Group 16 and 17_MECPL_210A_LH _ RH_NSN2010-00-906-6010 and 2010-00-906-6009.pdf

24599_210_1225_Rev -

WORK ITEM 1: Blade(s), Controllable Pitch Propeller (CPP), 210 “A” Class, Inspect and Repair

1. SCOPE

1.1 Intent – This work item defines the requirements to inspect and repair for 210 “A” Class CPP blade(s) to a serviceable, A-condition.

1.2 Government furnished property (GFP). The listed items are property of and managed by the United

States Coast Guard (USCG) Surface Forces Logistics Center (SFLC), Baltimore MD and will be issued to the contractor as issuance of a contract or contract delivery order.

ITEM DESCRIPTION NATIONAL STOCK NUMBER (NSN)

PART NUMBER (P/N)

Blade Set, Propeller, Type 1 - Left

Hand (LH), starboard side

NSN: 2010-00-906-6010

P/N: 615-WPC-4400-51 CCW

Blade Set, Propeller, Type 2 - Right

Hand (RH), port side

NSN: 2010-00-906-6009

P/N: 615-WPC-4400-54 CW

Hub, Dummy, Propeller LH & RH ACN: 2010-01-F88-0014

P/N: DH

Shipping Crate, Reusable NSN: N/A

PN: N/A

CAGE: N/A

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 618 WMEC 245-050, Rev C, 210 Ft WMEC Propeller Blade Left Hand

Rotation 63/4

Coast Guard Drawing 618 WMEC 245-051, Rev C, 210 Ft WMEC Propeller Blade Right Hand

Rotation 63/4

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2022, Welding and Allied Processes

OTHER REFERENCES

American Bureau of Shipbuilding (ABS) Rules for Survey After Construction 2021 - Guide for

Bronze and Stainless-Steel Propeller Castings, Part 7 Appendix 1, Section 10

ASTM E1417/E1417M, Dated 9/1/2021 – Standard Practice for Liquid Penetrant Testing

DOD-STD-2185 (SH) – Requirements for Repair and Straightening of Bronze Naval Ship

Propellers

NAVSEA Technical Manual, NAVSEA S9245-AR-TSM-010/PROP - Technical Manual Marine

Propeller Inspection, Repair and Certification

SAE-J-448A - Surface Texture Standard

3. REQUIREMENTS

3.1 General.

3.1.1 Inspection, repair and overhaul - general. All inspections, repairs and overhaul must be accomplished in accordance with the requirements set within this work item.

3.1.2 Workmanship. Upon completion of all work, all propellers must have a polished, professional finish and be free of dirt, grease, burrs, sharp edges, etc.

3.2 Inspections. Referring to the General Requirements work item for guidance, for each blade set received, the Contractor must accomplish the following inspections and submit an Open and Inspect

Report (OIR) on all of the following:

3.2.1 Arrival inspection.

3.2.2 Visual Preservation Inspection (VPI).

3.2.3 Visual and Technical Inspections (VTI). The Contractor must conduct all inspections required under paragraph 3.2.4 and follow-on paragraphs.

3.2.4 Geometrical/dimensional inspections. Prior to overhaul/repair, while using Coast Guard Drawings

618 WMEC 245-050 and 618 WMEC 245-051 and NAVSEA S9245-AR-TSM-010/PROP as guidance, the Contractor must conduct the following inspections and measurements, recording all results and deviations outside of prescribed tolerances.

NOTES

NAVSEA S9245-AR-TSM-010/PROP, Table 6-1, Class I is the guiding document for the inspections and repairs to be made. Class 1 measurements and tolerances apply unless explicitly stated otherwise.

3.2.4.1 Blade radius length. Measure each blade radius length.

3.2.4.2 Section pitch. Measure the pitch of each blade at the following radii: 0.5, 0.6, 0.7, 0.8, 0.9, 0.95, 0.975.

3.2.4.3 Blade pitch average. Calculate the average blade pitch using the radii prescribed in the above paragraph.

3.2.4.4 Blade section widths. Measure each blade section width at the radii prescribed in 3.2.4.2.

3.2.4.5 Maximum blade thicknesses. Measure the maximum blade thicknesses at the radii prescribed in

3.2.4.2.

3.2.4.6 Blade track. Measure each blade track at the 0.95 radius for each blade.

3.2.4.7 Fairness. Conduct a fairing survey for each blade, noting all locations and deviations from the prescribed fairness and fairness rate of change tolerances.

3.2.4.8 Surface finish. Using SAE-J-448A as guidance, conduct a surface finish survey for all blade surfaces, fillets and palms.

3.2.4.8.1 Blade surfaces must have a finish of 63 micro inches or better.

3.2.4.8.2 Blade fillets and palms, unless otherwise noted on the applicable drawings, must be 125 micro inches or better.

3.2.4.9 Surface inspections.

3.2.4.9.1 Surface inspection – visual. Conduct a visual inspection of each component while using MIL-

STD-2035, Section 4 as guidance; markup and report all discrepant physical condition findings on the forms (blades and palms) provided in Section 4.

3.2.4.9.2 Surface inspection – Nondestructive test (NDT). Using SFLC Std Spec 0740 as guidance, conduct a dye penetrant inspection on all component surfaces.

3.2.4.9.3 Surface inspection reports. Markup and report all discrepant visual and NDT findings on the forms (blades and palms) provided in Section 4 for each surface inspected.

NOTE

The Section 4 forms are provided for convenience and the Contractor may opt to use clearer forms in their submission.

3.2.4.10 Material composition determination. Three types of ABS material (ABS Rules for Survey After

Construction, Part 7) have been used for the 210 CPP blades: ABS Type 2 (MnBr), Type 3 (NiMnBr) and

Type 4 (NiBrAl); the Contractor must determine the composition for each blade.

3.2.4.11 Palm bolt and dowel pin holes. Measure all bolt and dowel pin holes for each blade palm.

3.2.4.12 Dowel hole centers survey. Measure the center-to-center dimensions between all dowel pin holes for each blade.

3.2.4.13 Bolt hole contact face measurements. For each blade, measure the parallel dimensions.

3.2.4.14 Palm dimension survey. For each blade, measure all palm dimensions shown on the applicable drawings.

3.2.4.15 Sealing surfaces survey. Determine and record the surface finishes and conditions for each blade sealing surface.

3.3 Overhaul/repair. If a Change Request has been authorized and released by the KO, the Contractor must make all recommended repairs (or as amended by the KO) for the affected blade(s) in accordance with the following:

3.3.1 Tolerances. The repair tolerances must be in accordance with NAVSEA S9245-AR-TSM-

010/PROP, Table 6-1, Class I in conjunction with Coast Guard Drawings 618 WMEC 245-050 and 618

WMEC 245-051 as applicable.

3.3.2 Welding specifics.

3.3.2.1 Prior to any material repairs (i.e., hot work), the Contractor must determine the exact alloy of the work piece(s).

3.3.2.2 Critical blade areas are described as the pressure face of a blade between the fillet and the .4 radius, starting at the leading edge encompassing 80% of the chord length taken at the 0.4 radius (see

Figure 1 of DOD-STD-2185).

WARNING!

Welding on the pressure face in the critical area must not be taken without prior KO approval.

3.3.2.3 Where repairs require incorporating a cast/forged patched piece, a zinc equivalent test must be performed to establish weld capability in accordance with DOD-STD-2185, paragraph 5.1.5.

CAUTION!

If the zinc content exceeds 45%, stop all work and notify the KO.

NOTE

Patches may be required for major repairs.

Major repairs may be, but not limited to, missing blade portions and/or cracks greater than 2” long and over 1/8” deep.

3.3.2.4 For hot work repairs done to those blades comprised of ABS Type 2 or Type 3 alloys, after all hot work is complete, the Contractor must stress relieve each affected blade in accordance with DOD-STD-

2185.

3.3.2.5 All welding performed must be documented on the visual inspection sheets for each blade; each weld must be dimensionally identified by location, length, width, and depth.

3.3.2.6 Provide photo documentation to the KO during in-process welding repairs and any discontinuities during dye penetrant inspection.

3.3.2.6.1 Each photograph shall include the component serial number and date the photograph was taken.

3.3.2.6.2 Color photographs must be taken with a digital camera and the images provided electronically in

“jpg format” to the KO during:

3.3.3 Surface finish. Blade and palm surfaces must be ground fair and polished to the following finishes in accordance with SAE-J-448A:

• Blade surfaces - 63 micro inches or better;

• Blade fillets and palms – 125 micro inches or better.

3.3.4 Balancing. While using the Government-furnished dummy hub, each blade set must be single plane balanced as follows:

NOTE

All balancing must be accomplished by means of balancing equipment that requires work piece rotation.

3.3.4.1 Prior to performing any balance tests, the Contractor must demonstrate the balance machine sensitivity using a weight determined by the following formula:

Ws = 0.1(U)/r

• Where, Ws = sensitivity weight

• U = residual unbalance tolerance;

• r = radial location of the weight.

3.3.4.2 In the presence of the Coast Guard Inspector and prior to using with attached blades, the

Contractor must inspect the dummy hub for squareness, confirm the dowel pin locations, and be balanced using the determined parameters detailed in 3.3.5.

3.3.4.3 Following hub balancing, blades must be balanced as a set of 4 and be marked (i.e., 1, 2, 3, 4) from a defined datum, and ascending in number, counter to rotation direction.

NOTE

This numbering method ensures reassembly in the same positions in which they were balanced.

Weight addition/removal shall be easily detected and discernable to the balance machine operator.

Material removed to balance shall be taken from the suction face of the heavy blade(s).

For blades, the area from which metal is taken must not come from within 10 percent of the chord length adjacent to the leading or trailing edges.

3.3.4.3 After the initial balance, the blades must be removed and rotated 90 degrees on the dummy hub.

3.3.4.4 Re-check balance after blade rotation to ensure that any corrections made are not attributable to changes in the dummy hub.

3.3.4.5 Document the final, actual unbalance amount for each blade set in the Final Inspection Report.

3.3.5 Residual imbalance. The residual imbalance in each component plane of correction must not exceed the value calculated via the following formula:

U = 4000W/N2

• Where, U = maximum allowable residual unbalance in oz.-in;

• W = weight of rotating part in pounds;

• N = maximum operating speed of unit.

3.3.5 Bolt hole thickness. The minimum thickness of each blade bolt hole shall not be less than 95.0 percent of the minimum thickness indicated on the referenced drawing.

ALTERNATE: Measure the palm thicknesses around the perimeter of each bolt shank hole; mark the locations and record those measuring less than 95% of the minimum, adjacent palm thickness indicated in the applicable drawing.

3.3.6 Sealing surface finish. Sealing surfaces must have surface finishes of 32 micro inches or better

(unless otherwise stated on the applicable drawing). Seal wear or rough surfaces must be machined to restore to 32 micro inches.

3.4 Final Inspection Report. The Contractor shall accomplish the following:

NOTE

Final inspections, tests and/or measurements that were not affected by repairs, and previously recorded in the OIR, are not required to be redone. However, the Final Inspection Report must include all the unaffected pre-repair data as post repair data.

3.4.1 In areas affected by repairs, again conduct the applicable inspections under 3.2.4 and follow-on paragraphs for the final inspections and tests.

3.4.2 Provide the final inspection and test results to the KO in the Final Inspection Report, including the final balancing data.

3.5 Stamping. Following all repairs, the Contractor must accomplish the following:

3.5.1 Each blade must be stamped with the following information (minimum), updated where necessary if the stamping already exists:

a. Repair facility/company name

b. Repair completion date

c. Blade number

d. Stress relief date (if applicable)

e. Blade set serial number

f. Rotation direction (left hand, LH or right hand, RH)

g. Material type

h. Weight

3.5.2 Stamping must be be at least 1/4” high, legible printing, or the same height of the existing stamping if only corrected stamping is required.

3.6 QA inspection.

3.6.1 Following KO acceptance and approval of the Final Inspection Report and prior to conducting any preservation, packing and packaging, the Contractor must schedule the Coast Guard SFLC QA inspection.

3.6.2 A copy of the Final Inspection Report must be provided to the Coast Guard QA Representative upon arrival for final inspection.

3.6.3 The KO must be given 10-calendar day advance notice ahead of desired inspection date.

3.7 Photography requirements. The Contractor shall provide photographs (.jpg format or similar) for the following evolutions:

3.7.1 during initial blade receipt; photos must show the suction and pressure faces, fillets and palms, plus four photographs of the shipping crate sides and top taken at 90° intervals.

3.7.2 prior to damaged area repairs affecting remarkable cost and/or time; close-up views showing the affected areas before and after those repairs must be provided.

3.7.3 pre-repair, failed NDT areas.

3.7.4 in-process repairs in areas requiring significant cropping, welding and/or machining of sealing surfaces.

3.7.5 following final inspection and prior to preservation/packaging, photograph suction and pressure sides of blade(s), palm(s), sealing face(s) surface texture/finish, including stamped markings.

3.7.6 prior to packing, photograph each component showing strippable compound application and installed blade edge protection.

3.7.7 prior to shipping, photograph all container markings.

4. NOTES

4.1 Post-repair/overhaul activities. Refer to the General Requirements work item, Section 5, for the preservation, packaging, packing, and shipping requirements.

4.2 Reference sources. Refer to General Requirements work item, Section 6, for referenced document sources.

Pressure side _____ Suction side _____

Pressure side _____ Suction side _____

Blade Palm

Top side _____ Bottom side ______

5. Supplementary Requirements and Information

NOTE

This information is specific to the serviced components and supplements the

General Requirements work item. Where information between the General

Requirements work item and herein conflict, the information here takes precedence.

5.1 Blade and dummy hub-specific preservation and packaging markings.

5.1.1 General Requirements (Work Item 1) Paragraph 5.6.1, “Quantity & unit of issue:” must be “1 –

SET” in lieu of “1 – EA”.

5.1.2 Beneath all markings per Work Item 1, Paragraph 5.6.1, add separate lines which read as follows:

• “REUSABLE CONTAINER – DO NOT DESTROY”.

• For blade set containers, add “BLADE SET, BOX {#} of 4.”

• For each blade set container, add the serial numbers for the corresponding, accompanying containers, i.e., “THE OTHER THREE BLADE SERIAL NUMBERS THAT MAKE UP

THIS SET INCLUDE {insert three serial numbers}”.

5.1.3 Markings examples:

a. Type 1 – BLADE SET, LEFT HAND

STOCK NUMBER 2010-00-906-6010

ITEM NAME BLADE SET LH, PROPELLER

PART NUMBER 615-WPC-4400-51 CCW

BLADE SERIAL NUMBER As marked on blade

BLADE SET SERIAL NUMBERS List serial numbers of the three

Other blades that make up this set

BLADE NUMBER As received or as balanced

BOX OF 4

SHIPPING WEIGHT As determined by Contractor

CONTRACT NUMBER As indicated on the contract

DELIVERY ORDER NUMBER As indicated on the delivery order

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1 - SET

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER - DO NOT DESTROY

b. Type 2 – BLADE SET, RIGHT HAND

STOCK NUMBER 2010-00-906-6009

ITEM NAME BLADE SET RH, PROPELLER

PART NUMBER 615-WPC-4400-54 CW

BLADE SERIAL NUMBER As marked on blade

BLADE SET SERIAL NUMBERS List serial numbers of the three

Other blades that make up this set

BLADE NUMBER As received or as balanced

BOX OF 4

SHIPPING WEIGHT As determined by Contractor

CONTRACT NUMBER As indicated on the contract

DELIVERY ORDER NUMBER As indicated on the delivery order

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1 - SET

c. Dummy Hub - DUMMY HUB RH & LH

STOCK NUMBER 2010-01-F88-0014

ITEM NAME HUB, DUMMY RH & LH

PART NUMBER DH 210A

SHIPPING WEIGHT As determined by Contractor

CONTRACT NUMBER As indicated on the contract

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1 - EA