2010014826135 _Propeller_65WYTL SOW.pdf

JPH_0621

WORK ITEM 1: 2010-01-482-6135, Propeller, Fabrication

1. SCOPE

1.1 Intent. This supply item describes the requirements for the Contractor to fabricate a new of bronze propellers used on 65-foot Class River Buoy

Tenders (WYTLs).

1.2 Government-Furnished Property.

None

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing Coast Guard Drawing 65B WYT 4400-003, Rev E, Propeller

COAST GUARD PUBLICATIONS

None

OTHER REFERENCES

American Bureau of Shipping (ABS); ABS Guidance Manual for Bronze & Stainless Steel Propeller Castings Dated 1984.

ASQ/ISO/IEC 17025:2005, General requirements for the Competence of Testing and Calibration Laboratories

MIL-DTL-2845E(SH) - DATED 18 AUG 1999, Propulsion Systems, Boat and Ship; Main Shafting, Propellers, Bearings, Gauges, Special

Tools, and Associated Repair Parts; Preservation, Packaging, Packing and Storage of

MIL-STD-129R, Feb 2014 Military Marking for Shipment and Storage

MIL-STD-2035A(SH) - DATED 15 MAY 1995, Nondestructive Testing Acceptance Criteria

DOD-STD-2185(SH) - DATED 28 OCT 1986, Requirements for Repair and Straightening of Bronze Naval Ship Propellers

International Organization for Standardization (ISO) 1940-1, 2003, Mechanical vibration – Balance quality requirements for rotors in a constant (rigid) state – Part 1

ISO/IEC 16388-2007 Information technology — Automatic identification and data capture techniques — Code 39 bar code symbology specification.

ISO 9001, Dated 15 Sep 2015, Quality Management Systems – Requirements

ISO/IEC 16388-2007 Information technology — Automatic identification and data capture techniques — Code 39 bar code symbology specification.

SAE J755-80 Dated June 1980, Marine Propeller-Shaft Ends & Hubs.

SAE-J-448A - Dated June 1963, Surface Texture Standard.

SAE AMS-T-22085 - DATED 01 June 1999, Tapes, Pressure-Sensitive, Adhesive, Preservation and Sealing–FSC 7510

International Organization for Standardization; ISO 484/2-1981 (E)- Shipbuilding - Ship screw propellers - Manufacturing tolerances -

Part 2: Propellers of diameter between 0.80 m and 2.50 m inclusive.

T9074-AS-GIB-010/271 - DATED 16 FEB 1999, Requirements for Nondestructive Testing Methods

3. REQUIREMENTS

3.1 GENERAL. The Contractor shall provide all equipment, labor, and materials to manufacture, , test, inspect, preserve, package, pack and mark a Right Hand (RH) 65 WYTL vessel propellers for the U.S. Coast Guard in accordance with the referenced drawing and data provided within this specification..

3.1.1. Since the referenced drawing lacks specific details required for manufacturing, the required propeller shall have design and performance characteristics equal to a Michigan Wheel Work Horse 4 blade propeller augmented by following Table of characteristics.

Table 1 - Required Propeller Characteristics

Cutter/Boat 65’ WYTL

Blade Orientation Right Hand (RH)

Diameter (in) 56

Pitch (in) 46

RPM 400

No. of Blades 4

Hub Bore, Nominal (in) Note 1

Hub Length, Nominal (in) Note 1

Key Size (in) 1.00

Note 1 –Hub Length and Special Details Shall be In Accordance with referenced drawing (65B WYT 4400-003)

3.1.2 Notify Contracting Officer of any conflicts of requirements between this specification, CG Dwg 65B WYT 4400-003 and standard design features of the Michigan Wheel Work Horse 4 blade for required clarifications and/or resolutions. The intention of the USCG in this procurement specification is to ensure fit of new propellers on existing shafting, equivalence to existing propeller operating performance, and attempting not to be overly restrictive in design requirements.

3.1.3 Packing gland assembly to be included.

3.2.2.1 The propeller shall come fitted with an inboard packing ring assembly as depicted in CG DWG 65B WYT 4400-003, including Ni-Al.Brz

Gland, 4-1/4”x5/16”dia NBR rubber seal ring, and 6(ea) monel studs, nuts, and split pins.

3.3 Material.

3.3.1 All materials shall be ABS Type 4 Nickel Aluminum Bronze as specified in ABS Guidance Manual section 1, part 1.2 (materials).

Classification or certification with ABS is not required.

3.3.2 The Contractor shall perform a material chemical composition analysis and a tensile properties test for each propeller casting. The documented results shall be submitted to the Coast Guard Contracting Officer for review/approval.

3.2.3 All material chemical composition analysis and tensile property tests shall be made by a laboratory meeting the calibration requirements in section 4.6 of this specification.

3.4 Test and inspection plan. The Contractor shall submit a test and inspection plan to the Contracting Officer for approval. This plan shall include the specific inspections and tests specified herein, and all tests and inspections made by the Contractor to verify conformance to every requirement and tolerance as specified in the cited drawings, technical publications, and this specification.

3.5 Construction of propeller castings. Each propeller casting shall be constructed in accordance with ABS Part 7 Section 10 entitled Guide for

Bronze and Stainless Steel Propeller Castings (dated 2015), and USCG DWG 65B WYT 4400-003.

3.5.1. Each propeller casting shall be formed with one continuous pour.

3.5.2. Each casting shall include a provision to allow for an integrally cast coupon. This coupon shall be tested for it’s chemical composition and tensile properties referenced in 3.3.1. of this specification.

3.6 Propeller finishing. Each propeller may be finished using Computer Numerical Controlled (CNC) machining using equipment that can be programmed for automatic contouring of hydrodynamic surfaces OR in the conventional casting manner that employs hand grinding and finishing for obtaining required blade contour and profile dimensions.

3.6.1 The tolerances specified at the design sections shall apply to all hydrodynamic surfaces.

3.6.2 The Contractor shall demonstrate a manufacturing or inspection process that ensures tolerances for all hydrodynamic surfaces are met.

3.6.3 Dimensional Inspection shall be in accordance with this specification and USCG Dwg 65B WYT 4400-003.

3.7 Dimensional tolerances. All tolerances shall be in accordance with ISO 484/2, Class II except as follows:

3.7.1 Pitch may be measured by a computer controlled coordinate measurement machine that can be shown to be calibrated to and to produce equivalent accuracy to the methods of Section 4 of ISO 484/2 for Class II propellers in addition to the methods of Section 4.

3.7.2 Where designated in table 1, propeller hubs shall be finished in accordance with the drawing or other instruction referenced in the notes to

Table 1All tolerances shall be in accordance with USCG DWG 65B WYT 4400-003, ISO 484/2, Class II, and this specification. Notify

Contracting Officer of any conflicts ore required clarifications:

3.7.12 Bores, keyways, hub dimensions & details - All bores, keyways, and hubs shall meet the dimensional requirements of SAE J755-80, Table

3 for hubs without sleeves, including surface finish.

3.7.12.1 The nominal hub bore diameter shall be as specified for each propeller in the deliverable list.

3.7.12.2 The hub shall be the full length of the taper as a minimum in accordance with table 3 or table 4 of SAE J755-80.

3.8 Weld repairs. If the castings require any weld repairs, welding procedures, welders, and welding operations shall be qualified in accordance with S9074-AQ-GIB-010/248 OR approved in accordance with the procedures outlined in ABS Guide for Bronze and Stainless Steel Propeller

Castings (dated 2008), paragraph 3.7.2.

3.8.1 No weld repair is authorized unless prior approval is received from the Contracting Officer.

3.8.2 Welding on the pressure face of any propeller casting in the critical area shall not be undertaken without prior approval of the Contracting

Officer.

• a The critical area is described as the pressure face of the blades between the fillet and the .4 radius and starting at the leading edge encompassing 80% of the chord length taken at the 0.4 radius. (Reference Figure 1 of DOD-STD-2185(SH).

• b Welding repairs of propeller castings shall meet the requirements of DOD-STD-2185(SH) or ABS Part 7 Section 10 entitled Guide for Bronze and Stainless Steel Propeller Castings (dated 2008).

3.9 Surface finish. Surfaces of the propeller blades and hub shall be ground fair and polished in accordance with SAE-J-448 to meet the following requirements:

3.9.1 Propeller blade surfaces - 63 micro inches or better.

3.9.2 Propeller Hub - 125 micro inches or better.

3.10 Surface inspections.

3.10.1 A visual inspection shall be performed on all exterior blade surfaces in accordance with MIL-STD-2035(SH), section 4.

• a All visual defects, even though deemed acceptable, shall be documented on the inspection report.

3.10.2 The Contractor shall perform a dye penetrant inspection over 100 percent of the blade surfaces including the hub in accordance with

T9074-AS-GIB-010/271. The acceptance criteria of MIL-STD-2035(SH) Table IV.

3.10.3 The Contractor shall document all propeller defects resulting from the visual and dye penetrant inspections. These defects shall be indicated by type and size on visual inspection sheets. Each propeller will require individual inspection sheets for the pressure face of the blades, suction face of the blades, the fillet, and the hub.

3.11 Test and inspection data requirements, final inspection report. The Contractor shall perform final dimensional, balancing, visual, and dye penetrant surface inspections for each propeller manufactured and record this data on a final inspection report. This report shall accurately reflect the final condition of each propeller.

3.11.1 The final inspection report shall contain, at a minimum, the following data:

• a Propeller blade radius.

• b Pitch at the 0.3 through 0.95 radii.

• c Average pitch of each blade at the 0.3 through 0.95 radii.

• d Blade section half widths at the 0.3 through 0.95 radii.

• e Thickness at every 10 percent station for each blade section from the 0.3 through 0.95 radii.

• f Leading and trailing edge profiles at the 0.3 through 0.95 radius.

• g Rake

• h Track

• i Angular spacing of blade center axes.

• j Fairing rod clearances

• k All propeller hub dimensions including taper and keyway

• l Surface finish of blade and hub areas

• m Surface inspection (visual and 100 percent dye penetrant)

• n Material composition

• o Balancing Data

3.11.2 The Final Inspection Report shall be submitted to the Contracting Officer for review. If this report is determined to be acceptable, the

Contracting Officer will authorize ELC’s Quality Assurance Branch to schedule final inspections/tests outlined in section 4.4. of this specification.

3.12 Propeller stamping. Each propeller shall have the diameter, pitch, rotation, and serial number clearly stamped on the outside diameter of the aft end of the hub and clear of the fillets, in addition to any ABS marking requirements. Stamping shall be neat and legible, 1/4” to 1/2” high, e.g.

46X48RH-12345.

3.12.1 The stampings shall be at least 1/4 to 1/2" high, neat, legible, and visible when the propeller is fully assembled.

3.13 Notifications & inspections. The contractor shall be responsible for notifying the Contracting Officer in writing no less than seven (7) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

3.14 Balancing

3.14.1 STATIC (Single Plane)

3.14.1.1 Each propeller shall be single plane balanced as stated herein. All balancing shall be accomplished by means of balancing equipment, which requires rotation of the work piece. The residual unbalance in each plane of correction shall not exceed the value determined by calculating the following formula: U = 4000W/N2 where:

U = Maximum allowable residual unbalance in oz.- inches.

W = Weight of rotating part in pounds.

N = Maximum operating speed of unit. (400 RPM)

3.14.1.1.1 Prior to performing any balance tests, the Contractor shall demonstrate the sensitivity of the balance machine using a weight determined from the following formula: Ws = 0.1(U)/r where:

Ws = Sensitivity Weight

U = Propeller residual unbalance tolerance

R = Radial location of the weight

3.14.1.1.2 The addition of this weight shall be easily detected and discernible to the balance machine operator.

3.14.1.2 The mandrel or concentric rings used to support the propeller during balancing shall not exceed a total indicated run-out (TIR) of .001 inches.

3.14.1.3 Material removed to effect balancing shall be taken from the suction face of the heavy blade. Care shall be taken to keep a fair surface.

The area from which metal is taken shall not come within 10 percent of the chord length to the leading or trailing edges. Coordinate material removal between static and dynamic efforts, if prudent wait for more sensitive dynamic balancing data to be produced before material removal.

3.14.1.4 The actual amount of unbalance for each propeller shall be documented (initial and after any balancing efforts) on each Final Inspection

Report.

4.0. QUALITY ASSURANCE

4.1 General. The contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and meet the requirements of ISO 9001 and available for review by the Coast Guard.

4.2 Records. The contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3 Calibration system. The contractor as well as any subcontractors shall be required to maintain a test equipment calibration program in compliance with ASQ/ISO/IEC 17025. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4 Responsibility for inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. The

Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the contractors facility prior to the Coast Guards acceptance. The Coast Guard reserves the right to verify or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements. The contractor shall notify the scheduled commencement of any inspections required by this specification.

4.5 Responsibility for compliance. All items shall meet the provisions of sections 3 & 5. The inspections set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.6 Inspections and tests. The inspections/tests required here and in the appropriate subsection in section 3 are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the contractor to assure the quality of the item in question. The following tests and inspections will be witnessed by an SFLC Quality Assurance Representative:

4.6.1 Dimensional inspection. See section 3.6 and 3.7.

4.6.2 Surface inspections. See section 3.10.

4.6.3 Balancing inspection. See section 3.14.

4.6.4 Stamping inspection. See section 3.12.

4.6.5 Packaging, packing and marking inspection. See section 5.

4.7 Failure responsibility. If the specified item fails to pass any inspection/test the contractor shall report the failure and the recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

• The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action.

• The inspection/testing shall be discontinued until all corrective action has been taken.

• After all corrective actions have been taken the inspection/tests shall be continued or repeated at the option of the Contracting Officer.

• Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

• All corrective actions shall be documented as part of the contractor’s inspection system and submitted for approval to the Contracting

Officer.

• Each corrective action report shall include, but not be limited to the cause of each defect, corrective action suggested, and the steps taken to prevent a recurrence of each defect.

4.8 Test & inspection reports. One copy of any required inspection, test or tolerance check done on each delivery order shall be sent to the

Contracting Officer for review and approval prior to authorization of Quality Insurance Inspection.

4.8.1 Quality assurance representative. A copy of any test, inspection or tolerance report shall be turned over to the Quality Assurance

Representative upon arrival at the contractor’s plant.

4.9 Packing inspection. The Contracting Officer shall be notified prior to the packaging and marking of the completed units in accordance with section 5.2 of this specification.

5. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 Preservation.

5.1.1 Prior to preservation, each propeller shall be cleaned by any process or combination of processes, which will accomplish thorough cleaning without damage to the propeller.

5.1.2 After cleaning, tape conforming to SAE AMS-T-22085 and strippable compound preservative shall be applied to each propeller in accordance with MIL-DTL-2845E, paragraph 3.14.1.3.

5.1.3 After the application of strippable compound, galvanized sheet metal blade edge protectors, utilizing corrosion resistant hardware, shall be installed in accordance with MIL-DTL-2845E paragraph 3.14.1.4.

5.2 Packing.

5.2.1 Each propeller shall be individually packed in accordance with MIL-DTL-2845E paragraph 3.14.2.2.2.

5.3 Marking. Each packaged crate/box shall have a water proof label securely attached or water proof stencil in the upper left-hand corner of the two longest sides (two opposite sides if square) of each box IAW MIL-STD-129R. The stencil marking shall be 3/4" -1" inch in height.

5.3.1 Marking layout.

5.3.1 See below for marking layout.

• Type 1 - PROPELLER, RIGHT HAND (RH)

• STOCK NUMBER: WORK ITEM 1: 2010-01-482-6135

• ITEM NAME: PROPELLER, RH

• PART NUMBER: 65 WYTL Propeller

• SERIAL NUMBER: As stamped on hub

• CONTRACT NUMBER: As indicated on contract

• DELIVERY ORDER NUMBER: As indicated on contract

• SHIPPING WEIGHT: As Determined by Contractor

• CONDITION CODE: CONDITION A

• QUANTITY & UNIT OF ISSUE: 1- EA

• COAST GUARD SFLC MATERIAL

• REUSABLE CONTAINER DO NOT DESTROY

5.3.2 Bar coding. U.S. Coast Guard requires bar coding of the NSN, IAW ISO/IEC 16388-2007 Code 39 Symbology.

5.3.2.1 The Bar Code Label can be applied separately or as part of the marking required in 5.3.

5.4 Shipping. The Contractor shall ship, and deliver the parts and components to the government address specified in paragraph 5.4.1. Notify the

Contracting Officer Representative (COR) and Contracting Officer about the shipment 7 days in advance. Provide timely shipping information to

COR including the name of the shipping company, date of shipment leaving Contractor’s facility, and expecting arrival date and time at the government facility. No shipment shall arrive outside of government normal business hours as determined by the Contracting Officer.

5.4.1 Address. Unless otherwise specified, the Contractor shall ship, and deliver all parts to the following government addresses:

• U.S. Coast Guard

• Surface Forces Logistics Center

• 2401 Hawkins Point Rd. Bldg. 88

• Baltimore, MD 21226

6 NOTES

6.1 Document sources.

6.1.1 Government document sources.

• Department of Defense Single Stock Point (DODSSP)

Building 4, Section D

700 Robbins Avenue

Philadelphia, PA 19111-5094

215-697-2667/2179

FAX 215-697-1462

• DOD & Navy Publications & Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

6.1.2 Coast Guard document sources.

• USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD. 21226-5000

Phone: 410-762-6171

ATTN: Contracting Branch, CPD1

6.1.3 Commercial document sources.

• Society of Automotive Engineers Inc. (SAE)

400 Commonwealth Drive

Warrendale, PA 15096

1-877-606-7323

FAX: 1-724-776-0790

• American Society for Testing & Materials (ASTM)

100 Barr Harbor Drive

West Conshohocken, PA 19428

610-832-9500

FAX: 610-832-9555

• American Society for Quality Control (ASQC)

611 East Wisconsin Ave.

Milwaukee, WI 53202

414-272-8575

FAX: 414-272-1734

• International Standard Organization (ISO)

1, ch. De la Voie-Creuse

CP 56 – CH-1211 Geneva 20

Switzerland

Phone +41 22 749 01 11

Fax: +41 22 733 34 30