Attachment 1_ WMSL Shaft Repair SPEC 12-17-23.pdf

PROPULSION SHAFT REFURBISHMENT 418’ WMSL U.S. COAST

GUARD VESSELS

1.0. SCOPE

1.1. This specification provides the requirements for the receipt, inspection & condition/test reports, refurbishment, testing, preservation, packaging, packing and marking of propulsion shafts used on WMSL U.S Coast Guard Vessels.

1.2. Classification

1.2.1. Types of propulsion shafts

CLIN

VESSEL

CLASS

U/I TITLE

NSN

Part Number

001 418’ WMSL EA PROPULSION SHAFT, LINE

2010-01-555-7582

150110-02/KMW 150643A

002 418’ WMSL EA SHAFT, STERN TUBE

2010-01-572-3915

150110-01/KWM 150642A

003 418’ WMSL EA PROPULSION SHAFT, TAIL

2010-01-555-5058

150108-01/ KWM 150641A

1.3. Government Furnished Property (GFP)

1.3.1. The propulsion shafts listed in 1.2.1 constitute all of the GFP applicable to this specification. This list contains propulsion shafts that have been in service.

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.

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 – 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.

2.2.1. 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

b. MIL-R-23461A, 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. DODD 4140.65-M-1, Dated 21 August 2012; Compliance for Defense

Packaging: Phytosanitary Requirements for Wood Packaging Material

(WPM).

2.2.2. Military Standards

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

b. MIL-STD-2199B, 28 January 2020; Department of Defense Standard Practice, Coverings of Waterborne Main Propulsion Shafting on U.S. Naval Surface

Ships and Submarines.

c. ISO 3452-1:2021, May 2021, Non-Destructive Testing, Penetrant Testing

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

Compound, Solvent Cutback, Cold- Application

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

Shipboard Equipment.

f. MIL-S-23284A (SH) - Dated 15 June 1990, Steel Forgings, Carbon and Alloy, for Shafts, Sleeves, Propeller Nuts, Couplings, and Stocks (Rudders and

Diving Planes).

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-011/0203-086-501A, Change D, 01 Jun 2004; 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), 16 Feb 1999; Requirements for Nondestructive

Testing Methods.

f. PROPULSION SHAFT COATINGS INTERIM DIRECTION Letter, Ser

05Z/367, Dated 21 Jun 2017.

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 Standard Specification 6310, 2012, Requirements for

Preservation of Ship Structures, For Underwater Body Paint Requirements.

b. MIL-STD-129R, Change 2, 27 September 2019, Department of Defense

Standard Practice, Military Marking for Shipment and Storage.

c. Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec

0740), 2022, Welding and Allied Processes

d. Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec

6310), 2022, Requirements for Preservation of Ship Structures

2.3.2. Drawings, Shafts

a. 803-2145807, Rev C 19 Dec 1988 NAVSEAS Standard Propulsion Shafting

Drawing

b. 750-WMSL-243-007 REV C DATED 09/08/2007, Propulsion Shafting System

Arrangement

c. 750-WMSL-243-008 REV C DATED 09/08/2007, Propulsion Shafting and

Appendages

d. 750-WMSL-243-010 REV C DATED 09/08/2007, Propulsion Shafting and

Appendages

e. Rolls Royce Naval Marine INC. ROLLS ROYCE drawing 150110, INTERMEADIATE SHAFT ASSEMBLY.

f. ROLLS ROYCE drawing 150108, revision A, PROPELLER SHAFT

ASSEMBLY

g. ROLLS ROYCE drawing 140164, revision M SHAFTING ARRANGEMENT

Chapter 5.1

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. Society of Automotive Engineers (SAE)

a. SAE J448, 01 Aug 2011, Surface Texture.

2.4.2. American Society for Testing & Materials (ASTM)

a. ASTM-A-668/A668M-04 (R 2009), 01 Mar 2004, Standard Specification for

Steel Forgings, Carbon and Alloy, for General Industrial Use.

b. ASTM B 369 – 09; 01 Apr 2009 Standard Specification for Copper-Nickel

Alloy Castings.

2.4.3. ISO/IEC 17025:2017 Requirements for the Calibration of Measuring and Test

Equipment

2.4.4. National Association of Corrosion Engineers (NACE)

a. NACE RP0375, Dated 03 Nov 2006, Field-Applied Underground Wax Coating

Systems for Underground Pipelines: Application, Performance, and Quality

Control.

2.4.5. ABS Guide for Bronze and Stainless Steel and Propeller Castings – DATED 2000

2.4.6. ASQ Q9001-2008, Dated 2008, Quality management systems-Requirements.

2.4.7. Society of Automotive Engineers (SAE) SAE-J-448A DATED 6/63 Surface

Texture Standard.

2.4.8. American Water Works Association (AWWA)

a. AWWA C217, Dated 16 Jan 2016, Microcrystalline Wax and Petrolatum Tape

Coating Systems for Steel Water Pipe and Fittings

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) – Contractor shall provide inside storage for all GFM with complete protection from the weather elements, stowed in the original shipping packaging when not in use.

3.3. General – Contractor shall provide all labor, equipment, and materials, except for any

GFM, required to evaluate, repair, test, inspect, preserve, package, pack and mark any of the propulsion shafts outlined on the NAVSEA 803-214807, and applicable USCG and

OEM drawings referenced in this specification as may be required by the Contracting

Officer.

3.4. Shaft Receipt: Upon receipt of each shaft, the Contractor shall:

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

b. Remove all corrosion and thoroughly clean the shaft and bore to facilitate a detailed Pre-repair Inspection.

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.

3.5. Pre-repair Inspection: After completing the requirements in section 3.4 of this specification, the Contractor shall perform a Pre-repair Inspection in accordance with chapter 3 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 this specification.

3.5.2. As per NAVSEA CWP Letter No. 372, ref. 2.2.3.f. of this specification, in-service one-time Ultrasonic Testing (UT) inspection requirement of surface ship main propulsion shafts for both fixed and controllable pitch propeller is no longer required and shall not be accomplished.

3.5.3. Initial action of Pre-repair Inspection shall be the determination of the installed shaft sleeve condition and their ability to meet the criteria outlined in section 3.9.1 of this specification. If they “do” meet the criteria, then they shall remain on the shaft and be repaired in lieu of removal / replacement. If it is determined that the shaft sleeves “do not” meet the criteria, then the sleeves shall be removed as part of the Pre-repair Inspection. The Contracting Officer shall be informed within 10 business days of this determination / action via CFR detailing specifics of why the sleeves did not meet the criteria. This CFR shall be provided prior to completion of the Pre-repair Inspection and submission of the Pre-repair Inspection Report.

3.6. Tests and Inspections – All applicable test and inspection procedures, and acceptance criteria shall be in accordance with the references cited in section 2.0 of this specification.

3.6.1. Chemical Composition – If the Chemical Composition of the propulsion shaft received for refurbishment is not known, (i.e., marked on forward end of received 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.

3.6.2. Packaging Inspection – The Contractor shall complete replacement of the shipping packaging / skid. The Contractor shall confirm that the shaft packaging conforms to the Phytosanitary Requirements for Wood Packaging Material (WPM)

IAW paragraph C2.1.1. of DoDD 4140.01-M-1, Compliance for Defense

Packaging, Ref. 2.2.1.d. of this specification.

3.7. Pre-repair Inspection Report: Based on the findings from the Pre-repair Inspection, the Contractor shall prepare a report detailing the pre-repair 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. Total Indicated Runout (TIR).

c. All Dimensional Data. That is listed on the applicable Drawings in Section

2.3.2 above.

d. Detailed bore ID Dimensions at ends, mid & quarter length locations, if applicable.

e. Non-destructive testing results.

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

g. As received condition of shaft shipping packaging / skid with digital photographs.

h. Verification that shipping package/skid meets requirements in 2.2.1.d.

3.7.2. Submission of Pre-repair Inspection Report – The Contractor shall 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 shall be in accordance with this specification and the references listed in sections 2.2, 2.3, and 2.4.

a. The Repair Plan shall include a detailed breakdown of all labor hours with associated skill sets, and associated material costs required to complete the overhaul / repair / refurbishment of the propulsion shaft, including the replacement cost of the shipping packaging / skid.

3.8. Approval to proceed with repairs – The Pre-repair Inspection Report and Repair Plan shall 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.

3.9. Bearing Sleeves

3.9.1. Use of Installed Bearing Sleeves – If the following conditions can be met, then the propulsion shafts sleeves shall remain installed upon the shaft and the 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 0.060 inch from the minimum designed outside diameter as listed on the applicable drawing.

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

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

NOTE: Repair by hand-smoothing shall 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 shall be detailed on the Pre-repair Inspection

Report and Repair Plan and shall be approved by the Contracting Officer before repairs are authorized.

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

a. Sleeves shall 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.a of this specification.

b. Prior to sleeve installation, the shaft journal outside diameter (OD), Surface finish dimension, Sleeve inside diameter (ID) and Sleeve inside surface finish dimension shall 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 shall 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 shall 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, shall be submitted to the Contracting Officer for review and approval.

3.10. Qualification of Welding Procedures & Personnel – Welding procedures, welders, and welding operations shall be qualified in accordance with section 5.0 of MIL-STD-

2191, reference 2.2.2.a of this specification.

3.10.1. 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 shall be submitted to the Contracting Officer for approval.

3.10.2. The welding procedures shall 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. shall 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.

3.11. Welding of cracks & deep pitting – These repairs shall be in accordance with MIL-

STD-2191, reference 2.2.2.a of this specification.

a. The welded areas shall be machined flush.

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

c. Welding repair of Cracks or Pitting exceeding 1/16-inch depth but less than

1/4-inch depth shall be reviewed on a case-by-case basis dependent upon shaft size and location of damage.

d. Surface finishes shall be 125 RMS unless otherwise stated.

e. 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.

3.12. Post Weld Heat Treatment – All shafts which have been welded, shall 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 shall comply with MIL-STD-2191 section 10.4.5.2.

b. “No Carb” heat resisting scale preventative shall 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” shall be submitted to the Contracting Officer for approval. Documentation detailing the chemical and material analysis shall accompany the submittal.

3.13. Straightening procedures – These repairs shall be in accordance with section 11 of

MIL-STD-2191, reference 2.2.2a of this specification.

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

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

3.14. Cold Rolling – This procedure shall 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 S9243-

AW-TRS-011/0203-086-501A, ref. 2.2.3.c of this specification.

a. Cold rolling shall be accomplished in accordance with direction given on the applicable shafting drawing. After all heat treatment, in accordance with the material military specification, has been accomplished and before machining keyways (for keyed shafts) the propeller shaft shall be cold rolled. The area of the propeller shaft to be rolled is to have a 125 micro-inch (RHR) or finer finish before rolling. Cold rolling shall be accomplished by the use of a 9-inch diameter hardening roller with a 1-1/2-inch crown radius bearing on the shaft.

The hardening roller shall be opposed on the opposite side of the shaft by a 9-inch diameter smoothing roller with a 4-inch crown radius. The shaft shall be rotated at a surface speed of about 60 feet per minute and the rate of feed of the roller shall be about 1/16 inch for each revolution of the shaft. Where the after end of the tail shaft terminates in a taper, cold rolling shall be continuous from a point starting 12 inches forward of the forward end of the after-shaft sleeve to a point 2 inches forward of the after end of the tail shaft taper. Where the after end of the tail shaft terminates in an integral flange, e.g., controllable pitch propeller installation, cold rolling shall be continuous starting from the junction of the weld inlay to a point 12 inches forward of the forward end of the after sleeve. The cold roller load shall be specified. Only one pass is to be made over the area to be rolled and this area shall be smeared with an extreme pressure lubricant during rolling. The load on the roller shall be applied to the shaft gradually for a distance of 2 inches ahead of the section to be rolled and decreased gradually for a distance of 2 inches following the section to be rolled. In the area rolled, the amount of metal removed at finish machining, after rolling, shall be kept to a minimum and shall not exceed 0.010 inch on the http://www.gwsmithandsons.com/ radius. Upon completion of cold rolling and finish machining of the tail shaft, the cold rolled area of the shaft shall be examined by the magnetic particle procedure specified in Military Specification MIL-S-23284A (SH). The shaft shall subsequently be demagnetized.

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 shall require this / these area(s) to be cold rolled.

3.15. 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.

3.16. Shaft Covering –All shaft coverings shall be glass reinforced plastic (GRP), applied in accordance with MIL-STD-2199B, reference 2.2.2.b of this specification.

a. All old coating shall be removed and replaced.

b. The resin used shall be an epoxy in accordance with MIL-R-23461.

c. Thixotropic fillers can be used as specified in section 5.2.1 of MIL-STD-

2199B.

d. Sealing/Fairing compound shall be in accordance with section 5.2.2. of MIL-

STD-2199B.

e. The environmental conditions required in section 5.4.6.1 thru 5.4.6.1.1 of MIL-

STD-2199B shall be followed.

f. The sleeve details on the applicable drawing shall be followed.

g. All shafting flanges shall be coated/covered/protected in accordance with paragraph 3 of “NAVSEA Propulsion Shaft Coatings Interim Direction”

Letter, reference 2.2.3.g. of this specification.

3.17. Identification Markings – In accordance with section 3.4.c. of this specification

Contractor shall inspect propulsion shaft for identification markings / number(s) and shall provide them to the Contracting Officer as part of the propulsion shaft arrival CFR.

3.17.1. Required markings – The following markings / numbers are the minimum required:

a. Serial number.

b. Drawing and /or part number.

c. Material type and class.

d. Weld repair & stress relief info IAW Sect 3.15 of this specification.

e. Contractor CAGE code & repair date

3.17.2. Serial Number – If propulsion shaft arrives without a serial number, Contractor shall request that one be provided by the Contracting Officer. This request, if required, shall be included in the propulsion shaft arrival CFR.

3.17.3. Absence of Markings – If all of the required markings are not stamped upon the forward face of the propulsion shaft, Contractor shall stamp onto the forward face of the propulsion shaft, the missing information, using block letter / numbers.

Markings shall be applied neatly and in a semi-circular pattern. Size of the letters / numbering shall be no smaller than 3/16 of an inch and no larger than 7/16 of an inch in size.

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

3.18. Post Repair Inspections & Tests – Contractor shall perform the following inspections and tests after final machining work is complete. The results shall be recorded on a

Post Repair Inspection Report and submitted to the Contracting Officer for approval.

a. Any areas repaired by welding shall 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 shall be dimensionally inspected for conformance to the applicable drawing(s) and this specification.

c. TIR inspections shall 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 3-4.13 of S9243-AW-TRS-011/0203-086-501A, Technical Repair

Standard for Surface Ships Main Propulsion Shafting Refurbishment

Procedures, reference 2.2.3.c of this specification, and the applicable drawing.

NOTE: The final TIR shall be conducted “after” the fiberglass covering is installed.

d. All GRP coated areas of shaft shall pass a spark test in accordance with section

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

e. Using the findings from the Post Repair Inspection, prepare a report detailing the post repair condition of each shaft. The report shall 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 voltage and results.

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

3.19.1. In the event a tolerance is not specified on the drawing; the following dimensions shall apply:

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

b. Decimal dimensions shall not exceed (x.xx) +/- 0.01”, (x.xxx) +/- 0.001”, (x.xxxx) +/- 0.0005”

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

d. Angular tolerance on all drilled holes shall 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.

3.20. MEASUREMENT PROCEDURES

3.20.1. Run Out Procedures – Total Indicated Run-out (TIR) inspections shall be conducted in accordance with the procedure outlined in MIL-STD-2191 (SH) section 11.2.1. For all run-out inspections all shafts shall be supported between lathe centers with no auxiliary supports.

3.20.2. All dial indicators shall be rigidly supported above the shaft, allowing no movement of the indicator body whatsoever while measurements are taken.

3.20.3. Run out readings shall be determined as follows: Conduct a dial indicator survey of the shaft run out at stations 24” apart to determine the magnitude and location of any bend.

3.20.4. At each station mark the position of the maximum run-out on the periphery of the shaft.

3.20.5. The run out shall be measured at the following locations unless otherwise stated on the applicable drawing.

a. At the small end, mid-length, and large end of all shaft tapers and coupling areas.

b. At a minimum every four feet on the shaft except for the areas defined above.

3.20.6. Outside Diameter - The O.D. shall be measured at a minimum from one end every four feet on the shaft.

3.20.7. Inside Diameter - The I.D. shall be measured at a minimum from one end every four feet in the shaft.

3.20.8. Concentricity Measurement and Accuracy–Variation in wall thickness shall be measured by calibrated pulse echo ultrasonic instrument in accordance with MIL-S-

23284A (SH), section 4.4.3 The shaft bore shall be accurate to within plus 0.016 inch minus 0.000 inch. The diameters of reduced bores shall be accurate to within minus 0.120 inch plus 0.000 inch. The variation of wall thickness of hollow shafting at any cross section shall not exceed 0.039 inch. The wall shall be measured by pulse echo ultrasonic instrument using a digital and/or a CRT display. Ultrasonic measurements shall be taken every 4 feet over the entire length of the shaft section.

Should these measurements indicate the possibility at a location between measured stations not conforming to these requirements, additional measurements shall be taken to verify that the requirements have been met.

3.21. Run out, Concentricity & Eccentricity

3.21.1. Shaft, and taper and coupling areas run out and concentricity, and associated tolerances, shall be in accordance with the Rolls-Royce drawings listed in section 2 of this specification.

3.21.2. The outside diameter of each shaft section shall be concentric with the axis of rotation within 0.0075 inch (0.015-inch runout). The change in concentricity in any

48 inches shall not exceed 0.0025 inch (0.0050-inch runout).

3.21.3. Shaft journal, sleeve fit area of shaft and sleeve outside diameters shall be concentric with the axis of rotation within 0.0005 inch (0.001-inch runout).

3.21.4. Shaft tapers shall be concentric with the axis of rotation within 0.0005 inch

(0.001-inch runout).

3.21.5. The outside diameter of each coupling, including inboard coupling shall be concentric with the axis of rotation within 0.0005 inch (0.001-inch runout).

3.21.6. The shaft spigot counter bore shall be concentric with the axis of rotation within

0.0005 inch (0.001-inch runout).

3.22. Balancing

3.22.1. Dynamic Balancing – All hollow shafts manufactured under this specification are required to be dynamically balanced in accordance with MIL-STD-167-1. Data concerning said balancing shall be submitted to the Contracting Officer for approval. The balance correction requirements shall be determined after finish machining the bore and with the outside diameter rough machined. The final balance check shall be made after finish machining of shaft and journals and before installation of shaft sleeves.

3.22.2. a. Dynamic balancing shall be accomplished on equipment that requires rotation of the shaft.

3.22.3. b. The minimum detectable imbalance of the machine used shall be below the allowable residual unbalance specified on the applicable drawing(s).

3.22.4. c. The shaft section shall be supported in the balancing machine at two locations at or near two-ninths of the shaft length from each end.

3.22.5. Residual Unbalance - The following residual unbalance requirements shall apply.

3.22.6. The minimum detectable unbalance of the machine used shall be below the residual unbalance of the shaft(s) as determined herein.

3.22.7. Each shaft shall be supported in the balance machine at two locations at or near two-ninths of the shaft length in from each end.

3.22.8. The residual dynamic unbalance resulting from the foregoing dynamic unbalance shall not exceed the amount calculated by the formula U= 4000W/N^2. Where U= the maximum allowable residual unbalance in inch oz., W= weight of the shaft in pounds, N= the maximum shaft RPM (230 RPM).

3.22.9. Balance Correction and Checks – For all hollow bored shaft sections, balance correction requirements shall be determined after finish machining the bore and with the outside diameter rough machined. Corrections shall be made by shifting lathe centers so as to change the bore position. The outside diameter shall be finish machined concentric about the new lathe centers. No other method of correction shall be made without specific approval by the Coast Guard Contracting Officer.

Intermediate balance checks may be made as machining progresses, but a final balance check of the finish machined shaft shall be made after finish machining of shaft and journals and before installation of the shaft sleeves and protective covering. In no case shall the maximum allowable values of runout or unbalance nor the allowable wall thickness tolerance be exceeded.

3.23. Reports – All reports prepared for submission shall 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.

3.24. Surface finish standards – All surface finishes shall be in accordance with SAE-J-448 to the Roughness Height “arithmetical average” (Ra) number indicated on the specified drawing. If not specified, tapered areas and journals shall have a finish of 32 micro-inch

Ra or better. All other areas shall have a 100 Ra finish or better.

3.25. Notifications & Inspections – Contractor shall 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 shall provide and maintain an inspection system which shall ensure each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Coast Guard.

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

4.3. Calibration System – The Contractor as well as subcontractors shall maintain a test equipment calibration program in compliance with ISO/IEC 17025. The program shall be documented and traceable to the National Institute of Standards (NIST), or the calibration facility shall be ISO/IEC 17025 accredited.

4.4. Responsibility for Inspection – Contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor shall provide space, personnel, and test equipment to perform all the inspection requirements. All inspection and testing shall 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. CG intends to have the QAR perform onsite inspections as listed below in Section 4.6.

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

b. TIR after final machining and application of fiberglass.

c. Complete Dimensional Inspection (100% as listed on the Approved Final

Dimensional Report).

d. Bore dimension, condition and preservation.

e. Proper application of GRP. In required locations IAW Applicable Dwg and

Ref 2.2.2.b. of this specification.

f. GRP System “Spark Test” verification of appropriate test voltage”.

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 shall report the failure and the recommended corrective action to the

Contracting Officer. If approved, the corrective action on the materials or processes shall be accomplished in accordance with this section.

4.7.1. General Statements

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

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

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

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

e. Each corrective action report shall 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 shall be turned over to the

Quality Assurance Representative upon arrival at the Contractors’ plant.

4.8. Packing Inspection – The Contracting Officer shall be notified prior to the packaging and marking of the completed units in accordance with section 3.24 of this specification.

5.0.PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. Preservation – Cleaning, drying, preservatives, preservation application criteria and methods of preservation shall be in accordance with MIL-DTL-2845(SH), section

3.5.1.1 level A, Table I, for finished machined steel shaft surfaces. Reference 2.2.1.a of this specification.

5.1.1. Shaft coupling, cooper bearing, bulkhead seal area and flange faces shall be wrapped and protected with an overlapping layer (1/3rd tape width), of petrolatum impregnated tape in addition to the prescribed cosmoline, barrier paper and canvas wraps required by MIL-DTL-2845E(SH).

5.1.2. Petrolatum tape system selected shall be in accordance with AWWA C217 and shall be applied in accordance with the tape manufacturer’s requirements and section 4 of NACE Standard RP0375-2006 Item No 21013 (see AWWA C217).

5.2. Packaging – Shall be in accordance with section 3.15.4. & 3.15.4.2. of MIL-DTL-

2845(SH).

5.2.1. After final coating of preservation film, (Cosmoline), has dried. All finished steel areas of propulsion shaft that are not covered with GRP, or paint, i.e., coupling taper, cooper bearing areas, bulkhead seal areas and flange faces, shall be wrapped / protected with a full coverage layer of Petrolatum Impregnated Tape, prior to installation of the remaining packaging material.

5.2.2. Flange faces where applicable shall be protected in accordance with MIL-DTL-

2845(SH), section 3.15.5.

5.3. Packing – Shall be in accordance with MIL-DTL-2845(SH), section 3.15.6.

5.4. Technical Reports – A complete copy of the KO / COR Reviewed Final Inspection

Report, and any other documentation requested by the Contracting Officer shall 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.

5.5. Wood Packaging material (WPM) Requirements – All packaging and packing material shall meet the Phytosanitary Requirements for WPM in accordance with paragraph C2.1.1. of DoDD 4140.65-M-1, Compliance for Defense Packaging, Ref.

2.2.1.d. of this specification.

5.5.1. 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

5.5.2. All new purchases of WPM shall be constructed from heat treated (treated to 56°

C. core temperature for 30 Minutes), lumber and certified by an accredited agency recognized by the American Lumber Standard Committee (ALSC) in accordance with Ref. 2.2.1.d. of this specification.

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

5.5.4. All solid wood utilized in the manufacture or repair of crating/skids shall have the appropriate markings in accordance with Ref. 2.2.1.d. of this specification.

5.6. Marking – Each preserved, packaged and packed item shall 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 shall be at least 1” high, in black print lettering on a highly contrasting white painted background.

5.6.1. This marking shall 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 PACKAGING DO NOT DESTROY.

5.6.2. Marking shall be laid out in this fashion:

STOCK NUMBER See delivery order.

ITEM NAME See delivery order.

PART NUMBER See delivery order.

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 PACKAGING DO NOT DESTROY

5.7. Bar Coding – Bar code labels shall be supplied on all CLIN’s except for those that require data submissions only.

5.7.1. All bar-coded labels shall be in accordance with MIL-STD-129R.

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

b. Each label shall contain encoded code 39 format data for the Stock Number.

5.8. Common Carrier Preparation – In addition to the transportation requirements specified in paragraph 3.15.10. of MIL-DTL-2545E(SH), reference 2.2.1.a of this specification. All packaged shaft(s) shall be loaded on a flatbed steel trailer with minimal camber and wooden floor only. No aluminum trailers are authorized. Shaft(s) are very sensitive and shall lay as flat and straight as possible.

5.8.1. Shaft(s) shall be loaded on the deck of the trailer only with no other items loaded on top of the crates.

5.8.2. Shim and secure crates as necessary to keep shaft(s) in a flat, straight position.

5.8.3. Carrier shall re-adjust shims as necessary if other shipped items are loaded or off-loaded which would result in changing the camber of the trailer.

6.0.NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Department of Defense Single Stock Point (DODSSP)

Building 4, Section D

700 Robins Avenue

Philadelphia, PA 19111-5094

215-697-2667/2179

FAX 215-697-1462

b. DOD & Navy Publications and Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2197

c. USCG Surface Forces Logistics Center

LRE Product Line

Contracting & Procurement 2

2401 Hawkins Point Road

Baltimore, MD. 21226-5000

(410) 762-6487

ATTN: John Kane

6.1.2. Commercial Documents

a. Society of Automotive Engineers INC. (SAE)

400 Commonwealth Drive

Warrendale, PA 15096-0001

412-776-4841

FAX 412-776-5760

www.sae.org

b. American Society for Testing & Materials (ASTM)

100 Barr Harbor Drive

PO Box C700

West Conshohocken, PA 19428-2959

610-832-9585

FAX 610-832-9555

www.astm.org

c. American National Standards Institute (ANSI)

25 West 43rd Street

(Between 5th and 6th Avenues) 4th Floor

New York, NY 10036

212-642-4900

FAX 212-398-0023

www.ansi.org

d. American Water Works Association (AWWA)

6666 W. Quincy Avenue

Denver, CO 80235

800-926-7337 (Phone)

303-347-0804 (Fax) https://www.awwa.org/

e. NACE International

15835 Park Ten Place

Houston, TX 77084-4906 http://www.sae.org/ http://www.astm.org/ http://www.ansi.org/ https://www.awwa.org/

800-797-6223 (Phone)

281-228-6300 (Fax) http://www.nace.org/ http://www.nace.org/