Group 9_IBCTPL_WLB-225_NSN 2010-01-421-8904.pdf

24599_225_0126_Rev -

Work Item 1: Blade(s), Controllable Pitch Propeller (CPP), 225 WLB Class, Inspect and Repair

1. SCOPE

1.1 Intent – This work item defines the requirements to inspect and repair for 225’ 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, Right Hand (RH) NSN: 2010-01-421-8904

P/N: 110252110

Dummy Hub, Propeller RH ACN: 2010-01-F04-0341

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 225-WLB-245-203, Rev E, CPP Propeller Blade Right Hand

COAST GUARD PUBLICATIONS

Coast Guard Specification D-000-0100, Rev G, Bar Coding for USCG Surface Forces Logistics

Center Procured Material

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 Drawing

225-WLB-245-203 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 II is the guiding document for the inspections and repairs to be made. Class II 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, and

0.95.

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 following radii: 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, and 0.95.

3.2.4.5 Maximum blade thicknesses. Measure the maximum blade thicknesses the following radii: 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, and 0.95.

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.

3.2.4.9 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 including the palm top and bottom surfaces, and fillets while using MIL-STD-2035, Table IV as acceptance criteria.

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. Determine the material 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 II in conjunction with Coast Guard Drawings 225-WLB-245-203 as applicable.

3.3.2 Welding specifics.

3.3.2.1 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.

3.3.2.2 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.

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

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

3.3.2.3.2 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.

• Propeller sealing surfaces – 16 micro inches or better

NOTE

Hand finishing may be required to obtain the 16 micro inch finish.

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.

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

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

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

3.3.4.7 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. 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.

CAUTION!

Thickness must not be less than 2.256 inches.

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 per paragraph 3.3.4 and follow-on paragraphs.

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.

4.3 Validation of inspections/tests. The following are required and will be validated by a Government

Quality Assurance Representative:

4.3.1 Geometrical/dimensional inspections per the following paragraphs:

• 3.2.4.1

• 3.2.4.2

• 3.2.4.3

• 3.2.4.4

• 3.2.4.5

• 3.2.4.6

• 3.2.4.7

• 3.2.4.11

• 3.2.4.12

• 3.2.4.13

• 3.2.4.15

4.3.2 Surface inspections per paragraph 3.2.4.9.

4.3.3 Balance checks per paragraph 3.3.4 and follow-on paragraphs.

4.3.4 Blade stamping per paragraph 3.5.

4.4 Component sketches.

Pressure side _____ Suction side _____

Pressure side _____ Suction side _____

Blade Palm

Top side _____ Bottom side ______

LH ______ RH _______

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, modify as follows:

5.1.1.1 In place of “serial number”, insert the following

• Blade serial number {as marked on the blade}

• Blade set serial numbers {list the serial numbers of the other three blades included in this set}

• Blade number {as received or as balanced}

• Box {insert} of 4

5.1.1.2 Beneath “Contract number”, insert “Delivery order number” {mark as indicated on the delivery order}.

5.1.1.3 The “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 the following:

• “REUSABLE CONTAINER – DO NOT DESTROY”.

5.1.3 Markings examples:

a. Type 1 – BLADE SET, LEFT HAND

STOCK NUMBER 2010-01-120-2871

ITEM NAME BLADE SET LH, PROPELLER

PART NUMBER 8-350-255 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 2010-01-119-3972

ITEM NAME BLADE SET RH, PROPELLER

PART NUMBER 8-350-254 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

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER - DO NOT DESTROY

c. Dummy Hub - DUMMY HUB RH & LH

STOCK NUMBER 2010-01-FST-0069

ITEM NAME HUB, DUMMY RH & LH

PART NUMBER 901 WMEC 245-007

SHIPPING WEIGHT As determined by Contractor

CONTRACT NUMBER As indicated on the contract

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1 - EA

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER - DO NOT DESTROY

5.2 270 Bar coding particulars. In lieu of the “General Requirements” bar coding, the 270 containers shall be bar coded as follows:

5.2.1 Actual labels must be in accordance with SFLC Specification D-000-0100, Type “V”, Grade “A”, Style “2”, Composition “b” with plastic laminate.

5.2.2 Each label shall contain encoded data for the national stock number.