the necessary dimensions, alignment and surface finish.
What range of flange facing does Royce Onsite Machining support?
Royce supports a broad range of onsite flange facing requirements, from smaller sealing surfaces through to large-diameter flanges. Our equipment and experienced engineers are capable of carrying out precision flange facing on complex components where removing the equipment or transporting it to a workshop would be impractical or costly.
Can flange facing be carried out without removing the component?
Yes. One of the key benefits of onsite flange facing is that machining can be carried out directly on the installed component. This can significantly reduce dismantling, transportation, workshop costs and overall equipment downtime.
Can Royce Onsite Machining provide workshop-quality results onsite?
Yes. Royce uses precision onsite machining equipment, experienced engineers and detailed dimensional inspection procedures to deliver results comparable with conventional workshop machining, subject to the specific component, tolerances and repair requirements.
For this VSP28 project, the 2,006 mm flange faces were machined onsite, alongside the 1,297 mm bores, with final dimensional and surface-finish checks confirming compliance with the required OEM tolerances.
