Attach 3 Specification CGC Polar Star and Healy Ice Breaker Shaft Recertification.pdf

REVISION No. - . CHANGE NO. - .

PROPULSION SHAFT RECERTIFICATION

399’ WAGB and 420’ WAGB, U. S. COAST GUARD VESSELS

ORIGINATED BY: A.K. Randolph . DATE: May 01, 2024

ORIGINATOR’S COMMAND: Surface Forces Logistics Center (SFLC) .

DEPARTMENT / DIVISION: Long Range Enforcer Supply One (LRE-SUP-1) .

INTERNAL REVIEWER: CWO John Kane . DATE: Aug 01, 2023 .

QA Review: D. Wells . DATE:

Oct 19, 2023 .

PROPULSION SHAFT RECERTIFICATION 399’ WAGB and 420’

WAGB U.S. COAST GUARD VESSELS

1.0.SCOPE

1.1. This specification provides the requirements for the receipt, inspection & condition/test reports, recertification, testing, preservation, packaging, packing, and marking of Certified Refurbished (RFI), propulsion shafts used on WAGB class U. S. Coast Guard Vessels.

1.2. Classification

1.2.1. Types of propulsion shafts

DATA

SHEET

VESSEL

CLASS U/I TITLE NSN Para 2.3.2

Dwgs

001 399 WAGB EA SHAFT, PROPULSION,

SHIP-WING 2010-01-030-4824 (c)

002 399 WAGB EA SHAFT, SHIP-CENTER LINE 2010-01-030-4825 (b)

003 420 WAGB EA SHAFT, PORT or STBS, WAGB 420 2010-01-453-5603 (f)

1.3. Government Furnished Property (GFP)

1.3.1. The RFI propulsion shafts listed in 1.2.1 constitute all the GFP applicable to this specification. Individual shaft(s) will be released to the Contractor as dictated by USCG requirements with the issuance of a delivery order.

a. Due to the large quantity of work required to repair / overhaul individual propulsion shafts, only one propulsion shaft, identified by individual part number and / or corresponding national stock number, will be repaired per delivery order.

1.4. Government Furnished Material (GFM)

1.4.1. The Government does not anticipate the need for additional GFM outside of the physical shafts.

2.0.APPLICABLE DOCUMENTS

2.1. General – The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2. Government Documents – SPECIFICATIONS, STANDARDS, PUBLICATIONS AND HANDBOOKS - The following specifications and standards form a part of this SOW to the extent specified herein. Unless otherwise specified, the versions in effect are those listed in the GSA Index of

Federal Specifications, Standards and Commercial Item Descriptions or the current Department of Defense Single Stock Point of Specifications and Standards, (DODSSP) and supplements thereto, cited in the solicitation or contract.

2.2.1. Military Specifications

a. MIL-DTL-2845E(SH), 18 Aug 1999; Propulsion Systems, Boat, and

Ship; Main Shafting, Propellers, Bearings, Gauges, Special Tools, and Associated Repair Parts; Preservation, Packaging, Packing and Storage of.

b. MIL-R-23461A(SH), 26 Jun 1987; Resin Compound, Room Temperature Curing, for Metal Coating

c. MIL-S-23284A, 15 Jun 1990; Steel Forgings, Carbon, and Alloy, for Shafts, Sleeves, Propeller Nuts, Couplings, and Stocks (Rudder and Diving Planes).

d. DOD 4140.01-M-1, Dated 7 Sep 2007; Compliance for Defense Packaging: Phytosanitary Requirements for Wood Packaging Material

(WPM).

e. MIL-PRF-16173E INT AMD 1, Dtd. 07 Sep 2006, Corrosion Preventive Compound, Solvent Cutback, Cold-Application.

2.2.2. Military Standards

a. MIL-STD-2191(SH), 05 Nov 1992; Repair Welding, Weld Cladding, Straightening, and Cold Rolling of Main Propulsion Shafting.

b. MIL-STD-2199B, 28 Jan 2020; Coverings for Waterborne Main

Propulsion Shafting on U.S. Naval Surface Ships And Submarines.

c. MIL-STD-2035A, 15 May 1995; Nondestructive Testing Acceptance

Criteria.

d. MIL-STD-129R (Chg 3), 28 Mar 2023, Military Marking for Shipment and Storage

2.2.3. NAVSEA Technical Publications

a. S9086-HM-STM-010/CH-243 (Rev 3), Dated 01 May 2009: NSTM

Chapter 243 Propulsion Shafting.

b. S9AA0-AB-GOS-010, 2004 Edition; General Specification for

Overhaul of Surface Ships (GSO) Department of The Navy Naval Sea Systems Command, Section 243 Propulsion Shafting.

c. S9243-AW-TRS-011, Rev 1, 18 Jun 2015; Technical Repair Standard for Surface Ships Main Propulsion Shafting Refurbishment Procedures.

d. S9074-AQ-GIB-010/248, 01 Aug 1995; Requirements for Welding and Brazing Procedure and Performance Qualification.

e. T9074-AS-GIB-010/271(1), 11 Sep 2014; Requirements for Nondestructive Testing Methods.

f. S9243-A5-MMD-010, 1995 Edition; Gages, Plug and Ring, Propellers and Propulsion Shafting, Repair, Inspection, Certification and Use.

g. S9243-AW-TRS-012/0203-086-501A Change B, 01 Jun 1991, Surface Ships Main Propulsion Shafting Examination, Test and Repair Action Record (Blue Contact Evaluation Guide Fig. C-13).

2.3. Other Government Documents – The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.3.1. Coast Guard Specifications.

a. USCG-SFLC Specification D-000-0100 Rev G, 02/2006; Bar Coding for USCG Surface Forces Logistics Center procured material.

b. USCG SFLC Standard Specification 6310, 2020, Requirements for

Preservation of Ship Structures, For Underwater Body Paint Requirements.

c. TP: 4395 Propulsion Shafting and CPP System, 399’ WAGB Class Cutters, Dated 25 AUG 1971.

2.3.2. Drawings, Shafts

a. USCG-400WAGB-4301-1 Rev AA Arrgt. of Shafting

b. USCG-400WAGB-4301-4 Rev 12, Jan 21, 1972 Center Tail shaft

(9022-D-1)

c. USCG-400WAGB-4301-5 Rev 11, Jan 22, 1972 Wing Tail shaft

(9022-E-1)

d. USCG-400WAGB-4301-6 Rev – Coupling Flange Master 395

e. USCG-400WAGB-4400-46 Rev – CPP Propeller Tailshaft Assembly

(Common to LH & RH)

f. USCG-400WAGB-4400-47 Rev – Controllable Pitch Propeller List of

Material

g. USCG-420WAGB 243-003 Rev “C” Apr 28, 1997 Shafting Details

h. 803-2145807, Rev C 19 Dec 1988 NAVSEA Standard Propulsion

Shafting Drawing

2.4. Commercial Documents – The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single Stock Point of Specifications and Standards (DODSSP) and supplements thereto.

2.4.1. GSA – FSS – Federal Supply Service

a. A-A-3108B, Date Oct 2004, Tinting Medium, Enamel: Universal Colorants

2.4.2. International Organization for Standardization

a. ISO/IEC 17025:2017 General requirements for the competence of testing and calibration laboratories.

b. ASQ/ANSI/ISO 9001 :2015, Quality Management Systems –

Requirements.

2.4.3. Society of Automotive Engineers (SAE)

a. SAE J448, 01 Feb 2023, Surface Texture.

2.4.4. American Society for Testing & Materials (ASTM)

a. ASTM D5162, 01 Nov 2021 Standard Practice for Discontinuity (Holiday) Testing of Nonconductive Protective Coating on Metallic Substrates

b. ASTM-D7478/D7478M-08E1, DATED 01 Nov 2011, Standard Specification for Heavy Duty Sheathed Wood Crates.

2.4.5. American Water Works Association

a. AWWA C217, 12 Jan 2023. Microcrystalline Wax and Petrolatum Tape Coating Systems for Steel Water Pipe and Fittings.

2.4.6. National Association of Corrosion Engineers (NACE)

a. NACE RP0375, 24 Apr 2018, Field-Applied Underground Wax Coating Systems for Underground Metallic Pipes: Application, Performance, and Quality Control – Item No. 21013.

2.5. Document Availability – To obtain the referenced documents see section 6.1 of this specification.

2.6. Specification Order of Precedence – In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0.REQUIREMENTS

3.1. Government Furnished Property (GFP) – Contractor shall provide inside storage for all GFP with complete protection from the weather elements.

3.2. Government Furnished Material (GFM) – There is no anticipated requirement for GFM in this contract. However, in the event the Government provides GFM, the Contractor shall provide inside storage for all GFM with complete protection from the weather elements, stowed in the original shipping containers when not in use.

3.3. General – RFI propulsion shafts have been exposed to excessive storage time in extreme environmental conditions, requiring inspection and repackaging.

Additionally, there have been vessel configuration changes requiring the machining of forward sleeves of RFI shafts to ensure recertified shafts align with current vessel configuration.

3.3.1. Contractor shall provide all labor, equipment, and materials, except for any required GFM, required to evaluate, test, machine, recertify, preserve, package, pack and mark the RFI propulsion shafts outlined in section 1.2.1 of this specification.

3.3.2. The use of forms located in Appendix C of ref 2.2.3.c or a locally produced form is required for the various reporting requirements within this specification. Locally produced forms must be provided to the Contracting Officer for approval prior to use in all reporting requirements after paragraph 3.4.c. of this specification.

3.4. Shaft Receipt – Upon receipt of each RFI shaft, the Contractor shall conduct a Visual Preservation Inspection (VPI), IAW with chapter 2 of the NAVSEA Technical Repair Standard, Ref 2.2.3.c. of this specification.

a. This inspection is limited to sections 2-1.1 through 2-1.3 of NAVSEA Technical Repair Standard, Ref 2.2.3.c. of this specification.

b. Results of this inspection shall be documented on contractor furnished drawings indicating the locations of damage to the packaging and included in the report required in para. 3.4.c. below.

c. Provide Contracting Officer with a “propulsion shaft arrival” Condition Found Report (CFR) containing the arrival date and time of the propulsion shaft and name of person who signed for the GFP. CFR shall also contain a listing of all identification type markings or numbering and location of markings on the propulsion shaft and packaging. This report is due to the Contracting Officer within five (5), working days after receipt of each shaft.

3.5. Technical Inspection – After completing the requirements in section 3.4. of this specification, the Contractor shall perform an inspection of RFI shafting in accordance with chapter 2 of the NAVSEA Technical Repair Standard, reference 2.2.3.c. of this specification.

3.5.1. All references to the various departments of Naval Sea Systems Command (NAVSEA) shall be changed to read the “SFLC Contracting Officer” for any contract referencing within this specification.

3.5.2. Packaging Inspection – The Contractor shall conduct a thorough inspection of the shaft packaging (Shipping Crate), to ascertain any needed repairs up to and including complete replacement of the shipping container / skid. If as received condition allows for re-use with minimal repairs, the Contractor shall confirm that the shaft packaging conforms to the Phytosanitary Requirements for Wood Packaging Material (WPM) IAW DODD 4140.01-M-1, reference 2.2.1.d. of this specification.

a. The contractor must include packaging repair costs along with cost to replace all packing to include the skid and all supports as part of the required technical inspection report in section 3.6. of this specification.

3.5.3. Shaft Visual Inspection – Contractor shall complete all other requirements of a visual inspection of each shaft IAW the requirements of section 2-2.1 of NAVSEA Technical Repair Standard, Ref 2.2.3.c. of this specification.

a. Contrary to guidance provided in para. 2-2.1.1 of NAVSEA Technical Repair Standard, Ref 2.2.3.c. of this specification. Contractor shall remove the Glass Reinforced Plastic (GRP), coating system in conjunction with completing the Technical Inspection. Contractor shall remove existing GRP coating system in a manner that shall not damage shaft body or shaft bearing sleeves.

b. Due to required removal of GRP in accordance with para 3.5.3.a. of this specification, Spark testing of GRP will not be required as part of the Technical Inspection.

3.5.4. Shaft Sleeves – Propulsion shaft Bearing Sleeves, “Shall NOT be Removed”, from their respective propulsion shafts without express written and signed consent given by the Contracting Officer and Contracting Officer’s Representative who holds the Technical Authority for this repair.

a. Contractor shall be liable and shall bear all labor and material costs incurred to renew any WAGB propulsion shaft bearing sleeve(s) that is and /or was removed without Contracting Officer’s written and signed consent.

3.5.5. Concentricity Inspection – The contractor must complete the concentricity inspections in accordance with section 2-2.2 of NAVSEA Technical Repair Standard, reference 2.2.3.c. of this specification. All measuring and test equipment shall be calibrated IAW ISO/IEC 17025:2017, ref 2.4.1.a. of this specification.

a. The shaft shall be checked for concentricity IAW section 2-2.1 through 2-2.6 of NAVSEA Technical Repair Standard, Ref 2.2.3.c. of this specification.

b. 2-2.2.6 Measurements must meet the following criteria:

a. Shaft tapers shall be concentric with the axis of rotation to within 0.002” TIR (0.001” eccentricity)

b. The periphery and spigot fit areas of each coupling or CPP flange must be concentric with the axis of rotation to within 0.002” TIR (0/001” eccentricity). Flange mating faces are to be perpendicular to within 0.002” TIR.

c. Shaft sleeves and inboard bearing journals shall be concentric to the axis of rotation to within 0.002” TIR (0.001” eccentricity).

3.5.6. Shaft Measurements – Each shaft must have the following measurements taken and recorded using calibrated Measuring and Test Equipment

(M&TE).

a. Shaft diameters shall be measured and recorded at the same locations as shaft runout measurements in 3.5.5. above.

b. Shaft flanges shall be measured and verified against the various profiles and features as indicated on applicable shaft drawings. These measurements shall include but are not limited to bolt hole diameters, bolt circles, spigot measurement (if applicable), flange diameter and flange thickness.

c. Surface finish shall be measured and recorded for the bearing sleeves in the same locations as runouts are measured on each sleeve, on the shaft taper or coupling end of shaft if not tapered, and where indicated on the shaft drawings for each flange.

3.5.7. Technical Inspection Report – Based on the findings from inspections in section 3.5., Contractor shall prepare and submit a report within 30 calendar days of receipt, detailing the as found condition of each shaft. The report shall include but not be limited to the following:

a. Serial number and part number/drawing number (if known).

b. Digital photographs of any markings and their locations on each shaft.

c. Total Indicated Runout (TIR).

d. All Dimensional Data.

e. Detailed bore ID Dimensions at ends, mid & qtr. length locations, if applicable.

f. Non-destructive testing results.

g. Detailed drawings of, and digital photographs showing location and severity of all surface defects.

h. As received condition of shaft shipping container / skid with digital photographs.

i. Verification that shipping container/skid meets requirements in 2.4.4.a.

3.6. Submission of Pre-repair Inspection Report – The Government does not anticipate these propulsion shafts to require repairs, however repair requirements are included in the event unanticipated damage or other non-conforming issues are discovered. In the event there is unanticipated damage to a shaft, the Contractor must submit a Pre-repair Inspection Report along with a Repair Plan that outlines proposed repairs to the Contracting Officer for review and approval.

The methods and procedures to accomplish these repairs must be in accordance with this specification and the references listed in sections 2.2, 2.3, and 2.4. The Pre-repair Inspection Report is due within 30 calendar days of receipt of each shaft.

3.6.1. The Repair Plan must include a detailed breakdown of all labor hours with associated skill sets/costs, associated material, and material costs required to complete the overhaul / repair / refurbishment of the propulsion shaft, including repair cost of the shipping container / skid as well as the cost to renew the shipping container/skid in its entirety.

3.7. Approval to proceed with repairs – The Pre-repair Inspection Report and Repair Plan must be submitted to the Contracting Officer for approval. No further work shall be accomplished or will be authorized until the submitted report is reviewed and approved in writing by the Contracting Officer.

3.8. Chemical Composition – In the event repairs are required, and the Chemical Composition of the propulsion shaft received for refurbishment is not known, (i.e. marked on fwd end of as rcvd propulsion shaft), the Contractor shall determine the chemical composition and material class of the propulsion shaft by taking a sample from the forward face. The findings shall be included in the Pre-repair and Post Repair Inspection Reports.

3.9. Bearing Sleeves

3.9.1. Use of Installed Bearing Sleeves – Existing bearing sleeves must not be removed from the shafts without prior written authorization signed by the Contracting Officer and Contracting Officers Technical Representative.

Propulsion shafts included in this requirement are new manufacture or previously refurbished and have not been in service, therefore the Government does not anticipate discovery of operational wear or damage to any bearing sleeves.

If the following conditions can be met, then the propulsion shaft(s) bearing sleeves must remain installed upon the shaft and sleeve roughness / damage, shall be removed by taking a skim cut on a lathe or hand smoothing.

a. Sleeves are minimally worn, pitted, or otherwise minimally damaged.

b. Sleeves can be machined smooth so that the sleeve diameters will not be reduced by more than 0.065 inch from the maximum designed outside diameter as listed on the applicable drawing.

c. Sleeves are constructed of Bronze or Copper Nickel (CuNi),

d. Propulsion Shaft can otherwise be repaired without removing the sleeve(s).

NOTE: Repair by hand-smoothing must be used as a last resort and kept to a minimum to avoid flat spots. All defects that the Contractor proposes to dress up or correct by hand-smoothing must be detailed on the Pre-repair Inspection Report and Repair Plan and must be approved by the Contracting Officer before repairs are authorized.

3.10. Forward Bearing Sleeve Machining – Recent configuration changes to 399’ WAGB Class Cutter Shaft seals have reduced the inside diameter (I.D.)

dimension of the shaft seals, requiring an equal reduction in outside diameter (O.D.) of forward bearing sleeves in the location where propulsion shaft seal(s) ride on shaft sleeve.

3.10.1. Centerline Propulsion Shaft – See Data Sheet 002 for nominal dimensional data and material information of the 399’ WAGB centerline propulsion shaft. Forward end of propulsion shaft is supported by a Cooper Double Roller, roller bearing, and not via conventional water lubricated stave bearing system.

Contractor shall reduce the O.D. of the forward bearing sleeve by 0.060” to an O.D. of 36.190 (+0.005” / -0.000”), throughout the entire length of the bearing sleeve.

3.10.2. Outboard (Wing), Propulsion Shaft – See Data Sheet 001 for nominal dimensional data and material information of the 399’ WAGB wing propulsion shaft. Forward end of propulsion shaft is supported by conventional water lubricated stave bearing system.

Contractor shall reduce the O.D. of the forward 16.500” of the forward bearing sleeve by 0.060” to an O.D. of 36.190 (+ 0.005 / -0.000”), ensuring that the transition taper between the existing 36.250” O.D. of the aft section/length of the sleeve and the machined/reduced 36.190” O.D.

section/length is faired into adjacent surfaces with a maximum radius so as to allow no abruptness in change of diameters; a transition length of ½” - ¾” is desired. Length of transition taper is not to be included within the 16.500 length of 36.190” O.D. sleeve section.

3.11. Installation of New Sleeves – Newly installed sleeves must be concentric with the axis of rotation to within 0.002” TIR.

a. Sleeves must be secured to the shaft by the shrink fit specified on the drawing. Any other method of securing shaft sleeves to the shaft is prohibited. In the event a shrink fit is not specified, refer to Table 59F on sheet 8 of the NAVSEA Standard Drawing, reference 2.3.2.d of this

b. Prior to sleeve installation, the shaft journal outside diameter (OD), Surface finish dimension, Sleeve inside diameter (ID) and Sleeve inside surface finish dimension must be measured and recorded for inclusion in the final inspection report.

c. After installing and finish machining the outside diameter of shaft sleeves, the Contractor must perform a Non-Destructive Test (NDT) utilizing liquid dye penetrant inspection of all sleeves for cracks / discontinuities in accordance with NAVSEA T9074-AS-GIB-010/271, Section 5, Group I or Group III, reference 2.2.3.e of this specification.

During the NDT process, the Contractor must pay particular attention to lock-ring and O-ring groove locations. If cracks / discontinuities are detected, a report detailing the specific location(s) and dimensions (length and depth) of these defects, including recommendations for repair, must be submitted to the Contracting Officer for review and approval.

3.12. Welding – Even though it is anticipated that welding will NOT be required during the inspection, minor machining and GRP replacement process, the welding requirements are included in the event any welding is performed.

3.12.1. Qualification of Welding Procedures & Personnel – Welding procedures, welders, and welding operations must be qualified in accordance with section 5.0 of MIL-STD-2191, reference 2.2.2.a of this specification.

a. Welding Procedure Specifications, Procedure Qualification Records, and Welder Performance Qualifications for the material that each of the propulsion shafts listed in section 1.2.1. of this specification are manufactured from must be submitted to the Contracting Officer for approval.

3.12.2. The welding procedures must include, as a minimum, the following:

a. Chemical analysis of the shaft.

b. Material specification.

c. Sketch of the defect, a drawing showing location, including dimensions and digital photographs of the defect.

d. Method used to remove the defect and cavity preparation.

e. Method used to inspect the cavity to ensure complete removal of the defect in accordance with T9074-AS-GIB-010/271(1) ref. 2.2.3.e. of this specification.

f. Base metal type and heat-treated condition.

g. Filler metal, size, and type (specification & AWS designation) Flux or gas, and gas flow rate.

h. Position of weld (down hand only).

i. Arc voltage and current range.

j. Minimum preheat temperature (as a general rule for base material not identified in MIL-STD-2191, reference 2.2.2.a of this specification, minimum preheat temp. must be at least 275 degrees F).

k. Maximum interpass temperature.

l. Post heat treatment.

m. Inspection method of completed welds as per T9074-AS-GIB-

010/271(1), ref 2.2.3.e of this specification.

3.13. Welding of cracks & deep pitting – These repairs must be in accordance with MIL-STD-2191, reference 2.2.2.a. of this specification.

a. All references to the Naval Sea Systems Command (NAVSEA) must be changed to read “the Contracting Officer” for any contract referencing this specification.

b. The welded areas must be machined flush.

c. Minor pitting not exceeding 1/16-inch depth must be hand worked or ground to a faired radius.

d. Welding repair of Cracks or Pitting exceeding 1/16-inch depth but less than 1/4-inch depth must be reviewed on a case-by-case basis dependent upon shaft size and location of damage.

e. Surface finishes must be a minimum of 125 RMS unless otherwise stated.

f. Before heat treatment, review the manufacturer data sheets/user directions for the heat resistant scale preventative chosen. Some of these materials can only be removed by mechanical methods.

3.14. Post Weld Heat Treatment – All shafts which have been welded, must be stress relief heat treated in accordance with section 10.4.5 of MIL-STD-2191 reference. 2.2.2.a of this specification.

a. Heat resistant scale preventative – Any anti-scale compound used on finish machined surfaces must comply with section 10.4.5.2. of MIL- STD-2191, reference 2.2.2.a. of this specification.

b. “No Carb” heat resisting scale preventative must not be used on any threaded surfaces as per the manufacturer’s recommendation.

Recommended alternatives are:

1. Protect-O-Metal No. 2 from G.W. Smith & Sons, Inc. 937-253- 5114, www.gwsmithandsons.com

2. Keepbryte, from Kasenite Company, available from many U.S.

suppliers.

c. Any material offered as “equal” must be submitted to the Contracting Officer for approval. Documentation detailing the chemical and material analysis must accompany the submittal.

http://www.gwsmithandsons.com/

3.15. Straightening procedures – These repairs must be in accordance with section 11 of MIL-STD-2191, reference 2.2.2a of this specification.

3.15.1. Determine location, magnitude, and type of bend – Prior to initiating straightening processes, the location, magnitude, and type of bend must be determined. *The entire shaft must be supported between centers on a lathe with no auxiliary supports.

*NOTE: This procedure must be used for all TIR checks on shafts refurbished in accordance with this specification.

3.16. Cold Rolling – This procedure must be accomplished in accordance with section 12 of MIL-STD-2191, ref. 2.2.2.a of this specification and section 3-4 of NAVSEA Technical Repair Standard, Ref 2.2.3.c. of this specification.

a. Cold rolling must be accomplished in accordance with direction given on the applicable shafting drawing.

b. Any weld repair of either the sleeve fit area at the aftermost bearing of a propeller shaft or to the propeller taper area of a propeller shaft must require this / these area(s) to be cold rolled.

c. Any area of the shaft that has been cold rolled must be examined via magnetic particle testing followed by demagnetizing per para. 12.2.8 of ref. 2.2.2.a., and Appendix A para. 50.1 of ref. 2.2.1.c.

3.17. Marking of Weld Repaired Shafts – Shafts that are reconditioned by means of welding, in accordance with an approved procedure, are to be stamped “Welded- S.R.”, along with the attending “Surveyor’s identification marks”, so that it will be clear to the installation Surveyor that such shafts have been welded and stress relieved. In cases where the original shaft identification marks have been obliterated, new marks are to be added at this time in a low stress area, i.e.

forward face of shaft.

3.18. Shaft Covering – Shaft coating(s) shall be the five-component coating system [primer coat, stripe coat, topcoat, sealing / fairing compound, and glass reinforced plastic (GRP)], as described in accordance with MIL-STD-2199B, reference 2.2.2.c of this specification.

a. The resin used must be an epoxy in accordance with MIL-R-23461.

b. Thixotropic fillers must only be used as specified in section 5.2.1 of

MIL-STD-2199B. reference 2.2.2.b. of this specification.

c. Sealing/Fairing compound must be in accordance with section 5.1.4. of, and applied in accordance with Appendix A of MIL-STD-2199B, reference 2.2.2.b. of this specification.

d. The environmental conditions required in Appendix A, section A.5.1 of MIL-STD-2199B, reference 2.2.2.b. of this specification. Must be adhered to.

e. The sleeve details on the applicable drawing(s) must be followed.

f. All shafting flanges must be covered/protected and coated in accordance with Appendix A of MIL-STD-2199B, reference 2.2.2.b. of this specification.

3.19. Identification Markings – In accordance with section 3.4.c. of this specification Contractor must inspect propulsion shaft for identification markings / number(s) and must provide them to the Contracting Officer as part of the propulsion shaft arrival CFR.

3.19.1. Required markings – The following markings / numbers are the minimum required and shall be IAW paragraph 3.19.3. or 3.19.4. of this specification.

a. Shaft serial number stamped marking in the following format: vessel class, vessel designation, last two digits of year of shaft manufacture, three-digit shaft item sequence number.

b. National Stock Number.

c. Manufacturer’s cage code stamped marking in the following format:

d. Date of shaft manufacture stamped marking in the following format:

MANUFACTURED: MMDDYYYY.

e. Maximum actual shaft tempering temperature in degrees Fahrenheit stamped marking in the following format: TEMPERED: MAX. (maximum actual shaft tempering temperature) DEG. F.

f. If shaft was stress relieved, shaft stress relief indication and shaft stress relief temperature in degrees Fahrenheit stamped marking in the following format: STRESS RELIEF: (shaft stress relief temperature) DEG. F.

g. Shaft material stamped marking in the following format: Specification, Class, and Material (e.g., MIL-S-23284A (SH) CLASS 1 CARBON STEEL.

h. OEM drawing/part number stamped marking.

3.19.2. Serial Number – If propulsion shaft arrives without a serial number, Contractor must request that one be provided by the Contracting Officer.

This request, if required, must be included in the propulsion shaft arrival

CFR.

3.19.3. Absence of Markings – If all required markings are not stamped upon the forward face of the propulsion shaft, Contractor must stamp onto the forward face of the propulsion shaft, the missing information, using block letter / numbers. Markings must be applied neatly and in a semi-circular pattern.

Size of the letters / numbering must be no smaller than 3/16 of an inch and no larger than 7/16 of an inch in size.

3.19.4. Partial Markings – If some of the required markings are not stamped upon the forward face of the propulsion shaft, Contractor must determine which information needs to be added and must stamp this information adjacent to any preexisting numbers / letters using the same size, shape, and format of the pre-existing letters / numbering.

3.20. Post Repair Inspections & Tests – Contractor must perform the following inspections and tests after final machining work is complete. The results must be recorded on a Post Repair Inspection Report and submitted to the Contracting Officer for approval.

a. Any areas repaired by welding must be inspected for cracks and other defects using the methods described in, and in accordance with the inspection requirements of section 7 of MIL-STD-2191, reference 2.2.2.a. of this specification, and the approved welding procedure.

b. Each shaft must be dimensionally inspected for conformance to the applicable drawing(s) and this specification.

NOTE: For 399’ WAGB propulsion shafts, (non-Inconel clad flange). The flange outside diameter (OD) dimension must be taken and digitally recorded by the Contractor prior to the application of the Primer and Topcoat coating system. This information must be provided with the post repair inspection report and to the CG Quality Assurance (QA) Representative during the final QA inspection of the propulsion shaft.

c. TIR inspections must be conducted in accordance with the procedure outlined in section 11.2.1 of MIL-STD-2191, reference 2.2.2.a. of this specification, and section 3-4.9 of NAVSEA Technical Repair Standard, ref. 2.2.3.c. of this specification, and the applicable drawing.

1. The final TIR must be conducted “after” the fiberglass covering is installed and fully cured.

d. All coated areas of shaft(s), “not just GRP/Fiberglass coated areas”, must pass a spark test in accordance with appendix A section A.6.2.2.m. and appendix B section B.5.2.e. of MIL-STD-2199B, reference 2.2.2.b of this specification.

1. Excessive voltage may damage the coating systems and shall not exceed 100 volts per 0.001” of coating thickness, use this rule when testing the primer, stripe, and topcoat areas of coating system. Do not exceed 14,000 VDC or 10,000 VAC, 3-10MHz when spark testing the GRP areas.

e. Using the findings from the Post Repair Inspection, prepare a report detailing the post repair condition of each shaft. The report must include but not be limited to the following.

1. Identification markings IAW section 3.15. and 3.17. of this specification.

2. TIR

3. Dimensional data.

4. Bore dimension and condition.

5. Chemical Composition.

6. Non-destructive testing results.

7. Spark test results

3.21. Dimensions – All dimensions and dimensional tolerances must be as indicated on the specified drawing(s).

3.21.1. If a tolerance is not specified on the drawing, the following dimensions must apply:

a. Fractional dimensions must not exceed +/- 1/64”

b. Decimal dimensions must not exceed (x.xx) +/- 0.01”, (x.xxx) +/-

0.001”, (x.xxxx) +/- 0.0005”

c. Angular dimensions must not exceed +/- 15 minutes.

d. Angular tolerance on all drilled holes must not exceed +/- 0.001” at the bolt circle. * *NOTE: This tolerance is only applicable if there is damage to the flange bolt holes that requires weld repair and re-drilling.

3.22. Reports – All reports prepared for submission must contain, at a minimum, the following information in addition to the specific information called for in the Pre-repair inspection report described in section 3.5. of this specification and the Post Repair Inspection Report described in section 3.18. of this specification.

a. Prime contractor company name, address, and telephone number.

b. Testing contractor contact info (if different from above).

c. Contract and delivery order numbers.

d. Test / measuring equipment used, nomenclature, serial number, and calibration date.

3.23. Surface finish standards – All surface finishes must be in accordance with SAE-J-448, reference 2.4.2.a. of this specification.to the Roughness Height “arithmetical average” (Ra) number indicated on the specified drawing.

3.24. Notifications & Inspections – Contractor must be responsible for notifying the Contracting Officer at least ten (10) calendar days prior to being ready for any inspections or testing.

4.0.QUALITY ASSURANCE

4.1. General – Contractor must provide and maintain an inspection system which must ensure each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system must be documented, meet the requirements of ASQ/ANSI/ISO 9001:2015, reference 2.4.1.b. of this specification, and be available for review by the Coast Guard.

4.2. Records – Contractor must maintain records of all inspections and tests. The records at a minimum must indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3. Calibration System – Contractor, as well as any subcontractors, must be required to maintain a test equipment calibration program in compliance with ISO/IEC 17025:2017, reference 2.4.1.a. of this specification. The program must be documented and traceable to the National Institute of Standards (NIST).

4.4. Responsibility for Inspection – Contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor must provide space, personnel, and test equipment to perform all the inspection requirements. All inspection and testing must be performed at the contractor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify, witness or have any of the inspections performed that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.5. Responsibility for Compliance – All items must meet the provisions of sections 3 & 5 of this specification. The inspections set forth in this specification must become part of the Contractor’s overall inspection system or quality program.

The absence of any inspection requirements in the specification must not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance 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.

4.6. Tests & Inspections – The inspections/tests required here and in the appropriate subsections outlined in section 3 of 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.

4.6.1. The following Post Repair tests and inspections will be witnessed by an SFLC Quality Assurance Representative:

a. Verify marking information IAW section 3.15 and 3.17 of this

b. TIR “after” final machining and application of fiberglass.

c. Complete Dimensions listed on the Approved Inspection Report from the KO.

d. Bore dimension, condition, and preservation.

e. Proper application of primer and elastomeric coating. In required locations IAW Applicable Dwg and Ref 2.2.2.b. of this specification.

f. Five Layer Coating System “Spark Test”.

g. Preservation Inspection.

h. Packaging, Packing and Marking Inspection.

4.7. Failure Responsibility – If the specified item fails to pass any inspection / test, the Contractor must report the failure and the recommended corrective action to the Contracting Officer. If approved, the corrective action on the materials or processes must be accomplished in accordance with this section.

4.7.1. General Statements

a. The inspection / test must be discontinued until all corrective action has been taken.

b. After all corrective actions have been taken the inspection / test must be repeated unless waived by the Contracting Officer.

c. Acceptance must be withheld contingent upon satisfactory completion of all inspections / tests.

d. All corrective actions must be documented as part of the Contractor’s inspection system and submitted for approval to the Contracting Officer.

e. Each corrective action report must include, but not be limited to the cause of each defect, corrective action suggested, and the steps taken to prevent a recurrence of each defect.

4.7.2. A copy of any test, inspection or tolerance report must be turned over to the Quality Assurance Representative upon arrival at the Contractors’ plant.

4.8. Packing Inspection – The Contracting Officer must be notified 10 days prior to the packaging and marking of the completed units in accordance with section

3.23 of this specification.

5.0 SCOPE (OPTIONAL WORK ITEM) – Fitting & Machining Flange

Coupling to CGC Polar Star Centerline & Wing Tailshaft.

5.1. This optional Statement of Work (SOW) provides the requirements for the receipt, inspection, fitting, machining/blue fitting of “A” condition propulsion hydraulic coupling assembly to “A” condition 420’ propulsion shaft, testing, preservation, packaging and marking of complete match shaft and shaft coupling assembly used on 420’ WAGB Cutter.

5.2. The manufacturing requirements described herein are the minimum and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure quality of the product.

5.3 The propulsion hydraulic coupling and propulsion shaft are managed by US Coast Guard Surface Forces Logistics Center (SFLC) and been released to the Contractor as Government Furnished Property (GFP), for refurbishment under separate delivery orders of SFLC Contract XXXXXX-XX-X-XXXXX.

5.3.1 Identified delivery orders (DO), of SFLC Contract HSCG40-15-D-30004 that shall be affected by this SOW are:

a. DO XX-XXXX

5.4 The propulsion shaft coupling assembly is managed by the US Coast Guard SSFLC under National Stock Number (NSN) 3010-01-138-2161 and consists of the following items:

a. Flange Coupling.

5.5 Government Furnished Material (GFM) – Item a. listed in paragraph 5.4 will be released to the Contractor as GFM.

6.0 REQUIREMENTS

6.1 General - The Contractor shall provide all labor and materials required to machine, finish and blue fit GFM hydraulic coupling to GFP propulsion shaft. Test, inspect, preserve, package, pack and mark each shaft coupling assembly used on 420’ WAGB Cutters, IAW CG Dwg. 4301-6 Rev -Coupling Flange Master 395, CG Dwg. 4301-4 Rev 12 Center Tail Shaft (9022-D-1), CG Dwg. 4301-5 Rev 11 Wing Tail Shaft (9022-E-1) ref. 2.3.2.a of this SOW and MIL-DTL-2845E (SH), ref. 2.2.1.a. of this SOW.

6.2 Coupling Assembly Receipt - Upon receipt of each flange coupling contractor must:

a. Uncrate and remove any and all existing protective coverings.

b. Remove all corrosion or coatings from all surfaces of the coupling body to facilitate a detailed Pre-blue fitting inspection.

c. Provide Contracting Officer with a “flange coupling arrival” Condition Found Report (CFR), containing date that flange coupling arrived and the name of the receiving person who signed for the flange coupling.

6.3 Coupling Taper Verification - – Each coupling shall arrive with final inspection and SFLC Quality Assurance Inspection reports contained within the shipping crate. Final taper dimension of coupling is listed within these reports, Contractor shall measure coupling body taper and confirm taper dimension is as indicated within the reports and IAW taper dimension requirements of CG Dwg.

4301-6 Rev -, Coupling Flange Master 395, CG Dwg. 4301-4 Rev 12 Center Tail Shaft (9022-D-1), CG Dwg. 4301-5 Rev 11 Wing Tail Shaft (9022_E-1), ref. 2.3.2.a of this SOW and provide confirmation of this dimension to Contracting Officer via same CFR provided and described in Para 3.2. of this SOW.

6.4 Fitting of Coupling Assembly to Propulsion Shaft – Utilizing the following steps as a guide the Contractor shall blue fit the coupling assembly to the propulsion shaft taper. Acceptable taper to taper blue fit contact shall be no less than 90%. Contact pattern shall be evenly distributed as described in sections 3-4 and 3-5 of S9243-A5-MMD-010, 1995, ref. 2.2.3.f. and Figure C, of S9243-AW-TRS- 012/0203-086-501A Change B, 01 Jun 1991, ref.2.2.3.g. of this SOW.

Do not lift the flange coupling (or any other shafting) with steel cables fed through the coupling flange bolt holes as this will damage the surface finish and result in a poor fit of the flange bolts for reassembly.

a. Set up shaft for blue fit, by supporting shaft in a horizontal position on multiple sets of V-Blocks W/O damaging or applied protective coating systems, i.e. glass reinforced plastic (GRP) / fiberglass.

b. Clean the shaft and flange coupling with solvent cleaner. Coat the entire tapered surface of the propulsion shaft with a uniform, thin coat of color “2a” blue dye listed in GSA-FSS-Federal Supply Service Specification, A-A-3108B, ref. 2.4.1.a. of this SOW. Spread the dye over the entire surface, using a soft, lint-free cloth to achieve a uniform translucent covering. Be sure this dye is thick enough to tint the shaft taper area blue, but not thick enough to be opaque.

c. Gently insert the flange coupling onto the shaft. Do not force the flange coupling. Only the own flange coupling weight is applied during the fit test. Blue fit the coupling taper to the shaft taper until a repeatable and evenly distributed fit of 90% is achieved on the coupling taper surface.

d. Repeat Step (c) until coupling slides fully on to shaft taper attaining full metal to metal contact without any contact resistance/interference to verify taper blue fit.

e. After verification of 90% or greater coupling blue fit, contractor shall determine the distance between the coupling body forward face and the face of the shaft where the shaft taper starts.

NOTE: An optional way to determine this distance is to scribe a circumferential line on the I.D. of the coupling taper upon completion of final blue fit, upon removal of the coupling body contractor shall measure the distance from this “scribe line” to the forward face of the coupling body.

f. Remove Coupling after final verification of blue fit and recording of coupling face to shaft taper face measurement.

g. Do Not Machine, Handwork, Sand or Grind on Shaft Taper. All fitting work is to be done to Flange Coupling Taper Surface Area.

h. Contractor must utilize the established serial number stamped on the forward face of shaft that coupling is being blue fit to. Utilizing numbers/letters stamps sized between 3/8” and 7/16”, the following information shall be stamped into the aft face of the coupling body under the new “coupling” serial number and manufacturing information. Each flange coupling, and shaft must have matching benchmark for reinstallation.

7.0 PRESERVATION, PACKAGING, PACKING, & MARKING

Preservation – Cleaning, drying, preservatives, preservation application criteria and methods of preservation shall be in accordance with MIL-PRF-16173E (SH) and MIL-DT 2845E (SH), section 3.5.1.1 level A, Table I, for finished machined steel shaft surfaces. Ref 2.2.1 of this specification.

Packaging – Must be in accordance with sections 3.15.4 and 3.15.4.1 of MIL- DTL-2845E(SH), ref. 2.2.1.a. of this specification.

7.1.1 After the second coating of initial preservation film, “Cosmoline”, has dried, all finished steel areas of propulsion shaft not covered with either GRP or paint, i.e. coupling taper, cooper bearing areas, bulkhead seal areas, shaft faces and shafting flange mating faces, shall be wrapped with 2 full coverage layers, each wrap overlapping by 1/3” tape width, of Petrolatum Impregnated Tape, prior to installation of the remaining packaging material. Where Petrolatum Impregnated Tape meets up with shaft sleeves or previously painted areas of propulsion shaft.

Petrolatum impregnated tape shall be wrapped around the entire circumference of the shaft sleeve end or painted surface and beyond the beginning of the shaft sleeve or painted area for a distance of not less than three inches (3”).

a. Petrolatum Impregnated Tape shall meet the requirements of AWWA C217, ref. 2.4.4.a. of this specification and shall be applied in accordance with manufacturer’s requirements and section 4 of NACE

Standard RP0375-2006 Item No. 21013, ref. 2.4.5.a. of this

7.1.2 Flange faces where applicable must be protected in accordance with section

3.15.5. of MIL-DTL-2845(SH), ref. 2.2.1.a of this specification.

7.2. Packing – Must be in accordance with section 3.15.6. of MIL-DTL- 2845(SH), ref. 2.2.1.a of this specification.

7.3. Technical Reports – A complete copy of the KO / COR Reviewed Final Inspection Report, verified and signed by Coast Guard SFLC QA Inspection personnel and any other documentation requested by the Contracting Officer must be packed with the propulsion shaft in accordance with section 3.15.8 of MIL-DTL- 2545E(SH), reference 2.2.1.a of this specification.

7.4. Wood Packaging material (WPM) Requirements – All packaging and packing material must meet the Phytosanitary Requirements for WPM in accordance DODD 4140.01-M-1, Compliance for Defense Packaging: Phytosanitary Requirements for Wood Packaging Material (WPM), Ref. 2.2.1.d. of this specification. Plywood Does Not Require HT Stamp due to it meeting the Phytosanitary requirements of WPM because of its manufacturing process.

7.4.1. WPM is defined as:

a. wood pallets

b. skids

c. load boards

d. pallet collars

e. wooden boxes

f. reels

g. dunnage

h. crates

i. frames

j. cleats

6.4.2. All new purchases of WPM must 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) in accordance with Ref. 2.2.1.d. of this specification.

6.4.3. For existing crating/skid, the Contractor must determine if the requirements listed in 5.5 are met. If the requirements are not met, the Contractor must determine if the crating / skid can be brought to meet the requirements or will require replacement.

6.4.4. All solid wood utilized in the manufacture or repair of crating/skids must have the appropriate markings in accordance with MIL-STD-129R and the required list, Ref. 2.2.1.d. of this specification.

6.5. Marking – Each preserved, packaged, and packed item must be marked in the upper left-hand side of the two longest sides (two opposite sides if square) of each box. If the lettering is stenciled on, it must be at least 2” high, in black print lettering on a highly contrasting white painted background.

6.5.1.This marking must consist of the STOCK NUMBER, ITEM NAME, PART

NUMBER, SERIAL NUMBER, CONTRACT NUMBER / DELIVERY ORDER

NUMBER, GROSS WEIGHT (in lbs.), condition code CONDITION “A”, unit of issue with quantity (i.e. 1-EA) and the words COAST GUARD SFLC

MATERIAL, REUSABLE CONTAINER DO NOT DESTROY.

6.5.2. Marking must be laid out in this fashion:

STOCK NUMBER See delivery order/Data sheet ITEM NAME See delivery order/Data sheet PART NUMBER See delivery order/Data sheet SERIAL NUMBER As assigned CONTRACT NUMBER See Contract DELIVERY ORDER NUMBER As issued SHIPPING WEIGHT As determined by contractor

CONDITION CODE CONDITION “A”

QUANTITY & UNIT OF ISSUE 1 – EACH

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER DO NOT DESTROY

Bar Coding – Bar code labels must be supplied on all CLIN’s except for those that require data submissions only. A bar coded label, in accordance with MIL- STD-129R shall be supplied on all deliverable material except for those that require data submissions only. Bar code labels may be applied separately or as part of the marking required by section 5.6 of this specification.

All bar-coded labels shall be in accordance with MIL-STD-129R (CODE 39).

Each label shall contain encoded data for the Stock Number, Contract number, and the Delivery and Order Number, if applicable. Code 39 is not covered by

MIL-STD-129R.

6.5.3. All bar code labels must be in accordance with SFLC specification D-000- 0100.

k. The actual labels must be Type “V”, Grade “A”, Style “2”, Composition “b” with plastic laminate.

l. Each label must contain encoded…