Group 14 and 15_154 (FRC) Propeller Inspection Compliance Forms OVERHAUL and REPAIR R1 - 3-22-2023.pdf

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154 (FRC) Propeller Inspection Compliance Forms

Initial Inspection: Final Inspection:

Propeller serial no: Date:

Contractor inspector name/title:

1. Material Composition (per ABS 7, Section 10, Type 4)

This section is not applicable to overhaul and repair.

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2. Hub Bore Inspection - NOTE: The bore dimensional inspection is a decision point. Report any failed measurement to the KO immediately upon finding.

Inspection Requirement Measured Pass/Fail

Bore dimensional inspection (for comparison to Coast

Guard Drawing 154 WPC

245-304)

Large end dia: 202.968 mm

+2%, -1.5%

Hub length: 550.00 mm

+2%, -1.5%

Bore taper 1:20

Helical groove depth

(minimum):

Large end dia:

Hub length:

Calculated taper:

Measured groove depth (min.):

Blue fit Go/No-Go (85% minimum)

Draw

Contractor inspector (written/signature): /

USCG (written/signature): /

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3. Surface Finish – NOTE: As part of Section 5 of the compliance forms, a sketch or photograph showing excessive surface finish may be provided in lieu of filling in the below table.

Locations Required Measured

Blade 1 from radius 0.2 outward

<3 micrometers Ra (Class 1)

Blade 2 from radius 0.2 outward

Blade 3 from radius 0.2 outward

Blade 4 from radius 0.2 outward

Blade 5 from radius 0.2 outward

Blade 6 from radius 0.2 outward

Hub/bore <3 micrometers Ra (Class 1)

4. Balancing

Class 1 per ISO 484/1 (static balanced) SAT UNSAT

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5. Surface Inspection

Document ALL defects on the following sheets. For the dye penetrant inspection, highlight/annotate ALL defects that fall outside of the allowable parameters set by ABS Part 7, Section 10, Table 1. Provide two sheets, one per face and label pages 5a and 5b.

NOTE: Photographs may be inserted in place of these inspection forms provided the photos collectively encompass the entire propeller and adhere to the instructions for documenting/highlighting/annotating defects. The photographs must be labeled such that the blades, hub locations and defect locations are identifiable. See the following page for the hub diagram.

Pressure Face Suction Face

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6. Inspection Report Data

a. Propeller Blade Radii

Location Required Measured

Blade 1

933.5 mm +/- 0.3% (930.7 mm to 936.3 mm)

Blade 2

Blade 3

Blade 4

Blade 5

Blade 6

b. Local Pitches (measured over three equal segments) with +/- 2.0% pitch tolerance (ISO 484/2, Class 1) applied to the requirement.

Blade 1 Radius Segment 1

(mm)

LE

Segment 1 measurement

(mm)

Segment 2

(mm)

Segment 2 measurement

(mm)

Segment 3

(mm)

TE

Segment 3 measurement

(mm)

.3R

Ref 3077

-2% 3016 2426 1956

+2% 3139 2525 2036

.4R

Ref 2824

-2% 2767 2503 2259

+2% 2880 2606 2352

.5R

Ref 2637

-2% 2584 2478 2423

+2% 2690 2579 2522

.6R

Ref 2442

-2% 2393 2452 2502

+2% 2491 2552 2604

.7R

Ref 2405

-2% 2357 2387 2526

+2% 2453 2484 2629

.8R Ref 2319

-2% 2273 2271 2465

+2% 2365 2364 2566

.9R

Ref 2125

-2% 2082 2017 2200

+2% 2167 2099 2290

.95R

Ref 1962

-2% 1923 1799 1909

+2% 2001 1872 1987

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(mm)

LE

Segment 1 measurement

(mm)

Segment 2

(mm)

Segment 2 measurement

(mm)

Segment 3

(mm)

TE

Segment 3 measurement

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(mm)

LE

Segment 1 measurement

(mm)

Segment 2

(mm)

Segment 2 measurement

(mm)

Segment 3

(mm)

TE

Segment 3 measurement

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Blade 4

(mm)

LE

Segment 1 measurement

(mm)

Segment 2

(mm)

Segment 2 measurement

(mm)

Segment 3

(mm)

TE

Segment 3 measurement

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(mm)

LE

Segment 1 measurement

(mm)

Segment 2

(mm)

Segment 2 measurement

(mm)

Segment 3

(mm)

TE

Segment 3 measurement

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(mm)

LE

Segment 1 measurement

(mm)

Segment 2

(mm)

Segment 2 measurement

(mm)

Segment 3

(mm)

TE

Segment 3 measurement

c. Section Pitch

Radius Requirement

Measured (mm)

Blade 1 Blade 2 Blade 3 Blade 4 Blade 5 Blade 6

.3R 2451

(2414 – 2488)

.4R 2548

(2509 – 2586)

.5R 2544

(2505 – 2582)

.6R 2517

(2479 – 2555)

.7R 2471

(2434 – 2508)

.8R 2383

(2347 – 2418)

.9R 2141

(2109 – 2173)

.95R 1914

(1885 – 1943)

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d. Mean Pitch per Blade

Requirement mm Blade 1 Blade 2 Blade 3 Blade 4 Blade 5 Blade 6

Ref

-1%

+1%

e. Mean Propeller Pitch

Requirement (mm)

(+/- 0.75%)

Measured

(2353 – 2389)

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f. Blade Section Widths

Blade 1

Radius Requirement, full width, mm

Full width, measured .7R 756.1

(741.0 - 771.2)

.8R 692.3

(678.4 - 706.1)

.9R 533.3

(522.6 – 544.0)

.95R 373.6

(366.1 – 381.1) width, mm

Full width, measured width, mm

Full width, measured

Blade 4 width, mm

Full width, measured

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Full width, measured width, mm

Full width, measured

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g. Maximum Thickness at Prescribed Stations (all units in mm with new manufacture tolerance of +3% (1 mm, min)/-1.5% (1 mm, min)

Blade 1 – thicknesses (Indicate MAX thickness measurement, only)

Radius (Xc mm, max point at design)

Design (mm) Measured (mm)

3R (353.90) 59.92

4R (379.70) 47.93

5R (402.23) 38.36

6R (379.86) 31.40

7R (415.85) 31.77

8R (380.77) 27.94

9R (293.37) 17.94

95R (205.51) 11.11

Blade 2 – thicknesses point at design)

Design (mm) Measured (mm)

3R (353.90) 59.92

4R (379.70) 47.93

5R (402.23) 38.36

6R (379.86) 31.40

7R (415.85) 31.77

8R (380.77) 27.94

Blade 3 – thicknesses point at design)

Design (mm) Measured (mm)

3R (353.90) 59.92

4R (379.70) 47.93

5R (402.23) 38.36

6R (379.86) 31.40

7R (415.85) 31.77

8R (380.77) 27.94

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Blade 4 – thicknesses point at design)

Design (mm) Measured (mm)

3R (353.90) 59.92

4R (379.70) 47.93

5R (402.23) 38.36

6R (379.86) 31.40

7R (415.85) 31.77

8R (380.77) 27.94

Blade 5 – thicknesses point at design)

Design (mm) Measured (mm)

3R (353.90) 59.92

4R (379.70) 47.93

5R (402.23) 38.36

6R (379.86) 31.40

7R (415.85) 31.77

8R (380.77) 27.94

Blade 6 – thicknesses point at design)

Design (mm) Measured (mm)

3R (353.90) 59.92

4R (379.70) 47.93

5R (402.23) 38.36

6R (379.86) 31.40

7R (415.85) 31.77

8R (380.77) 27.94

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h. Track Deviation/Rake

Note: ISO 484/2, Section 13 provides locations for measurement

Requirement

(Max deviation, +/- 1% propeller diameter)

Rake

Point A Measured Point B Measured Point C Measured

Blade 1

Blade 2

Blade 3

Blade 4

Blade 5

Blade 6

Max deviation between ANY two blades (max – min)

i. Edge conditions, smooth, not sharp edges – Acceptance of data presented in Section 6 herein fulfills this requirement?

Yes / No

j. Blade Center Axis Angular Spacing

Requirement Blade 1 & 2

Measured

Blade 2 & 3

Measured

Blade 3 & 4

Measured

Blade 4 & 5

Measured

Blade 5 & 6

Measured

Blade 6 & 1

Measured

60.0° +/- 0.5°

k. Propeller Hub Inspection - Acceptance of data presented in Section 2 herein fulfills this requirement?

l. Surface Finish of Blade, Hub and Bore Areas – Acceptance of data presented in Section 5 herein fulfills this requirement?

m. Balancing Data – Acceptance of data presented in Section 6 herein fulfills the requirement?

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n. Surface Inspection (Visual and 100 Percent Dye Penetrant) – Acceptance of data presented in Sections 4 and 5 herein fulfills this requirement?

o. Fairness – Indicate areas of unacceptable fairness. Provide two sheets, one per face and label pages 18a and

18b.

Pressure Face Suction Face

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7. Propeller Identification Markings

The following are marked in ¼” to ½” high text on all newly manufactured propellers (check beside each box when verified):

a. Serial number (provided by Contracting Officer)

b. Ship class – 154 WPC

c. Starboard or Port

d. Rotation direction (from aft looking forward)

e. National Stock Number (NSN)

f. Design diameter – 1867 mm

g. Design pitch at .7R – 2449 mm

h. Manufacturer name/date of manufacture

i. Actual propeller weight

j. Material grade – ABS Grade 4