70Z08520RP4501500 Attachment 2 - Specifications Rev 1.pdf

i (Rev-0)

USCGC POLAR CLASS ICEBREAKER

SPECIFICATION TO REPAIR POLAR CLASS ICEBREAKER CONTROLLABLE PITCH

PROPELLER (CPP) HUB ASSEMBLY

Developed By: David E Kent

(Rev-1, 15 April 2020) ii (Rev-0)

TABLE OF CONTENTS

TABLE OF CONTENTS .............................................................................................................................. ii Revisions Record ......................................................................................................................................... iii Consolidated List of References .................................................................................................................. iv Consolidated List of Government-furnished Property ................................................................................. vi Consolidated List of Critical Inspection Items ........................................................................................... vii

GENERAL REQUIREMENTS

WORK ITEM 1: Controllable Pitch Propeller (CPP) Hub Assembly Overhaul WORK ITEM 2: Controllable Pitch Propeller (CPP) Trunnion Renewal WORK ITEM 3: Controllable Pitch Propeller (CPP) Hub Adjusting Crank Renewal;

WORK ITEM 4: Controllable Pitch Propeller (CPP); Locknut Renewal WORK ITEM 5: Controllable Pitch Propeller (CPP) Drive Pin Renewal WORK ITEM 6: Controllable Pitch Propeller (CPP) Link Pin Fabrication; and Op-Rod

Machining WORK ITEM 7: Controllable Pitch Propeller (CPP) Hub Trunnion Bushing Renewal WORK ITEM 8: Controllable Pitch Propeller (CPP) Hub Trunnion Thread Diameter Restoration iii (Rev-0)

REVISIONS RECORD

This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

4/15/2020 1 1 Modified list of CG Drawings 4/15/2020 1 2 Modified list of CG Drawings 4/15/2020 1 3 Modified list of CG Drawings 4/15/2020 1 4 Modified list of CG Drawings 4/15/2020 1 5 Modified list of CG Drawings 4/15/2020 1 6 Modified list of CG Drawings 4/15/2020 1 7 Modified list of CG Drawings 4/15/2020 1 8 Modified list of CG Drawings 4/15/2020 1 1 Modified NOTE 4/15/2020 1 1 Modified 3.7.1.6 4/15/2020 1 1 Modified 3.7.19 4/15/2020 1 1 Modified 3.10.12 4/15/2020 1 2 Modified 3.2.2.2 4/15/2020 1 2 Modified 3.2.3.2 4/15/2020 1 3 Modified 3.2.3 4/15/2020 1 5 Modified 3.2.4 4/15/2020 1 7 Modified 3.4.3.1 4/15/2020 1 7 Modified 3.4.4.1 4/15/2020 1 8 Modified 3.2.1

NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

iv (Rev-0)

CONSOLIDATED LIST OF REFERENCES

COAST GUARD DRAWINGS

400-WAGB_4400_5, Rev -, CPP LH Propeller Blade:

400-WAGB_4400_6, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_7, Rev -, CPP LH Propeller Blade Design

400-WAGB_4400_26, Rev -, CPP Master Cross Reference Drawing List

400-WAGB_4400_27, Rev -, CPP Right Hand Hub Assembly (Elev Section-Side Profile)

400-WAGB_4400_28, Rev -, CPP Right Hand Propeller Blade

400-WAGB_4400_29, Rev -, CPP Right Hand Adjusting Crank Arm

400-WAGB_4400_30, Rev -, CPP Right Hand Adjusting Crank Arm Dowell Location And Drive Pin Matrix

400-WAGB_4400_31, Rev -, CPP RH Operating Rod

400-WAGB_4400_32, Rev -, CPP RH Link Arm Assy

400-WAGB_4400_33, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_34, Rev -, CPP 69 Inch Dia LH Prop Hub Assy (Elev Sect)

400-WAGB_4400_35, Rev -, CPP LH Propeller Blade

400-WAGB_4400_36, Rev -, CPP LH Adjusting Crank Arm (Unsigned)

400-WAGB_4400_37, Rev -, CPP Left Hand Adjusting Crank Arm Dowel Location

400-WAGB_4400_38, Rev -, CPP Left Hand Operating Rod

400-WAGB_4400_39, Rev -, CPP Left Hand Link Arm Assembly

400-WAGB_4400_40, Rev -, CPP Left Hand Propeller Blade Design

400-WAGB_4400_41, Rev -, CPP Hub Cylinder (Common To LH & RH)

400-WAGB_4400_42, Rev -, CPP Propeller Hub (Common To LH & RH)

400-WAGB_4400_43, Rev -, CPP Piston (Common To LH & RH)

400-WAGB_4400_44, Rev -, CPP Guide Rod & Guide Flange (Common To LH & RH)

400-WAGB_4400_45, Rev -, CPP Locknut (Trunnion) (Common To LH & RH)

400-WAGB_4400_46, Rev -, CPP Propeller Tailshaft Assembly (Common To LH & RH)

400-WAGB_4400_47, Rev -, CPP List of Material

COAST GUARD PUBLICATIONS

Coast Guard Commandant Instruction (COMDTINST) M10360.3C, Change 1, Jun 2006, Coatings and Color Manual

Coast Guard Technical Publication (TP) 4986, Controllable Pitch Propeller System, Modified, Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

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

Rev-1 v (Rev-0)

OTHER REFERENCES

Allis Chalmers 4842-ARA-5 Rev 02, Locknut

Allis Chalmers 9001-E-1 REV B, LH CPP Hub Blade

Allis Chalmers 9004-F-1 Rev 12, Adjusting Crank (RH)

American Bureau of Shipping (ABS), Part 7 Appendix Section 10 - Guide for Bronze and Stainless Steel Propeller Castings, 2011

American Bureau of Shipping, Guide for Bronze and Stainless Steel Propeller Castings, 2011

American Bureau of Shipping, Guide for Bronze and Stainless Steel Castings, 2011

ASTM International (ASTM) D4417, 2003, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel

Code of Federal Regulations (CFR) Title 33 CFR, 2008, Navigation and Navigable Waters

Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency

Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation

Commercial Item Description (CID) A-A-59316, Nov 2003, Abrasive Materials for Blasting Hydraulic CPP hub Test Unit

Hytorc Hydraulic Operating Instructions

MIL-A-22262, Mar 1996, Abrasive Blasting Media Ship Hull Blast Cleaning

MIL-DTL-16232G, Jan 2000, Phosphate Coating, Heavy, Manganese or Zinc Base

MIL-DTL-2845E (SH); Propulsion Systems, Boat And Ship; Main Shafting, CPP hubs, Bearings, Gauges, Special Tools, And Associated Repair Parts; Preservation, Packaging, Packing and Storage Of, Dated 18 August 1999

NAVSEA Technical Specification S9074-AR-GIB-010/278, Requirements for Fabrication Welding and Inspection, and Casting Inspection and Repair for Machinery, Piping, and Pressure Vessels

Sulzer Escher Wyss 8306041; Locknut

The Society for Protective Coatings (SSPC) VIS 1, 2004, Guide and Reference Photographs for Steel Surfaces Prepared by Dry Abrasive Blast Cleaning vi (Rev-0)

CONSOLIDATED LIST OF GOVERNMENT-FURNISHED PROPERTY

The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings.

WORK

ITEM

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

1 Y *Work (overhaul) Stands Coast Guard Tool 3 ea 5,000 1 Y *60 Ton Hydraulic Jack, Hollow Center Coast Guard Tool 1 ea 400 1 Y *Pin Puller Bolts Coast Guard Tool 2 ea 200 1 Y *Pin Puller Adapter Sleeve Coast Guard Tool 1 ea 100 1 Y *Lifting Plate w/8 ea. 1-1/2" hex head bolts Coast Guard Tool 1 ea 750 1 Y *Pad Eye for Operating Rod Coast Guard Tool 1 ea 250 1 Y *Blade Lifting Clamp Coast Guard Tool 1 ea 400 1 Y *Eye Bolt for Lifting Cylinder Coast Guard Tool 1 ea 250 1 Y *Flat Wrenches (4", 6-1/4", 6-1/2", 6-5/8") Coast Guard Tool 4 ea 400 1 Y *Hydraulic Test Fixture (3 pieces + clamps) Coast Guard Tool 1 ea 800 1 Y *Shipping Stands Coast Guard Tool 3 ea 1250 1 Y *Guide Rod Nut Wrench Coast Guard Tool 1 ea 450 1 Y *CPP hub Blade Edge Clamp Coast Guard Tool 2 ea 200 1 Y *Hydraulic Test Unit Coast Guard Tool 1 ea 12,000 1 Y *HYTORC hydraulic wrench Coast Guard Tool 1 ea 1,500 1 Y *HYTORC hydraulic pump unit Coast Guard Tool 1 ea 700 1 Y *Cylinder Assembly Guide Pins Coast Guard Tool 4 ea 300 1 Y *Pitch Measuring Device (for use in O-2) Coast Guard Tool 1 ea 550 1 Y *Mounting Assembly (Hub to Work stand hold down (assemblies) Coast Guard Tool 4 set 450

1 Y *4 dummy link pin set Coast Guard Tool 6 ea 800 1 Y *Hub check valve test fixture Coast Guard Tool 1 ea 350 1 Y *Aluminum trunnion blade thread gage Coast Guard Tool 1 ea 200 1 Y *Blade holding/clamp fixture for machining Coast Guard Tool 1 ea 550 1 Y *Piston ring compressor tool Coast Guard Tool 1 ea 250 1 Y *Blade dowel pin positioning fixture Coast Guard Tool 1 ea 750 1 Y *Link arm fixture for machining Coast Guard Tool 1 ea 500 1 Y *Adjustable Reamer Coast Guard Tool 2 ea 600 2 N Adjusting Cranks (Either RH set or LH set) Escher Wyss 4 ea 40,000 2 N Adjusting Cranks link pins, Escher Wyss 4 ea 500 2 N Spherical Bearings Escher Wyss 8 ea 2,000 3 N Outer Trunnion Bushing (Rough Cut

Condition) Escher Wyss 1 ea 1,250.00

3 N Inner Trunnion Bushing (Rough Cut Condition)

Escher Wyss 1 ea 1,000.00

*Government-loaned property, which shall be returned to the vessel upon completion of the availability.

**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 either the vessel or the C4IT ServiceCenter vii (Rev-0)

CONSOLIDATED LIST OF CRITICAL INSPECTION ITEMS

The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000_STD, paragraph 3.2.6.5 (Inspection report particulars)):

This section is not applicable to this package.

8 (Rev-1)

00000_0413_FLT

REC_00000_FLT_ Commercial Project @ Contractor’ Facility (1212)

GENERAL REQUIREMENTS

1. SCOPE

1.1 Intent. This standard specification invokes general requirements for conducting vessel repairs performed at a commercial contractor’s facility for Coast Guard vessels.

1.2 Term interchangeability. The terms 'Contractor', 'CG Yard', 'NAVSTA EVERETT', 'shipyard', 'Base', and 'Coast Guard Industrial' are used interchangeably in this specification. Where the primary service provider is Coast Guard personnel, references to contractor and other noted descriptors within this specification or within drawings, publications, SFLC Standard Specifications or other commercial and military references are deemed the same as prime service provider.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

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

OTHER REFERENCES

Code of Federal Regulations (CFR) Title 33 CFR, Jul 2010, Navigation and Navigable Waters

Code of Federal Regulations (CFR) Title 40, Chapter I, 2008, Environmental Protection Agency

Code of Federal Regulations (CFR) Title 49, Chapter I, 2008, Pipeline and Hazardous Materials Safety Administration, Department Of Transportation

3. REQUIREMENTS

3.1 General. The Contractor shall conform to all requirements specified in SFLC Std Spec 0000 and in this item, as applicable, during the performance of this availability.

9 (Rev-1)

NOTE

The requirements of paragraph 3.1 (General) applies to all work under the scope of this contract, whether explicitly stated in work items or not, and also to all other work subsequently authorized by changes, modifications, or extensions to the contract.

3.2 Fire watch requirements. The Contractor shall provide all fire watch personnel and and equipment.

3.3 Preservation requirements. The Contractor shall accomplish all preservation tasks, including touch-ups, in accordance with SFLC Std Spec 6310.

3.3.1 Brand name approval. Ensure that all contractor-furnished coatings are in accordance with SFLC Std Spec 6310, Appendix C (Authorized Coatings for Use on Cutters and Boats).

3.3.2 Coating colors and system color schemes. Ensure that all colors and color coat/paint schemes are in accordance with SFLC Std Spec 6310, Chapter 11 (Cutter and Boat Colors Exterior and Interior).

NOTE

Unless a waiver has been granted (in writing) by the KO, deviations from authorized coatings (listed in Appendix C of SFLC Std Spec 6310) and colors and color schemes (provided in Chapter 11 of SFLC Std Spec 6310) are strictly prohibited.

3.4 Welding and brazing requirements. The Contractor shall perform all welding and allied processes, and NDI in accordance with SFLC Std Spec 0740.

NOTE

NAVSEA approval is NOT required for welding procedures submitted but the procedures must be reviewed and shown to satisfy the requirements set forth in NAVSEA TP 1688, by a welding regulatory agency. The requirements for welding Weldox 900 shall be considered the same as those for welding HY-

3.5 HW disposal. The Contractor is considered as the generator of all contract-generated hazardous wastes and shall use its facility’s EPA generator ID number for management, transportation, and disposal of said hazardous wastes. Ensure the following:

3.5.1 Contractor’s hazardous waste handlers shall comply with applicable requirements of 40 CFR 262.

3.5.2 All contract generated hazardous wastes shall be packaged in 49 CFR-compliant containers.

3.5.3 The designated wastes shall be disposed of at a state or Federally-approved and permitted Hazardous Waste Treatment Storage and Disposal Facilities (TSDF).

3.5.4 Name of destination TSDF shall be submitted to the KO at the Arrival Conference.

10 (Rev-1)

4. NOTES

None.

11 (Rev-1)

24509_JPH_0511_400

WORK ITEM 1: Controllable Pitch Propeller (CPP) Hub Assembly Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to disassemble, inspect, overhaul, reassemble and test one right hand or one left hand Polar Class Icebreaker CPP hub assembly.

1.2 Government-furnished property.

MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Y *Work (overhaul) Stands Coast Guard Tool 3 ea 5,000 Y *60 Ton Hydraulic Jack, Hollow Center Coast Guard Tool 1 ea 400 Y *Pin Puller Bolts Coast Guard Tool 2 ea 200 Y *Pin Puller Adapter Sleeve Coast Guard Tool 1 ea 100 Y *Lifting Plate w/8 ea. 1-1/2" hex head bolts Coast Guard Tool 1 ea 750

Y *Pad Eye for Operating Rod Coast Guard Tool 1 ea 250 Y *Blade Lifting Clamp Coast Guard Tool 1 ea 400 Y *Eye Bolt for Lifting Cylinder Coast Guard Tool 1 ea 250 Y *Flat Wrenches (4", 6-1/4", 6-1/2", 6-

5/8") Coast Guard Tool 4 ea 400

Y *Hydraulic Test Fixture (3 pieces + clamps)

Coast Guard Tool 1 ea 800

Y *Shipping Stands Coast Guard Tool 3 ea 1250 Y *Guide Rod Nut Wrench Coast Guard Tool 1 ea 450 Y *CPP hub Blade Edge Clamp Coast Guard Tool 2 ea 200 Y *Hydraulic Test Unit Coast Guard Tool 1 ea 12,000 Y *HYTORC hydraulic wrench Coast Guard Tool 1 ea 1,500 Y *HYTORC hydraulic pump unit Coast Guard Tool 1 ea 700 Y *Cylinder Assembly Guide Pins Coast Guard Tool 4 ea 300 Y *Pitch Measuring Device (for use in O-2) Coast Guard Tool 1 ea 550 Y *Mounting Assembly (Hub to Work stand hold down (assemblies) Coast Guard Tool 4 set 450

Y *4 dummy link pin set Coast Guard Tool 6 ea 800 Y *Hub check valve test fixture Coast Guard Tool 1 ea 350 Y *Aluminum trunnion blade thread gage Coast Guard Tool 1 ea 200 Y *Blade holding/clamp fixture for machining Coast Guard Tool 1 ea 550

Y *Piston ring compressor tool Coast Guard Tool 1 ea 250 Y *Blade dowel pin positioning fixture Coast Guard Tool 1 ea 750

12 (Rev-1)

Y *Link arm fixture for machining Coast Guard Tool 1 ea 500 Y *Adjustable Reamer Coast Guard Tool 2 ea 600 *Government-loaned property, which shall be returned to the vessel upon completion of the availability.

**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 either the vessel or the C4IT Service Center.

2. REFERENCES

COAST GUARD DRAWINGS

400-WAGB_4400_5, Rev -, CPP LH Propeller Blade:

400-WAGB_4400_6, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_7, Rev -, CPP LH Propeller Blade Design

400-WAGB_4400_26, Rev -, CPP Master Cross Reference Drawing List

400-WAGB_4400_27, Rev -, CPP Right Hand Hub Assembly (Elev Section-Side Profile)

400-WAGB_4400_28, Rev -, CPP Right Hand Propeller Blade

400-WAGB_4400_29, Rev -, CPP Right Hand Adjusting Crank Arm

400-WAGB_4400_30, Rev -, CPP Right Hand Adjusting Crank Arm Dowell Location And Drive Pin Matrix

400-WAGB_4400_31, Rev -, CPP RH Operating Rod

400-WAGB_4400_32, Rev -, CPP RH Link Arm Assy

400-WAGB_4400_33, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_34, Rev -, CPP 69 Inch Dia LH Prop Hub Assy (Elev Sect)

400-WAGB_4400_35, Rev -, CPP LH Propeller Blade

400-WAGB_4400_36, Rev -, CPP LH Adjusting Crank Arm (Unsigned)

400-WAGB_4400_37, Rev -, CPP Left Hand Adjusting Crank Arm Dowel Location

400-WAGB_4400_38, Rev -, CPP Left Hand Operating Rod

400-WAGB_4400_39, Rev -, CPP Left Hand Link Arm Assembly

400-WAGB_4400_40, Rev -, CPP Left Hand Propeller Blade Design

400-WAGB_4400_41, Rev -, CPP Hub Cylinder (Common To LH & RH)

400-WAGB_4400_42, Rev -, CPP Propeller Hub (Common To LH & RH)

400-WAGB_4400_43, Rev -, CPP Piston (Common To LH & RH)

400-WAGB_4400_44, Rev -, CPP Guide Rod & Guide Flange (Common To LH & RH)

400-WAGB_4400_45, Rev -, CPP Locknut (Trunnion) (Common To LH & RH)

400-WAGB_4400_46, Rev -, CPP Propeller Tailshaft Assembly (Common To LH & RH)

400-WAGB_4400_47, Rev -, CPP List of Material

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 4986, Controllable Pitch Propeller System, Modified, Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

13 (Rev-1)

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

OTHER REFERENCES

American Bureau of Shipping (ABS), Part 7 Appendix Section 10 - Guide for Bronze and Stainless Steel Propeller Castings, 2011

Hytorc Hydraulic Operating Instructions

Hydraulic CPP hub Test Unit

MIL-DTL-2845E (SH); Propulsion Systems, Boat And Ship; Main Shafting, CPP hubs, Bearings, Gauges, Special Tools, And Associated Repair Parts; Preservation, Packaging, Packing and Storage Of, Dated 18 August 1999

MIL-DTL-16232G, Jan 2000, Phosphate Coating, Heavy, Manganese or Zinc Base

NAVSEA Technical Specification S9074-AR-GIB-010/278, Requirements for Fabrication Welding and Inspection, and Casting Inspection and Repair for Machinery, Piping, and Pressure Vessels

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative.

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

3.1.3.1 Cleanliness is of the utmost importance in hydraulic systems. The Contractor shall ensure that cleanliness standards are maintained in accordance with ISO Cleanliness Code of 17/14 per ISO 4406 during all phases of work.

3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.2 Receipt.

3.2.1 The CPP hub assembly will be removed from the vessel by a commercial shipyard and placed in the shipping stand. The shipyard will then load the CPP hub and shipping stand assembly onto a truck for transport to the Contractor’s overhaul facility.

14 (Rev-1)

3.2.2 The Contractor shall arrange, furnish, and bear all costs for transportation of the CPP hub assembly from the shipyard to the overhaul facility. A shipyard point of contact will be supplied to aide and coordinate transportation details. The COR will provide the Contractor with at least 5 days advance notice prior to the desired shipping date for coordination efforts with the shipyard.

3.2.3 Upon receipt of the hub the Contractor shall make note of the condition of the lifting plates, hub stand, and all associated hardware. Submit a CFR confirming arrival of the hub at the Contractor facility and documenting the results of the initial inspection.

NOTE

The approximate weight of each CPP hub assembly and shipping stand is 47 tons. Approximate dimensions of hub and shipping stand are 15 ft. wide, 15

ft. long and 9 ft. high.

3.4 Pre-Disassembly Hydraulic Testing.

3.4.1 Prior to disassembling the CPP hub, it shall be mounted on a suitable stand and hydraulically tested in the presence of the Coast Guard Inspector.

3.4.2 The test shall be performed using the GFP hydraulic test unit. A copy of the operating instructions for the test unit (reference “Hydraulic CPP Hub Test Unit”) will be supplied to Contractor after contract award and prior to its first expected use. It is the Contractor's responsibility to safely operate this equipment within the manufacturer's operating instructions. The Contractor shall continuously monitor operation of the test unit for damage, unusual performance, or unsafe operation and notify the COR immediately of any discrepancies via CFR.

3.4.3 The Contractor shall supply hydraulic oil of ISO viscosity grade 32, meeting ASTM 4304 Rev A Type III, in sufficient quantity to fill the CPP hub and operate the test unit (approximately 150 gals). This oil shall be filtered through a 10 micron filter prior to entering the hydraulic test unit or the CPP hub.

3.4.4 The Contractor shall complete the pre-disassembly test data sheets during testing. Hydraulic testing includes the following procedures:

3.4.4.1 Hydraulically pitch the CPP hub, full stroke, in both directions, to determine the minimum pressure required to operate the CPP hub. Sufficient tests shall be conducted to ensure repeatability of the data. There shall be a minimum of two full tests conducted.

3.4.4.2 Once the minimum operating pressure is determined, increase the pump pressure to 250 psig and conduct a timed operation test. Sufficient tests shall be conducted to ensure repeatability of the data.

There shall be a minimum of two full tests conducted.

3.4.4.3 The Contractor shall determine the amount of leakage between astern and return oil passages as a function of pressure from 0 to 600 psi in 100 psi increments.

3.4.4.4 Upon completion of test, pitch blade to hardstop ahead. Drain oil from hub back to the hydraulic test unit and remove hydraulic test equipment.

3.4.4.5 After removal of hydraulic test equipment, determine the X3 dimensions for design ahead, hard stop ahead, and hard stop astern using the GFP Measuring Bar. X3 is the distance from the face of the

15 (Rev-1) hub to the end of the operating rod, measured in at least four locations equally spaced around the hub perimeter and calculating the average reading. Blade #1 pitch markings shall be used for design ahead pitch reference.

NOTE

X3 dimensions are taken again at the conclusion of work and after final testing in paragraph 3.10. With hydraulics removed, blades are pitched to desired pitch angles by use of blade edge clamps and straps/chains connected to overhead crane.

3.5 Disassembly.

3.5.1 Completely disassemble the CPP hub including the removal of the operating rod and the CPP hub blades.

3.5.1.1 Clean each blade of marine growth prior to disassembly.

3.5.1.2 During removal of each hub blade, weigh each blade and record the measurement. Submit the weight of each blade via CFR.

3.5.2 Disassembly includes the removal of the following major components. This is not meant to be an all inclusive list of all smaller piece parts:

TABLE 1-1: DISASSEMBLY COMPONENTS

ITEM

PART NUMBER DESCRIPTION

1 P.N. 396-15 Hub Cylinder Cover 2 P.N. 019-1 Hub Cylinder 3 P.N. 017-25 Lock Plate 4 P.N. 017-9 Operating Rod Nut 5 P.N. 019-5 Piston 6 P.N. 017-37 Operating Rod Link Pins 7 P.N. 018-350 Operating Rod 8 P.N. 017-12 Guide Flange 9 P.N. 017-8 Guide Rods 10 P.N. 017-36 Adjusting Crank Link Pin 11 P.N. 017-49 Link Assembly 12 P.N. 017-17 Locknut 13 P.N. 017-35 Drive Pin 14 P.N. 017-301 Adjusting Crank 15 P.N. 014-2 CPP hub Blade 16 P.N. 019-6 Piston rings

NOTE

Coast Guard Drawing 400 WAGB 4400-27 for a right-hand CPP hub. These numbers may differ for left hand CPP hubs. Consult CG TP-4986 section 7 for additional information.

3.5.3 Use the GFP HYTORC hydraulic wrench and hydraulic power unit to remove/install the 24 each 2- 8UNC cylinder socket head cap screws (P/N 019/7). Only the GFP HYTORC hydraulic wrench shall be

16 (Rev-1) used for removing and installing these socket head cap screws. A copy of the operating instructions for the HYTORC hydraulic wrench and hydraulic power unit (reference “Hytorc Hydraulic Operating Instructions”) shall be supplied to the Contractor after contract award and prior to its first expected use. It remains the Contractor's sole responsibility to safely operate this tool within the manufacturer's operating instructions and guidelines (including printed safety instructions). The Contractor shall continuously monitor operation of the tool for damage, unusual performance, or unsafe operation and notify the COR immediately of any discrepancies via CFR.

3.6 Inspection And Measurement.

3.6.1 When disassembly is complete, inspect all accessible components of the CPP hub assembly, measure and record all dimensions, clearances, and runouts on the enclosed forms (see “Measurement, Data, and Procedure Sheets” at the end of this work item). Submit a CFR for any wear or damage found in the initial disassembly inspection, including recommendations for restoration/repair.

3.6.2 The initial inspections and measurements outlined above shall be completed within 60 days of CPP hub receipt.

3.6.3 If a CPP hub has been provided for an “Accelerated Overhaul,” disassembly, inspections and measurements shall be completed within 14 days of CPP hub receipt.

3.6.4 Hub Dimensional Checks.

3.6.4.1 Concentricity of the small, large and seal bores of each hub blade port shall be verified. This verification shall be accomplished concurrent with collection of hub runout readings required by sheet 2 of Figure 01-A, “Measurement, Data, and Procedure Sheets”. The following mandatory procedure shall be used to setup, measure, and record hub runout readings required by sheet 2 of Figure 01-A, “Measurement, Data, and Procedure Sheets.” Other methods for verifying concentricity and collecting hub runout readings are not permitted. Once the hub is set up for measurements, it shall not be moved from, or repositioned on, the machine table until all measurements for all four blade ports are complete.

3.6.4.2 The Contractor shall use a horizontal, universal milling machine with universal milling head (min. 3-axis). Milling machine shall have a rotatable table capable of supporting the full hub weight.

3.6.4.3 Place the hub on the rotatable table with its face centered to this table. Use the spigot of the CPP hub shaft connection for centering to establish spindle on common vertical plane with the hub's axis of rotation.

3.6.4.4 Align the large thrust face perpendicular to the spindle axis.

3.6.4.5 Repeat this procedure with all other ports using the first one as zero and record differences.

3.6.4.6 Select the optimum one for zero. The spindle axis should not be adjusted from then on, the spindle axis is fixed.

3.6.4.7 With the table rotated so that the blade ports are centered and using each blade port's large bore as a reference, adjust the spindle centerline (vertical positioning of spindle). If the wear pattern (bushing not removed) indicates a larger weardown in a part of circumference this area shall not be considered for this zeroing.

17 (Rev-1)

3.6.4.8 Perform runout readings for each blade port as necessary to complete sheet 2 of Figure 01-A, “Measurement, Data, and Procedure Sheets”.

3.6.5 Blade Dimensional Checks.

3.6.5.1 The following mandatory procedure shall be used to setup, measure, and record blade runout readings required by sheet 20 and 21 of Figure 01-A, “Measurement, Data, and Procedure Sheets”:

3.6.5.2 The Contractor shall use a horizontal, universal milling machine with universal milling head (min. 3-axis). Milling machine shall have table capable of supporting weight of blade or hub.

3.6.5.3 Roughly align blade on table with the aid of water balance (level) on the larger seat (surface B1, B2 on sheet 20 and 21).

3.6.5.4 Align the axial face of the outer trunnion (E1) perpendicular to the spindle axis. Align by fine adjustment of the table (preferable), or if necessary by moving the blade with hydraulic jacks or similar.

3.6.5.5 Align the spindle centerline preferably with two gauges mounted to the same holder, one gauge on each radial seat, outer trunnion (B1, B2) and inner trunnion (A1, A2). This alignment should be made by fine adjustment of table (preferable), or if moving the table is impossible then by moving the entire blade.

NOTE

The intent of the above steps is to ensure the trunnion surface E1 and B1 are used for zeroing.

3.6.5.6 Perform runout readings necessary to complete sheet 20 and 21 of Figure 01-A, “Measurement, Data, and Procedure Sheets”.

3.6.5.7 Measure blade trunnion diameter and length using sheet 5, 6, 7 and 8 of Figure 01-A, “Measurement, Data, and Procedure Sheets”.

3.6.6 O-ring Seating Surfaces Inspections.

3.6.6.1 Visually inspect all o-ring seating surfaces throughout the hub for any gouges, pitting, scratches, nicks, or other damage that would affect optimal sealing. Report all discovered deficiencies via CFR.

3.6.7 Miscellaneous Measurements.

3.6.7.1 Measure and take readings of the following dimensions:

Link Pin Diameters (sheet 9).

Spherical Ball Bearing (sheet 10 and 11).

Adjusting Cranks (sheet 12 and 13).

Guide Rod (sheet 14).

Op Rod (sheet 15).

Piston (sheet 16).

Op Rod Bushing (sheet 17).

Hub, Cylinder Spigot (sheet 18).

Cylinder, include O-ring depth (sheet 19).

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Link Arms (sheet 23 and 24).

Drive Pins (sheet 25).

Thread Diameter Measurements (sheet 26 Rev 5/2004).

Dowel Pins and Bores Op Rods (sheet 27).

3.6.7.2 Blade Weights

3.6.7.2.1 Measure and record the weights of each blade after conducting all required repairs and prior to reassembly. Submit via CFR.

3.6.8 Dye Penetrant Examinations.

3.6.8.1 The Contractor shall perform a 100% dye penetrant inspection in accordance with reference NAVSEA Technical Specification S9074-AR-GIB-010/278, of the surfaces detailed inbelow. Analysis of discrepant areas shall be evaluated against acceptance and rejection criteria detailed in Table 1.1 of reference American Bureau of Shipping (ABS), Part 7 Appendix Section 10 - Guide for Bronze and Stainless Steel Propeller Castings. Critical and non-critical areas of the CPP hub shall be determined in accordance with Figure 1.1 of same ABS reference. Written results of the evaluation shall be submitted via CFR.

Blade Outer trunnions, including the drive pin holes.

Blade suction and pressure faces, fillets, and blade edges. For purposes of determining acceptance criteria critical areas of CPP hub blade are identified in Figure 01-B; “Critical Areas of Blade”.

Operating rod nut.

Blade outer trunnion relief groove; outer trunnion to crank seat transition taper, inner trunnion to locknut ring relief groove.

The eight removed spherical bearings. Perform NDT prior to recoating.

The adjusting cranks' ring to ear transitions.

3.6.9 Fluorescent Penetrant Examinations.

3.6.9.1 The Contractor shall perform a fluorescent penetrant examination on the all 2-8UNC cylinder socket head cap screws, P/N 019/7 (QTY 24), all CPP hub blade threads, and all CPP hub blade locknut threads.

All 2-8UNC cylinder socket head cap screws, P/N 019/7 (QTY 24).

Blade, trunnuion threads.

Blade locknut, threads.

Blade,outer trunnions, including the drive pin holes.

3.7 Repair/Modifications.

3.7.1 The Contractor shall perform the following work.

3.7.1.1 Renew the following parts utilizing the same materials as shown in CG TP-4986 section 7 titled "Parts List":

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TABLE 1-2: REPAIR PARTS LIST

ITEM

PART NUMBER QTY DESCRIPTION

1 P.N. 017-10 4 ea o-ring for guide rods (some hubs require 8 ea) 2 P.N. 017-14 1 ea 0.250" Dia. Bar X 60" Lg 3 P.N. 017-27 1 ea 0.047" Dia. Lock-wire 4 P.N. 017-41 8 ea 0.047" Dia. Lock-wire 5 P.N. 018-4 1 ea o-ring for Inner Oil Pipe 6 P.N. 019-3 1 ea o-ring for Hub to Cylinder Seal 7 P.N. 014-3 4 ea o-rings for CPP hub Blade Seals 8 P.N. 017-50 4 ea Link Pin Lock Plates (adjusting crank) 9 P.N. 017-113 8 ea Flat Head Cap Screw (for adjusting crank's link pin lock plate)

3.7.1.2 When material information is not clear on drawings, material shall be equivalent to existing. This is true for P.N. 017-50 and P.N. 017-113 above.

3.7.1.3 Lance with solvent, and wipe down all hub cavities and components to remove all traces of dirt, dust and other contaminants. Protect surfaces with a light coat of hydraulic oil of ISO viscosity grade 32, meeting ASTM 4304 Rev A Type III .

3.7.1.4 Renew the lubrication on the eight spherical bearings by applying one coat of zinc phosphate conforming to MIL-P-16232, type 2, class 3, followed by one coat of dry-film anti-friction coating.

Subject coating shall be an organic binder, heat set product infused with Molydenum Di-sulfide particles.

Suitable coatings include, but are not limited to, Molykote 106, Berucoat AF 130 or 291, Technolubeseal Spray Dry Moly.

3.7.1.5 Measure and report the average thickness of the bearing zinc phosphate and lubrication film with a dryfilm thickness gauge. Dryfilm thickness gauge shall be capable of measuring film thickness within 0.0005". Total average film thickness shall not exceed 0.001".

3.7.1.6 Hand dress the CPP hub blade ports and trunnions with a fine emery cloth to restore the surface finishes in accordance with CG Dwgs.

3.7.1.7 Polish the o-ring contact surfaces to a 32 micro inch RMS finish with a fine emery cloth. Install four new GFP CPP hub blade seals. (use same lubricant as used on the spherical bearings.)

3.7.1.8 Renew the four (4) drain plug o-rings.

3.7.1.9 Reface/grind the ball retainer seat in accordance with CG Dwgs.

3.7.1.10 After the retainer seat has been refaced, conduct pressure test of the four (04) check valves at 600 psi using system hydraulic oil as the test medium. Acceptance criteria: no leakage in 10 minutes holding time. Document results via CFR.

3.8 Fit Test

3.8.1 A hub fit test shall be conducted to determine if any additional work is required to re-assemble the hub. The test shall be performed prior to final assembly.

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3.8.2 The blades shall, without link arms and without adjusting cranks, be inserted into their respective trunnion bushing in the hub one at a time while still attached to the blade lifting device.

3.8.3 Each blades shall be carefully manipulated to both their "design ahead" and “design astern” position

3.8.4 Upon the completion of a fit test for each blade submit a CFR with results of test to the COR.

3.9 Reassembly.

3.9.1 The Contractor shall demonstrate in the presence of the Coast Guard Inspector the proper fit of adjusting crank, drive pins, blade, and locknut for each individual blade set, per drawings, on the shop floor prior to final assembly in the CPP hub. (Install Check Valves last).

3.9.2 At the conclusion of any hand or machine work required to restore the flatness of the Inner Trunnion Surface, G, on the blades and their respective crank rings, perform the following: In the presence of the Coast Guard Inspector, conduct a blue-fit check of these mating surfaces between the crank ring and Trunnion in way of the drive pins. The locknut shall be torqued similar to hub assembly procedure. Minimum allowed contact is 75%. Submit a CFR with results of blue-fit test.

3.9.3 Lock-wiring and securing wire by tack welds shall be in accordance with drawing 400-WAGB 4400-25 and the notes within. Acceptable lock-wire practices are illustrated in Figure 01-C; “Lock-wire Practice”.

3.9.4 The COR shall be notified 72 hours prior to Contractor commencing final reassembly of components into the CPP hub. After all inspections and repairs have been completed, and hub internals have been cleaned, re-assemble the CPP hub. All tolerances, fits, and torque requirements shall be in accordance with applicable references. Assembly check sheets in accordance with Figure 01-A, “Measurement, Data, and Procedure Sheets” shall be completed during the reassembly and testing of the CPP hub. The Contractor and the COR blocks on the check sheet shall be initialed at the completion of every step before work proceeds further.

3.9.5 Some crank rings have been modified to accept TWO locknut locking plates. Where configured, both shall be installed.

3.9.6 Installation of the piston nut retainer, item 015/25, shall be accomplished utilizing the following procedure. After the nut, item 017/9, has been torqued, measure the depth of the end of the operating rod relative to the plane of the top of the nut. Remove sufficient material from the bottom of the retainer such that it rests flat upon the nut with a 0.004 inch gap between the retainer and the operating rod. Install hardware and lock-wire.

3.9.7 The Contractor shall use C5-A Copper anti seize on all threaded components.

3.9.8 The Contractor shall use the four GFP cylinder assembly guide pins when lowering the cylinder onto the CPP hub. Guide pins temporarily thread into four of the 2-8UNC cylinder socket head cap screws (P/N 019/7) holes and are removed once the cylinder is safely landed. Prior to installing the cylinder, validate freedom of movement of all internal components by physically moving the Op Rod.

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3.9.9 In the presence of the Coast Guard Inspector, torque all socket head cap screws to the final torque value in a minimum three equal step process, 1000, 2000, 3000 ft/lb, following a star pattern using the GFP HYTORC wrench.

3.10 CPP Hub Testing.

3.10.1 The Contractor shall notify COR 72 hours prior to commencing filling or testing. All testing shall be done in the presence of a Coast Guard Inspector or the COR.

3.10.2 All hydraulic testing shall be performed using the GFP hydraulic test unit. Operating instructions for the test unit shall be supplied to Contractor prior to its first expected use. It remains the Contractor's sole responsibility to safely operate this equipment within the manufacturer's operating instructions. The Contractor shall continuously monitor operation of tool for damage, unusual performance, or unsafe operation and notify the COR immediately in addition to submitting a CFR noting all discrepancies.

3.10.3 The Contractor shall supply hydraulic oil of ISO viscosity grade 32, meeting ASTM 4304 Rev A Type III, in sufficient quantity to fill the CPP hub and operate the test unit (approximately 150 gals). This oil shall be filtered through a 10 micron filter prior to entering the hydraulic test unit or the CPP hub.

3.10.4 The Contractor shall complete the post-assembly test data sheets during this completion testing (sheet 22). To accomplish that the following will happen:

3.10.5 Hydraulically pitch the CPP hub, full stroke, in both directions, to determine the minimum pressure required to operate the CPP hub. Sufficient test runs shall be conducted to ensure repeatability of the data. There shall be a minimum of two full test runs.

3.10.6 Once the minimum operating pressure is determined, increase the pump pressure to 250 psig and conduct a timed operation test. Sufficient test runs shall be conducted to ensure repeatability of the data.

There shall be a minimum of two full test runs.

3.10.7 The Contractor shall determine the amount of leakage between astern and return oil passages as a function of pressure from 0 to 600 psi in 100 psi increments (sheet 22).

3.10.8 The hub shall be hydrostatically tested for external leaks at 600 psi astern pressure using system hydraulic oil.

3.10.9 During the test, the Contractor shall determine, by measuring, the stroke of the operating rod (piston) from full astern to maximum ahead, from 0 degrees pitch to design ahead, and 3from 0 degrees pitch to maximum ahead. Use Blade #1 pitch markings for pitch reference (sheet 31 of Figure 01-A, “Measurement, Data, and Procedure Sheets”).

3.10.10 Upon completion of test drain oil from hub.

3.10.11 The drained oil from hubs and leftover oil from the test stand shall be reclaimed, reused and recycled by the purification process. All test equipment, including the Hydraulic Test Unit, hoses, HPU shall be cleaned, returned to working condition, and ready for reuse.

3.10.12 Upon satisfactory completion of testing, the Contractor shall re-torque all head cap screws, using the HYTORC wrench, to the final torque value. The Contractor shall tack weld external fasteners (end

22 (Rev-1) cap and hub cylinder bolts) with stainless steel lock-wire as per referenced CG Dwgs3.10.13 Polish the external surfaces of the hub and blades to a 125 micro inch RMS average finish.

3.11 Measurement.

3.11.1 After all required tests of paragraph 3.9 have been completed, the Contractor shall take the following measurements in the presence of the Coast Guard Inspector. The measurement is to obtain the value of X1 (sheet 31) as shown in Figure 01-A, “Measurement, Data, and Procedure Sheets”.

3.11.2 Pitch CPP hub to the design ahead position.

3.11.3 Measure and record X3 from the face of the hub to the end of the operating rod in at least 4 locations equally spaced around the hub, and calculate the average.

3.11.4 Measure and record X2 from the end of the operating rod to the end of the inner oil tube.

3.11.5 Calculate X1: X1 = X3 - X2

3.11.6 On a card, as well as on data sheet, record the following information (sheet 31 of Figure 01-A, “Measurement, Data, and Procedure Sheets”):

Hub # _________ LH or RH (circle one)

Date

X3(at design ahead)=

X2 =

X1 =

X3 dim at hard stop astern=

X3 dim at hard stop ahead =

Signature of Contractor's test operator

Signature of COR/QA Representative

3.11.7 The filled-out information card shall be encased in plastic and securely fastened to the hub so that it does not fall off due to weather and/or normal CPP hub handling procedure. A duplicate copy with the measurements shall be submitted via CFR.

3.11 Storage and Preparation.

3.12.1 After final tests and acceptance by the Coast Guard, the Contractor shall protect the CPP hub against physical damage and contamination, and shall load it back onto the shipping stand. Drain the CPP hub completely prior to load onto the shipping stand. The CPP hub shall be shipped empty of hydraulic fluid, and with its coupling and spacers.

3.12.2 The Contractor shall arrange for preparation and packaging for shipment of the CPP hub on its shipping stand. The Contractor shall prepare and package the CPP hub in accordance with MIL-DTL- 2845E, Level A., and store the CPP hub at his facility until the shipping destination and delivery schedule is designated by the Contracting Officer.

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3.12.3 Upon notice from the Coast Guard, the CPP hub Overhaul Contractor shall transport/ship the overhauled hub assembly from their overhaul facility to the designated shipyard. A shipyard point of contact will be supplied to aide and coordinate transportation details. The Coast Guard will provide at least 5 days advanced warning of desired shipping date, to allow for coordination between CPP hub Overhaul Contractor and shipyard. The Contractor shall be responsible for obeying all pertinent rules, regulations, and/or laws in safely and legally transporting CPP hubs along roadways to the shipyard.

4. NOTES

All required inspection, measurement, assembly, and check sheets will be provided by the COR in a separate document.

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24501_JPH_0511_400

WORK ITEM 2: Controllable Pitch Propeller (CPP) Trunnion Renewal

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to perform the following on one CPP hub: machine the blade trunnions both small and large. Since the machine work entailed by this work item will affect the blade trunnion sizes, it is mandatory that new trunnion bushings be also installed. This will be accomplished by the simultaneous (4 times) exercising of Item; "Controllable Pitch CPP hub (CPP) Trunnion Bushing Renewal" whenever this work item is exercised.

1.2 Government-furnished property.

None.

2. REFERENCES

COAST GUARD DRAWINGS

400-WAGB_4400_5, Rev -, CPP LH Propeller Blade:

400-WAGB_4400_6, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_7, Rev -, CPP LH Propeller Blade Design

400-WAGB_4400_26, Rev -, CPP Master Cross Reference Drawing List

400-WAGB_4400_27, Rev -, CPP Right Hand Hub Assembly (Elev Section-Side Profile)

400-WAGB_4400_28, Rev -, CPP Right Hand Propeller Blade

400-WAGB_4400_29, Rev -, CPP Right Hand Adjusting Crank Arm

400-WAGB_4400_30, Rev -, CPP Right Hand Adjusting Crank Arm Dowell Location And Drive Pin Matrix

400-WAGB_4400_31, Rev -, CPP RH Operating Rod

400-WAGB_4400_32, Rev -, CPP RH Link Arm Assy

400-WAGB_4400_33, Rev -, CPP RH Propeller Blade Design

400-WAGB_4400_34, Rev -, CPP 69 Inch Dia LH Prop Hub Assy (Elev Sect)

400-WAGB_4400_35, Rev -, CPP LH Propeller Blade

400-WAGB_4400_36, Rev -, CPP LH Adjusting Crank Arm (Unsigned)

400-WAGB_4400_37, Rev -, CPP Left Hand Adjusting Crank Arm Dowel Location

400-WAGB_4400_38, Rev -, CPP Left Hand Operating Rod

400-WAGB_4400_39, Rev -, CPP Left Hand Link Arm Assembly

400-WAGB_4400_40, Rev -, CPP Left Hand Propeller Blade Design

400-WAGB_4400_41, Rev -, CPP Hub Cylinder (Common To LH & RH)

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400-WAGB_4400_42, Rev -, CPP Propeller Hub (Common To LH & RH)

400-WAGB_4400_43, Rev -, CPP Piston (Common To LH & RH)

400-WAGB_4400_44, Rev -, CPP Guide Rod & Guide Flange (Common To LH & RH)

400-WAGB_4400_45, Rev -, CPP Locknut (Trunnion) (Common To LH & RH)

400-WAGB_4400_46, Rev -, CPP Propeller Tailshaft Assembly (Common To LH & RH)

400-WAGB_4400_47, Rev -, CPP List of Material

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 4986, Controllable Pitch Propeller System, Modified, Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

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

OTHER REFERENCES

Sulzer Escher Wyss 8306041; Locknut

Allis Chalmers 9001-E-1 REV B, LH CPP Hub Blade

Allis Chalmers 9004-F-1 Rev 12, Adjusting Crank (RH)

Allis Chalmers 4842-ARA-5 Rev 02, Locknut

3. REQUIREMENTS

3.1 General.

3.1.1 CIR.

None.

3.1.2 Technical Representative.

Not applicable.

3.1.3 Protective measures. The Contractor shall furnish and install suitable covering to seal off and protect all non-affected surfaces/equipment and spaces in the vicinity of the work area against contamination during the performance of work. Upon completion of work, remove protective material and inspect for the presence of contamination. Clean all equipment and spaces, contaminated due to improper protection, to original condition of cleanliness.

3.1.3.1 Cleanliness is of the utmost importance in hydraulic systems. The Contractor shall ensure that cleanliness standards are maintained in accordance with ISO Cleanliness Code of 17/14 per ISO 4406 during all phases of work.

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3.1.4 Interferences. The Contractor shall handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences).

3.2 Blade Related Machining.

3.2.1 Blade Setup on Milling Machine.

NOTE

The most important step that will determine the success and accuracy of this work is the care and detail of the initial setup of each blade on the milling machine.

3.2.1.1 The Contractor shall follow the machining setup process established below or develop their own alternate procedure (that results in equivalent accuracies) to be submitted to the COR for Coast Guard approval prior to use of such alternate procedures. Submit alternate procedures 10 working days in advance of anticipated work.

NOTE

The surface designation used in the following paragraphs i.e. ("E1") refer to sheet 21 of Figure 01-A, Measurement, Data, and Procedure Sheets (Work item, “CPP Hub Assembly Overhaul”).

3.2.1.2 Align the axial face of the outer trunnion ("E1").

3.2.1.3 Align the machining centerline by establishing the center of the blade seal surface ("C1").

3.2.1.4 The Contractor shall keep the surfaces "C1" and "E1" as they are, then shall machine the remaining surfaces "A1/A2", "B1/B2", "O1", crank seating surface, and blade threads.

3.2.1.5 Once the blade is aligned to surface "E1" and "C1", the Contractor shall take runout readings on the radial seats of both trunnions and thrust surface ("O1").

3.2.1.6 Once the blade is properly setup in the machine tool and the optimal centerline determined, the Contractor shall (by using the runout information and measurement data already collected) calculate and report: the required new inner and outer trunnion diameters; the required machining on the thrust surface O1; and any forecasted problems that would prevent attaining the specified other blade related machining results of paragraphs 3.2.2 and 3.2.3 below. Submit results via CFR.

3.2.2 Inner and Outer Trunnion Surface Machining.

3.2.2.1 With the blade still setup on the machine tool and in conjunction with the blade thread and crank seat work, the blade's inner and outer trunnions shall be cleaned up by removing the minimal metal necessary to make them both circular, concentric, cylindrical, and parallel.

3.2.2.2 Except for the new trunnion diameters that will result by this work, all other tolerances, perpendicularity, concentricity, surface finishes and other information depicted on CG Dwgs shall be obtained.

3.2.2.3 Prior to actual machining of the trunnions, the Contractor shall calculate new target trunnion diameters for each blade and submit to the COR for approval via CFR.

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3.2.2.4 The reliefs found at the inboard transitions of each trunnion (inner and outer) shall be inspected as disturbed by undercutting the trunnions and be touched up by careful grinding or machining to restore their original geometry. All rough edges shall be removed.

3.2…