Attachment_2_Work_Specification.pdf

IDC_0416

Change Request - 059: Controllable Pitch Propeller Hub Assembly, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the overhaul, packaging, packing, acceptance testing, and marking of Rolls-Royce controllable pitch propeller (CPP) hubs for 418’ WMSL Coast Guard Cutters.

1.2 Government-Furnished Property.

MTI ITEM DESCRIPTION NSN

P/N

CAGE

QTY

(EA.)

Y Style A- Starboard, Left Hand CPP Hub

NSN: 2010-01-555-7256

PN: 140158_03

Y Style B- Port, Right Hand CPP Hub

NSN: 2010-01-555-7247

PN: 140158_02

*Government-loaned property, which shall be returned to the Coast Guard upon completion of the contract.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by the Coast Guard.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Specification D-000-0100, Rev. G, Change 1, Bar Coding for

SFLC Stocked Material Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

OTHER REFERENCES

MIL-PRF-16173E w/ Int. Amendment 1, Sep 2006, Corrosion Preventive Compound, Solvent

Cutback, Cold- Application DOD 4140.01-M-1, 7 Sep 2007; Compliance for Defense Packaging: Phytosanitary Requirements for Wood Packaging Material (WPM) DOD-P-24562A Dated 1 November 1982, Propellers, Ship, Controllable Pitch (Metric) MIL-DTL-2845E (SH), Dated 18 August 99, Propulsion Systems, Boat and Ship;

Main Shafting, Propellers, Bearings, Gauges, Special Tools, and Associated Repair

Parts; Preservation, Packaging, Packing and Storage of.

MIL-STD-167-1A (SHIPS), 02 November 2005, Mechanical Vibrations of Shipboard Equipment.

NCSL Z540.3 Dated 03 August, 2006, Requirements for the Calibration of Measuring and Test

Equipment ASQ Q9001-2008, Dated 2008, Quality management systems-Requirements ABS Guide for Bronze and Stainless Steel and Propeller Castings – DATED 2007 Rolls Royce User Manual, 11668-U-1, R1-3, as revised, Part 7, Maintenance instructions, Chapter 5.1 KAMEWA Drawing NAV 132XF5/5D-B/CLW

3. REQUIREMENTS

NOTE

In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

3.1 General.

3.1.1 Tech Rep. Not applicable.

3.2 Purchase procurement. The Contractor shall provide all equipment, labor and materials to overhaul, test, inspect, preserve, package, pack and mark the hub assemblies. The Hub assembly, installation, and overhaul kits shall be in accordance with the Original Equipment Manufacturer (OEM) specifications, drawing(s) and data provided within this specification including and primarily the contractor shall use any propriety OEM specifications, drawings and data used to overhaul the OEM Hubs to the strict tolerances, measurements, and exactness to the original Hubs and their performances; that the USCG-SFLC may not be privilege to.

3.3 Test & inspection plans. The Contractor shall submit test and inspection plans to the Contracting Officer within ten days of the award of contract for approval. Each 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 OEM's drawings, specifications, and technical publications.

3.4 Cleanliness. The area in which hub assembly, testing, and inspections are performed shall be kept free of any accumulation of dust, dirt, metal shavings, or contaminated fluids, and shall be separate from the manufacturing and machining area.

3.5 Cleaning & finishing. The Contractor shall clean and polish all machined surfaces as necessary to remove any etching, scoring, or other imperfections that would be detrimental to the operation of the hub.

3.6 Balancing. Each complete hub assembly, less blades, shall be dynamically (2-plane) balanced on a rotating balancing machine. The maximum allowable out-of-balance force shall be calculated in accordance with DOD-P-24562A 3.18 and 4.4.1.1; MIL-STD-167-l paragraph 5.2.

3.7.1 Balancing inspection. The Contractor shall balance the hubs in the presence of the Coast Guard Quality Assurance Representative. The Contractor shall provide the Contracting Officer with a 10 day notification before the balance inspection.

3.8 Hub testing, operating and preservation oil. Oil used for all testing, operating and preservation of the hubs shall be in accordance with Rolls Royce user manual, Part 7, Chapter 5.1 or equivalent. Oil from different manufacturers or brands shall NOT be mixed. The hubs will be filled with oil and a head tank full of oil will be installed in the crate to feed oil to the hub should oil be needed.

3.9 Hub actuation testing. Each hub assembly shall be hydraulically actuated to the full ahead and full astern positions. Observations shall be made and documented to assure smooth movement to each position with no binding or obstruction of movement. The Contractor shall document the capacity of the hydraulic power unit used to conduct the actuation test along with the elapsed time it took to actuate to each position. Testing shall be accomplished in the presence of the Coast Guard Quality Assurance Representative.

3.10 Hub cavity pressure testing. This test shall be performed only after satisfactory completion of the Hub Actuation Testing in section 3.9. With the hub fully assembled, the hub cavity shall be pressurized with hydraulic fluid in accordance with the OEM test plan. After the pressure stabilizes, the pump shall be secured and there shall be zero pressure drop for a minimum duration of 30 minutes.

3.11 Final acceptance operational inspection/test report. This report shall include the following items along with any others needed to verify all requirements.

Date of inspection.

Inspector’s name.

Identification of units by serial number, part number, and stock number.

Complete final measurement report of all critical dimensions and applicable assembly tolerances for each part to include clearances and thrust measurements.

A final operational test of each completely assembled hub using hydraulic pressure to actuate the hub from the full ahead to the full astern position. The measured actuation time and hydraulic supply parameters (supply pressure, flow, time, and temperature) shall be documented on the report.

A cavity pressure test of each completely assembled hub to assure that no leaks occur. The hydraulic pressures and duration times used to conduct this test shall be documented in the report.

A complete listing of all test equipment used with a current calibration date for each piece of test equipment. The test equipment shall include pressure gauges, hoses, hydraulic power unit, and tools.

A complete description of each test and inspection including step by step procedures for all tests and inspections, in chronological order, with pass/fail criteria.

Dynamic (2-plane) balance in accordance with DOD-P-24562A Based on the findings of the inspection, overhaul, and tests provide a service life estimate to include the recommended number of years the hubs can go between overhauls.

3.11.1 No tests or inspections required herein are intended to supplant any controls, examinations, inspections, or tests normally employed by the Contractor to ensure the quality of the hub assemblies overhauled.

3.11.2 No hub shall be delivered until the final operational acceptance and cavity pressure test results are approved by the Contracting Officer.

3.12 Hub markings. The stampings shall be at least ¼” high of legible printing. The stampings shall include, at the minimum, the following information.

STOCK NUMBER - See section 5.2.

PART NUMBER – See section 5.2.

SERIAL NUMBER – See section 5.2.

STARBOARD (OR PORT)

TYPE OF MATERIAL

PITCH MARKS AT EACH BLADE

3.13 Notifications & inspections. The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) calendar days prior to said Contractor being ready for any inspections testing, or balancing required herein.

4. QUALITY ASSURANCE

4.1 Inspections & tests (completed units). The inspections & tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the Contractor to assure the quality of the product.

4.1.1 Contractor shall have the latest versions of the drawings, specifications, tolerances, approved test procedures and test equipment calibration certificates available traceable to NIST for inspection, as necessary.

4.1.2 The following are required and will be monitored by a CG-SFLC Quality Assurance Representative:

Dimensional tolerances are in accordance with the drawing.

Surface texture (stock section).

Weld inspection.

Hub Actuation Testing Blade straightness in reference to the centerline on the drawing.

Packing, packaging, marking and bar-coding prior to shipping.

5. PACKING, MARKING, AND SHIPPING

5.1 Packing. Each hub shall be individually packaged in its own reusable wood box, or a new reusable shipping container.

NOTE

All GFP must be stored indoors in a locked, environmentally controlled location at the contractor's facility. Any new crates fabricated per this statement of work shall be safe guarded and stored in the same place as other

GFP.

5.2 New reusable shipping container. When a change request is authorized by the KO, the Contractor shall construct a new reusable shipping container as follows:

5.2.1 The wooden box shall be constructed using 2” x 8” framing and ¾” plywood top and bottom.

Particle board, flake board, OSB etc. will not be acceptable. The box shall be skid mounted and constructed with a removable lid secured with corrosion resistant wood screws to allow easy access and removal of the enclosed part without damage to the box.

5.2.2 Wood Packing Material (WPM) Requirements. The new shipping container shall meet the Phytosanitary Requirements for WPM in accordance with DOD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.1.1. WPM is defined as wood pallets, skids, load boards, pallet collars, wooden boxes, reels, dunnage, crates, frames and cleats. 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). 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).

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

5.2.4 Newly manufactured shipping containers shall be secured and stored per 5.1 note.

5.3 Marking. Shipping container shall be stenciled with the information laid out below. Markings shall be placed on each side of the two longest sides of the container so it will be visible to a forklift driver during storage and shipment. Stencil shall be applied directly on the container and a minimum of 1inch height black characters on a highly contrasting painted background, using permanent waterproof ink or enamel paint.

5.3.1 Each preserved and packaged item shall be marked in the upper left- hand side of the two longest sides, (two opposite sides if square) of each crate. The lettering shall be black painted stencil and permanently affixed to each container. The lettering shall be at least 1” high, and be applied on a highly contrasting background.

5.3.2 This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, SERIAL NUMBER, CONTRACT NUMBER, , SHIPPING WEIGHT (in lbs.), CONDITION CODE, i.e.

CONDITION A, UNIT OF ISSUE with QUANTITY(1) and the words U. S. COAST GUARD SFLC

MATERIAL CONDITION "A" REUSABLE CONTAINER, DO NOT DESTROY, REMOVE BOLTS,

LIFT CRATE FROM SKID.

5.3.3 See below for marking layout.

HUB TYPE 1, STYLE A

STOCK NUMBER

2010-01-555-7069

ITEM NAME

Hub Assembly, Propeller, STBD

PART NUMBER

140158_03

SERIAL NUMBER

As recorded from Hub Assembly

CONTRACT NUMBER

(See Contract)

SHIPPING WEIGHT

As Determined by Contractor

QUANTITY & UNIT OF ISSUE

1 - EA

CONDITION CODE

CONDITION A

OTHER DATA AS DIRECTED

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER, DO NOT

DESTROY, REMOVE BOLTS, LIFT

CRATE FROM SKID.

HUB TYPE 1, STYLE B

2010-01-555-7104

ITEM NAME

Hub Assembly, Propeller, PORT

PART NUMBER

140158_02

SERIAL NUMBER

As recorded from Hub Assembly

CONTRACT NUMBER

(See Contract)

SHIPPING WEIGHT

As Determined by Contractor

QUANTITY & UNIT OF ISSUE

1 - EA

CONDITION CODE

CONDITION A

OTHER DATA AS DIRECTED

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER, DO NOT

HUB INSTALL KIT

2010-01-642-8265

ITEM NAME

Hub Install Kit

PART NUMBER

U-1-6-65

CONTRACT NUMBER

(See Contract)

SHIPPING WEIGHT

As Determined by Contractor

QUANTITY & UNIT OF ISSUE

1 - EA

CONDITION CODE

CONDITION A

OTHER DATA AS DIRECTED

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER, DO NOT

HUB OVERHAUL KIT

2010-01-642-8281

ITEM NAME

Hub Overhaul Kit

PART NUMBER

U-1-6-66

CONTRACT NUMBER

(See Contract)

SHIPPING WEIGHT

As Determined by Contractor

QUANTITY & UNIT OF ISSUE

1 - EA

CONDITION CODE

CONDITION A

OTHER DATA AS DIRECTED

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER, DO NOT

5.4 Bar coding. A bar coded label, in accordance with SFLC specification D-000-0100 shall also be applied. The Bar Code Label can be applied separately or as part of the marking required in 5.3 of this specification.

5.4.1 The actual labels shall be Type "V", Grade "C" Style "2", Composition "a" with or without plastic laminate.

5.4.2 Each label shall contain encoded data for the Stock Number.

5.5 Shipping. The Contractor shall ship, and deliver the hub and components to the government address specified in paragraph 5.5.1. Notice the Contracting Officer representative (COR) and KO 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 KO.

5.5.1 Unless otherwise specified, the Contractor shall ship, and deliver the hub(s) to the following government address:

US Coast Guard Surface Forces Logistics Center 2401 Hawkins Point RD, Receiving Room - Bldg 88 Curtis Bay, MD 21226

NOTE

Normal deliver hours at the warehouse are Monday through Friday 0730- 1300. If delivery is needed to be made outside that delivery window the Contractor shall notify the Contracting Officer.

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 Commercial document sources.

American National Standards Institute (ANSI)

25 West 43rd Street (Between 5th and 6th Avenues) 4th Floor New York, New York 10036 212-642-4900

FAX: 212-398-0023

www.ansi.org

American Society For Quality Control (ASQC) 611 East Wisconsin Avenue Milwaukee, Wisconsin 53202 414-272-8575 Fax: 414-272-1734