Propeller General Requirements for Overhaul and Repair.pdf

24500_1125_FLT

WORK ITEM 1: General Requirements – Controllable Pitch Propeller (CPP) Blades and Monobloc Propeller, Overhaul and Repair

1. SCOPE

1.1 Intent. These General Requirements apply for conducting USCG CPP blade and monobloc propeller inspections, repairs and overhauls, including packaging and shipping preparations, performed at commercial contractor facilities. All components serviced via this specification and contract must adhere to these general requirements except as modified by the applicable, individual work items.

1.2 Requirements precedence. Where conflict exists between these General Requirements and the specific, individual work item requirements in the overall specification, the individual work item requirements take precedence.

1.3 Terminology. The term “component” used within these General Requirements will occasionally be used in lieu of “propeller(s)” and/or “blade(s)”. Where the term “blade(s)” is used, it is in reference to CPP blades unless otherwise defined, i.e., “propeller blades” for monobloc propellers.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

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

Allied Processes

OTHER REFERENCES

ANSI/ASQC Q9001, Quality Management Systems - Requirements - T860E

DOD 4140.01-M-1, Compliance for Defense Packaging

ISO/IEC 17025, General requirements for the Competence of Testing and Calibration Laboratories -

Third Edition

MIL-DTL-2845E (SH), Propulsion Systems, Boat and Ship; Main Shafting, Propellers, Bearings, Gauges, Special Tools, and Associated Repair Parts; Preservation, Packaging, Packing and Storage of

SAE AMS-T-22085, Tapes, Pressure-Sensitive, Adhesive, Preservation and Sealing

2.1 Document availability. To obtain documents referenced anywhere in this specification, refer to Section 6.1

(Document sources) herein.

2.2 References order of precedence. The references listed are required to be adhered to in fulfilling the contract. In the event of a conflict between the text of this specification and the references cited herein, this specification and the work items within shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. GENERAL REQUIREMENTS

3.1 Work responsibility. The Contractor must provide all labor and materials required to inspect and possibly repair or overhaul designated components in accordance with the requirements and references cited in the applicable work items of this specification.

3.2 Welding and brazing – general.

3.2.1 Process requirements. The Contractor must perform all welding, allied processes, and NDE in accordance with SFLC Std Spec 0740.

3.2.2 Certifications. Welder and weld procedure certifications must be in accordance with the applicable sections of SFLC Std Spec 0740 and made available for review to the Contracting Officer (KO), Contracting Specialist

(KS), and/or the USCG Quality Assurance Representative (QAR) upon request at any time during the contract period.

3.3 Inspections - general.

3.3.1 Personnel requirements. Visual Preservation Inspections (VPI), Visual Technical Inspections (VTI) and geometrical/dimensional inspections must be conducted by those trained and qualified via the NAVSEA Propeller

Visual Inspection Course, or a proposed and acceptable industry/society equivalent.

NOTE

PRIOR TO AWARD, the Contractor is responsible for providing to the KS/KO the proposed industry/society equivalent for review and approval. The proposed equivalent will be used in the Contractor technical evaluation.

3.3.2 Arrival inspections. Upon receipt of Government-Furnished Property (GFP), the Contractor must verify that the items received are in accordance with the applicable contract and/or contract delivery order. Within 5 business days, the Contractor must provide to the KO an Arrival Inspection Report, accounting for all arrived

GFP and any missing items, if any.

NOTE

Once in Contractor possession, the Contractor is responsible for the care and security of all GFP received.

3.3.3 Visual preservation inspections (VPI). Prior to moving and/or opening any propeller or blade crate(s), the

Contractor must inspect each crate and provide a written report for any observed damage to the crate. Once opened, the Contractor must observe and detail any damage to the content preservation and protection systems inside the crates, i.e., protective edges, preservation coating, etc. Submit CFRs for each prior to removing the container contents.

3.3.4 Visual inspections – general.

3.3.4.1 Component visual pre-inspection requirements. Each propeller and/or blade to be inspected must be thoroughly and wholly cleaned, free of all growth, scale, dirt, etc., prior to conducting any visual inspections.

3.3.4.2 Open, Inspect and Report (OIR) requirements. An OIR detailing the information sought in the following paragraphs must be submitted to the KO within ten (10) days of receipt of GFP.

3.3.4.2.1. Following the propeller and/or blade packaging inspection and cleaning, the Contractor must conduct a

Visual Technical Inspection (VTI) of the component(s) and make an initial determination for expected work required to return each item to “A” condition as defined below.

NOTE

“A” condition is defined as a repaired or overhauled item meeting all requirements herein. All items must be capable of functioning and performing in the same manner as an identical, new item, although it may not have the appearance of a new item.

3.3.4.2.2 OIRs must include all estimated costs of labor and materials (per task) including in-process and post-repair testing. Also included must be costs associated with the repair and/or renewal of packaging, protection, and crate(s).

CAUTION!

If at any time, while performing the initial inspection or during authorized work, the

Contractor determines the propeller and/or blade is beyond economical repair (BER), the KO and COR must be notified immediately with detailed, supporting information for the determination.

No further work beyond the OIR is to proceed until authorized by the KO in writing.

NOTE

Out-of-tolerance or damaged propeller bores will often render a BER condition; it is recommended to start propeller inspections with the bore absent another obvious

BER condition.

3.3.4.2.3 OIR information. The OIR must contain the following information:

• Contractor name, address, and telephone number.

• Date of inspection.

• Contract number and delivery order number, as applicable.

• Name of personnel conducting inspections.

• Component(s) serial number(s).

• Estimated cost to complete repair/overhaul.

• Estimated cost to repair or replace shipping container, if required.

• Estimated cost to complete any work that is beyond the scope the applicable work item.

• Contractor recommendation (repair or BER) to the KO for each propeller and/or blade; the KO will advise the Contractor how to proceed.

3.3.4.2.4 BER disposition. BER options are as follows:

• Contractor to scrap onsite and provide credit to the Coast Guard based on current regional material scrap prices.

• Propeller(s) to be re-packaged in the original shipping container (unless replaced), properly marked

“H Condition” per section 5.6 and returned to SFLC Baltimore, MD at the address listed in section

5.8.1.

3.3.5 Geometrical/dimensional inspections - general.

3.3.5.1 Measuring equipment. The Contractor must adhere to the following dimensional and geometrical measurement inspections requirements:

3.3.5.1.1 All propeller and/or blade surfaces must be measured using electronic, computer-aided equipment

(exceptions permitted for bore diameter measurements or other inaccessible areas). Known, acceptable computer-aided inspection systems, i.e., 3-dimensional coordinate measuring machines (CMM, preferred), Prop Scan, Hale

Measurement Recording Instrument (MRI), or a combination of these systems, or a proposed equivalent system, shall be used for all inspections.

CAUTION!

Drop-style pitchometers and/or sheet metal gauges must not be used unless explicitly required in a specific work item.

NOTE

Areas where hand measurement tools are more appropriate are authorized with KO notification, i.e., digital micrometer/caliper for bore measurements, cursory measurements, etc.

3.3.5.1.2 Prior to contract award, the contractor must identify the inspection system/method to be used to the KO.

3.3.5.1.3 All measuring equipment accuracy shall be a minimum of 0.001”.

3.3.5.2 Ancillary equipment. All rotational equipment, i.e., mandrels, concentric rings, shafts, etc., used to for propeller/blade inspections and balancing must not exceed a total indicated run-out (TIR) of 0.001”.

3.3.5.4 Data and tolerances. All required data points and tolerance bands will be in accordance with the specific work items in the larger specification.

3.3.6 Blue fit inspections. When required, blue fit inspections are recommended to be done using a blue coating thickness of .0002” and .0004” for best results.

NOTE

If blue fit inspections are required and a certified companion component is unavailable, the Contractor may propose a virtual fit-up inspection via three-dimensional CMM scanning of the existing component overlaid with a companion component CAD model.

3.4 Final inspections and test reports. The Contractor must submit to the KO for approval detailed, final inspection reports prior to scheduling an onsite Coast Guard SFLC Quality Assurance (QA) verification inspection.

CAUTION!

All components require a 100% Coast Guard QA verification inspection at the

Contractor’s facility prior to shipping to their final locations as designated by the

KO.

NOTE

For the safety of Coast Guard personnel and shop workers, QA inspections shall be completed indoors away from normal shop work, operating machinery, loud noise, welding (arching) and grinding operations if permissible.

3.4.1 The report must detail the final condition of each component after all work has been completed. All final technical measurements must be recorded and presented for SFLC QA desk audit, including any final dye penetrant (PT) inspection reports.

3.4.2 The Contractor is responsible for notifying the KO at least ten (10) calendar days prior the contractor being ready for any Coast Guard QA inspections or testing as required herein.

3.4.3 A copy of all test and inspection reports shall be turned over to the SFLC QA Representative upon arrival at the Contractor’s facility.

3.4.4 The final inspection report must be in the English language and reported dimensions must be presented in standard or metric as represented on drawings or any compliance forms.

3.4.5 All Coast Guard QA inspections must be completed within the continental United States of America.

3.5 Warranty. Standard manufacturer’s warranty applies to items serviced under this specification.

4. QUALITY ASSURANCE

4.1 General. The Contractor must maintain an inspection system in compliance with ANSI/ASQC Q9001 and ensures each item offered to the Coast Guard for acceptance and approval meets all contractual requirements.

4.2 Records.

4.2.1 The Contractor must maintain complete inspection and test records for all components serviced, serialized and traceable to each component.

4.2.2 In addition to the recorded conditions and measurements, pre- and post-work, the records must track all conditions found, actions taken, and final outcomes.

4.3 Calibration system. The Contractor, as well as any subcontractors, must maintain a test equipment calibration program in compliance with ISO/IEC 17025. The program shall be documented and traceable to the National

Institute of Standards (NIST).

4.4 Inspection responsibility. The Contractor must conduct all required inspections with a NAVSEA qualified propeller inspector. The Contractor must provide the space, personnel, and test equipment to conduct and meet all inspection requirements, ensuring all final products conform to the contractual requirements.

4.5 Compliance.

4.5.1 All work must meet the general requirements detailed in Sections 3 and 5. The absence of any requirements in the specification shall not relieve the Contractor of the responsibility of assuring that all components returned to the government 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.

4.5.2 The inspections and tests required by this specification 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.

4.6 Coast Guard SFLC QAR reviews. The following are required and must be observed by Coast Guard SFLC

QAR(s):

• Condition and care of all GFE.

• Propeller inspection requires 100% verification to assure full compliance with the applicable drawings, references, compliance sheets and this work item.

• Mandatory replacement parts in accordance with the applicable work item.

• Welder certifications in accordance with paragraph 3.2.2 herein.

• Preservation, packaging, packing, marking, and bar-coding of each propeller prior to shipping in accordance with Section 5 below and subsections.

4.6 Document responsibility. The Contractor must have the latest versions of the drawings, specifications, tolerances and approved test procedures available for review when requested.

4.7 Failure and corrective action responsibility. If a propeller fails to pass any inspection or test, the Contractor must report the failure and provide a corrective action recommendation to the KO for approval.

4.7.1 Only with KO approval and authorization will the corrective action be taken. No further testing or inspection is to be taken until the corrective action has been completed, with exception of any in-process checks that are required. Only after the corrective action is complete will the KO authorize post-work inspections or testing.

NOTE

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

4.7.2 Acceptance will be withheld until post-corrective action inspection and/or testing has been successfully demonstrated.

4.7.3 The Contractor must document all corrective actions and submit post-work inspection/testing reports to the

KO for approval.

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

5. PRESERVATION, PACKAGING, PACKING, MARKING, AND SHIPPING

5.1 General. Each component must individually cleaned, preserved, packaged, packed, marked and bar-coded in its own reusable shipping container, or a new reusable shipping container, if approved. Preservation, packaging, packing, marking and bar-coding will be inspected by Coast Guard SFLC QA personnel at Contractor’s facility.

WARNING!

Prior to the packaging and marking of the completed units, the KO must be notified to permit USCG QA inspection. Only following satisfactory inspection can the

Contractor begin the process covered under Section 5 herein.

5.2 Cleaning, preservation and protection.

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

5.2.2 After cleaning, apply to each component tape conforming to SAE AMS-T-22085, TYPE II and strippable compound preservative in accordance with MIL-DTL-2845E (SH) section 3.14.1.3.1.

5.2.3 After applying strippable compound, galvanized sheet metal blade edge protectors shall be installed in accordance with MIL-DTL-2845E (SH) section 3.14.1.4. The edge protection shall be held in place with all stainless steel grade hardware.

5.2.4 Plastic flange plugs/caps shall be inserted in the large and small bore openings, as applicable, and in all bolt holes.

5.3 Packaging and packing. Each component shall be individually packed in accordance with MIL-DTL-2845E paragraph 3.14.2.2.2.

5.3.1 The Contractor must enclose a print-out summation of all measured results with each component. The results shall be placed in an envelope and marked “For the USCG cognizant engineer”.

5.3.2 After enclosing the print-out, the container cover must be carefully secured using lag bolts.

NOTE

Packaging and packing photo examples are available in section 6.2

5.4 New, reusable wood crate. When authorized by the KO, the Contractor must construct a new reusable shipping container in accordance with MIL-DTL-2845E paragraph 3.14.2.2.2 suitably sized for the component to be contained.

5.5 Wood Packing Material (WPM) requirements.

5.5.1 New, reusable shipping containers shall meet the phytosanitary requirements for WPM in accordance with paragraph C2.1.1 of DOD 4140.01-M-1, Compliance for Defense Packaging.

5.5.2 WPM is defined as wood pallets, skids, load boards, pallet collars, wooden boxes, reels, dunnage, crates, frames and cleats.

5.5.3 Packaging material exempt from the requirements are materials that have undergone a manufacturing process such as corrugated fiberboard, plywood, particleboard, veneer and oriented strand board (OSB).

5.5.4 All new purchases of WPM shall be constructed from heat treated (treated to 56° C. core temperature for 30

Minutes) lumber and certified by an accredited agency recognized by the American Lumber Standard Committee

(ALSC).

5.5.5 All shipping containers must have the appropriate markings in accordance with DOD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.5.

5.5.6 Newly manufactured skid-type shipping containers shall be secured and stored per section 3.1.

5.6 Markings. Each packaged and packed component must be marked in the upper left-hand side of the two longest sides, (two opposite sides if square facing the forklift driver) of each shipping container. The container lettering shall be black waterproof painted stencil and permanently affixed. The lettering shall be painted on a white background. Additional marking requirements are listed in section 5.6.1 and 5.6.2.

NOTE

Marking examples can be seen in section 6.2

5.6.1 Marking must consist of the following:

• National stock number (NSN): {insert NSN}

• Item name: {insert item name, including “LH” for left hand or “RH” for right hand, as applicable}

• Part number (P/N): {insert part number}

• Serial number (S/N): {insert part number}

• Contract number: {insert contract number}

• Shipping weight (lbs): {insert measured container + component weights}

• Condition: CONDITION A

• Quantity & unit of issue: 1 – EA {or as applicable}

• Other data as directed: U.S. Coast Guard SFLC MATERIAL

5.6.2 Additional marking requirements. The Contractor must also complete the additional requirements as stated below for newly manufactured shipping containers.

a. The Contractor must paint the area of the top screws to be removed and lifting eye stencil white. A two-inch red square shall be painted to identify each screw that is used to secure the top to the container. The screws must be in the center of the square. The stencil must be waterproof with one-inch black block letters. Four eye bolts (one on each corner) must be adequately sized and installed to lift the lid. The following stencil shall be put on the crate in the area of the eye bolts:

THESE LIFTING EYES PROVIDED

FOR REMOVAL OF COVER ONLY

DO NOT USE FOR HANDLING OR MOVING

CONTAINED COMPONENTS

See example of markings in section 6.2.4, figure 4.

b. The Contractor must stencil a note on the top of the container in the center using waterproof one-inch black block lettering on a contracting white background. The stencil shall state the following:

NOTE: TO OPEN CONTAINER

REMOVE RED SCREWS AND LIFT

COVER USING LIFTING EYES

See example of markings in section 6.2.5, figure 5.

5.7 Bar coding. The U.S. Coast Guard requires bar coding of the NSN in accordance with MIL-STD-129R. See paragraph 5.4.1.2.1, page 51 of MIL-STD-129R for identification linear (Code 39) and 2D (PDF417) bar code markings and locations.

5.7.1 The bar code label can be applied separately or as part of the marking required in 5.6.

5.8 Shipping. Unless otherwise directed, the Contractor must ship and deliver the component(s) as follows:

5.8.1 Shipping must be to the following Government address:

US COAST GUARD

SURFACE FORCES LOGISTICS CENTER

2401 Hawkins Point Road

Receiving Room – Building 88

Baltimore, MD 21226

5.8.2 Notify the KO and Contracting Officer’s Representative (COR) 7 days in advance of shipping.

5.8.3 Provide timely shipping information to KO and COR including the name of the shipping company, date of shipment, and arrival date expected to the government facility.

NOTE

No shipment shall arrive outside of government normal business hours as determined by the KO.

5.8.4 Delivery acceptance will be made at destination by a Government representative. Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of the order, including the Contractor’s compliance with the preservation, packaging, packing, marking and bar-coding requirements.

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

• USCG Surface Forces Logistics Center

2401 Hawkins Point Road Baltimore, MD 21226-5000

Phone: 410-762-6649

ATTN: Contracting Branch, CPD1

6.1.2 Commercial document sources.

• ASTM International

1916 Race Street

Philadelphia, PA 19103-1187

Phone: 215-299-5585

Fax: 215-977-9679

• American National Standards Institute (ANSI)

1430 Broadway New York, NY 10018

Phone: 212-642-4900

• 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

• American Society of Mechanical Engineers (ASME)

Two Park Avenue

New York, NY 10016-5990

Phone: 800-843-2763

• The Society for Protective Coatings (SSPC)

800 Trumbull Drive

Pittsburgh, PA 15205

Phone: 1-877-281-7772

Fax: 412-444-3591

• Society of Automotive Engineers (SAE)

400 Commonwealth Drive

Warrendale, PA 15096

Phone: 724-776-4841

Fax: 724-776-0790

6.2 Photo examples.

(See below)

6.2.1 Figure 1: Example of a prepared propeller crate.

6.2.2 Figure 2: Example of propeller with edge guards and cap over bore.

6.2.3 Figure 3: Example of propeller with edge guards and cap over bore.

6.2.4 Figure 4: Example of crate markings and lifting eyes on top of crate.

6.2.5 Figure 5: Example of crate markings to remove top off crate.

6.2.6 Figure 6: Example of finished propeller crate with markings.