This comprehensive three-day, intermediate-to-advanced training program is designed to provide mechanical engineers, foremen, and RP fitters with the in-depth knowledge and practical skills required to execute a complete Control Pitch Propeller (CPP) Overhaul in line with marine industry standards and specific Scope of Work requirements. Building upon the foundational two-day structure, this expanded course dedicates additional time to hands-on application, complex problem-solving, and advanced testing protocols. Participants will progress through the entire overhaul lifecycle—from initial system familiarization and technical documentation review to intricate component dismantling, Non-Destructive Testing (NDT), hydraulic system servicing, precision reassembly, and rigorous performance validation. The extra day allows for deeper dives into critical areas such as advanced machining criteria, detailed blade repair workshops, comprehensive hydraulic circuit analysis, and simulated sea trial preparations.
Through a blended approach of theoretical instruction, detailed case studies, and extensive practical exercises using diagrams and component replicas, this course ensures attendees can confidently manage every phase of a CPP overhaul, ensuring reliability, safety, and compliance with classification society regulations.
COURSE OBJECTIVES
By the end of this course, participants will be able to:
- Interpret complex CPP system drawings and technical documentation to identify all components, lifting points, and spare parts.
- Execute systematic pre-overhaul inspections and dismantling procedures for the propeller hub, blades, shafting, and hydraulic actuators, ensuring component integrity and safety.
- Apply appropriate Non-Destructive Testing (NDT) methods, including Ultrasonic Testing (UT) and Magnetic Particle Inspection (MPI), to evaluate critical components for defects.
- Assess blade and hub damage to make informed decisions on repair, refurbishment (including machining criteria), or replacement.
- Perform a complete overhaul of the CPP hydraulic control system, including component inspection, calibration, fluid management, and leak-checking.
- Conduct the precision reassembly of the CPP system, adhering to strict protocols for alignment, torqueing, shimming, and lubrication.
- Perform and analyze post-overhaul tests, including system leak tests and dynamic pitching tests up to Ahead Point A.
- Complete all necessary overhaul documentation, maintenance reports, and handover checklists in compliance with operational and class society standards.
COURSE METHODOLOGY
At Intelliness, our training methodology is built around delivering meaningful learning experiences that translate into real workplace capabilities. Each program is carefully engineered to blend theory with practice, ensuring participants not only understand the concepts but can confidently apply them on the job.
Engaging Learning Environment
Sessions are conducted using real case studies, scenario-based discussions, and collaborative activities that encourage critical thinking and practical problem-solving.
Practical Skill Application
Participants take part in structured hands-on exercises and simulations designed to mirror real operational challenges, enabling them to develop confidence through doing—not just listening.
Smart Learning Tools
Our programs leverage modern digital platforms, including LMS-based modules, interactive content, and online resources that support flexible learning and continuous progress monitoring.
Ongoing Evaluation & Guidance
Regular checkpoints, quizzes, and facilitator feedback help track understanding, close knowledge gaps, and ensure each learner progresses at the right pace.
After-Training Reinforcement
To promote long-term retention, we provide post-training materials, optional follow-up sessions, and access to expert guidance, ensuring learners can continue applying their skills effectively beyond the classroom.
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Module 1: Introduction to Marine CPP Systems & Principles-
- The role and significance of CPP in vessel maneuverability and efficiency.
- Overview of different CPP types and their basic hydraulic/mechanical control principles.
- Interaction between the CPP system, main engine, and vessel control systems.
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2
Module 2: Technical Data Review & Component Identification
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- In-depth study of CPP general arrangement and detailed component drawings.
- Identifying all major parts: blades, hub, SKF coupling, shaft, seals, bearings, hydraulic blocks.
- Understanding lifting points and safe handling procedures for heavy components.
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Module 3: Pre-Overhaul Inspection & Assessment
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- Methodology for initial visual and operational inspection.
- Checking and verifying spare parts against the bill of materials.
- Assessing wear on blades, hub, seals, and bearings to plan the overhaul scope.
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Module 4: Safe Dismantling Procedures & Sequencing
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- Step-by-step guide to shaft withdrawal and securing.
- Procedures for dismantling propeller blades: labeling, extraction, and handling.
- Hub dismantling: sequence for removing the hub assembly, pitch control mechanism, and seals.
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Module 5: Cleaning, Measurement & Non-Destructive Testing (NDT)
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- Practical cleaning techniques for heavy marine components.
- Dimensional inspection and calibration of blades and hub components.
- Hands-on demonstration and application of NDT methods: Ultrasonic Testing (UT) and Magnetic Particle Inspection (MPI) for crack detection.
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Module 6: Component Repair & Replacement Criteria
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- Evaluating NDT and inspection reports to determine component condition.
- Guidelines for blade edge repair, welding, and machining limits.
- Decision-making framework for part refurbishment versus replacement, including sourcing compatible spares.
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Module 7: Hydraulic System Overhauling
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- Disassembly, inspection, and cleaning of hydraulic cylinders, servo motors, and control valves.
- Calibration of hydraulic components and pressure testing.
- Best practices for hydraulic fluid flushing, filtration, and recharge.
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Module 8: Precision Reassembly & Alignment
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- Step-by-step reassembly sequence of the hub, blades, and shaft.
- Critical procedures for achieving proper alignment, applying correct bolt torque, and setting clearances.
- Reconnecting hydraulic lines, lubrication systems, and pitch feedback sensors.
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Module 9: System Testing & Commissioning
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- Conducting static and dynamic leak tests on hydraulic and lubrication systems.
- Executing and monitoring the pitching test cycle through full range to Ahead Point A.
- Performing functional checks and preparing the system for operational sea trials.
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Module 10: Documentation, Reporting & Handover
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- Compiling the overhaul technical file: records of inspections, NDT reports, parts replaced, and tests performed.
- Completing final handover documentation and checklist for class surveyor review.
- Overview of maintenance reporting requirements post-overhaul.
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