Attachment 17 - Repair Specification for AQ22 shafts.pdf

REVISION No. . CHANGE NO. .

PROPULSION SHAFT OVERHAUL

SPECIFICATION FOR AQ22HS

ORGINATED BY A.G. Ollerman . DATE 05/2013 .

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

DEPARTMENT / DIVISION Ice Break Buoy and Construction Tender Product Line .

INTERNAL REVIEWER . DATE .

SWORB APPROVAL . DATE _________.

PROPULSION SHAFT PREPAIR SPECIFICATION FOR AQ22HS

1.0 SCOPE

1.1. This specification sets forth the requirements overhaul Aqua-met 22HS propulsion shafts.

This specification also describes the inspection, preservation, packaging, packing and marking of the propulsion shafts.

1.2. GOVERNMENT FURNISHED PROPERTY for overhaul:

a. 160’ WLIC, NSN: 2010-01-076-3907, Part Number: 160WLIC-4301-003 Piece-1

b. 65’ WYTL, NSN: 2010-01-534-9802, Part Number: 65WYT 4301-4

c. 75’ WAGL, NSN: 2010-01-557-1512, Part Number: 75-WAGL-4301-4-PC1

2.0 APPLICABLE DOCUMENTS

2.1. DOCUMENT AVAILABILITY - To obtain the referenced documents see section 6.1.

2.2. GOVERNMENT DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein.

2.2.1. SPECIFICATIONS, DOD

a. MIL-DTL-2845E (SH) DATED Aug 18, 1999, Packaging of Main propulsion Shafting, Bearings, Boat & Ship Propellers and associated Repair Parts.

b. MIL-STD-2191 (SH) DATED Nov 5, 1992 DOD Standard Practice, Repair Welding, Weld Cladding, Straightening, And Cold Rolling Of Main Propulsion Shafting.

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. DRAWINGS

a. 160-WLIC-4301-003 Rev B, Dated 09/09/11; Shafting Arrangement and Details

b. 65B-WYT-4301-4 Rev A, Dated 09/09, Propulsion Shaft Single Sheet Detail

65-WYT-4301-2 Rev A, Dated 05/09, 65601 Thru 65615 Shafting Plan

c. 75-WAGL-4301-5 Rev N, Dated 04/13, Shafting Machining Details to Suit I-F 1312

MDE

2.3.2. US COAST GUARD SPECIFICATIONS

a. USCG-SFLC SPECIFICATION D-000-0100 (latest REV) Bar Coding for use on Surface

Forces Logistics Center material.

2.4. COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization.

2.4.1. Society of Automotive Engineers (SAE)

a. SAE-J-448A Dated 6/63 Surface Texture

b. SAE J-755 Dated 6/80, Marine Propeller Shaft Ends and Hubs

2.4.2. National Conference of Standards Laboratories (NCSL)

a. NCSL Z540-3-2006 Dated, 2006, Requirements for the Calibration of Measuring and

Test Equipment.

2.4.3. American Society for Testing Materials (ASTM)

a. ASTM A 276-04, DATED 01 Feb 2004, Standard Specification for Stainless Steel Bars and Shapes.

b. ASTM A 564/ A564M – 04 Dated 01 Mar 2004, Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes.

2.4.4. American Boat and Yacht Council (ABYC)

a. ABYC P-6 Dated July 2002, Propeller Shafting Systems

2.5. 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.

3.0 REQUIREMENTS

3.1. GENERAL - The contractor shall provide all labor and materials required to overhaul used propulsion shafts, and or manufacture new shafts. The contractor shall also provide all labor and materials necessary to inspect, preserve, package, pack & mark the propulsion shafts as outlined in this specification.

3.1.1. The shaft material shall be as follows: Brand name or equal in production methods, chemistry, and mechanical properties of Aquamet 22HS.

3.1.2. Tapers, shall be machined by a computer numerically controlled (CNC) lathe.

1.1.2. The Shaft End Taper(s) – The shaft(s) end tapers shall be blue fit to a “certified ring gage” with a tolerance of +0.0015” – 0.000” per foot of diameter. Ring Gage shall be constructed in accordance with NAVSEA S9243-A5-MMD-010. “The certified ring gage shall be furnished by the contractor”. Required shaft taper dimensions are as follows:

a. 160 WLIC (NSN: 2010-01-076-3907) - 0.750”/Ft. for Propeller end and 1.000”/Ft. for Coupling end.

b. 65 WYT (NSN: 2010-01-534-9802) – 0.750”/Ft. for Propeller and Coupling ends.

c. 65B WD & 75 WAGL (NSN: 2010-01-557-1512) - 0.750”/Ft. for Propeller and Coupling ends.

3.1.3. The blue fit shall be a minimum of 80% contact

3.2. ADDITIONAL PARTS – See the specific drawing for each shaft specified. The following pieces shall be manufactured for each shaft ordered. Pieces shall, at a minimum, be preserved, packaged, packed, marked and attached to each applicable shaft in accordance with section

3.15.7 of MIL-DTL-2845E(SH).

3.2.1. 160 WLIC (NSN: 2010-01-076-3907) – Utilize drawing 160-WLIC-4301-003, ref.

2.3.1.a of this specification for the following items. Piece 18 (Coupling Nut), shall be made from Nitronic 60 / UNS Designation S21800, Chromium Nickel with Nitrogen alloy (CF-10SMnN) IA. Piece 4 (Fairwater Cap & Nut Combination), shall be made from Ni-Al Bronze UNS Designation C95800. Piece 6 (Fairwater Nut Lock Washer) shall be made from Monel Steel. Piece 17 (Socket HD Cap Screw, 5/16”-18 Thd x 1” Lng, 2 ea) shall be made from Grade B8S / B8SA UNS Designation S21800 Austenitic Steel IAW ASTM A 193/A 193 M.

3.2.2. 65 WYT (NSN: 2010-01-534-9802) – Utilize drawing 65-WYT-4301-2 Rev J, ref.

2.3.1.b of this specification for the following items: Piece 1, (Coupling Nut Washer) shall be made from alloy steel in accordance with (IAW) ASTM-F-436. Piece 43 (Coupling Nut) shall be made from 316L stainless steel in accordance with (IAW) ASTM A 193/A 193 M.

3.2.3. 65B WD & 75 WAGL (NSN: 2010-01-557-1512) – Utilize drawing 75-WAGL-4301-5 Rev N, Dated 04/13 , ref. 2.3.1.c of this specification for the following items: Piece 4, (Nut, Hex, Heavy Full) shall be made from NiBrAl (ASTM B30, B505 or C95300). Piece 5 (Nut, Heavy, Hex, Jam) shall be made from NiBrAl (ASTM B30, B505 or C95300).

Piece 6, (Coupling Key) shall be made from 17-4 PH (ASTM A564 Condition H1150).

Piece 7, (Propeller Key) shall be made from 17-4 PH (ASTM A564 Condition H1150).

3.3. DIMENSIONS - All dimensions and dimensional tolerances shall be as indicated on the specified drawing.

3.3.1. If not specified, tolerances shall be as listed below:

a. Fractional dimensions + / - 1/64”

b. Decimal dimensions (xx) + / - 0.01”, (xxx) + / - 0.001, (xxxx) +/- 0.0005”

c. Fractional dimensions on shaft length shall be + / - 1/16”

3.4. SURFACE FINISH STANDARDS - All surface finishes shall be in accordance with SAE-J-

448A “Surface Texture” to RMS 32 finish.

3.5. MEASUREMENT PROCEDURES - Runout readings using a dial indicator to be taken by supporting the shaft on precision rollers (two total) 24 inches from the ends of the shaft, or between lathe centers. (No additional supports shall be used.)

3.5.1. Runout 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.

a. Each station shall be marked at the position of the maximum run-out on the periphery of the shaft.

3.6. RUNOUT, CONCENTRICITY, ECCENTRICITY & TAPER INSPECTION - The runout, concentricity, and eccentricity shall be as specified below.

3.6.1. Shaft Total Indicated Runout (T.I.R) - The outside diameter of each shaft section shall be concentric with the axis of rotation to within 0.005” T.I.R.

3.6.2. Taper Concentricity & Eccentricity - Shall be concentric with the axis of rotation to within

0.002” T.I.R.

3.7. WELDING – Weld repairs on used shafts are permitted but shall be accomplished in accordance with MIL-STD-2191 (SH) and an ABS or NAVSEA approved weld procedure for the specified shaft material.

3.8. STRAIGHTENING - Shall be accomplished by the “cold press” method only. No heat will be used to straighten shafts repaired in accordance with this specification.

3.9. KEYWAYS- Shall be machined in accordance with the applicable drawing

3.10. TEST/INSPECTION REPORTS

3.10.1. All reports prepared for submission shall contain at a minimum the data listed herein.

a. Prime Contractor Company Name, address, telephone Number

b. Testing Contractor (if different from above)

c. Contract & Delivery Order No

d. Test equipment used, Nomenclature, S/N, Calibration date

e. Shaft serial number

f. All test and inspection information as required in section 3.10.1. of this specification

3.10 TEST & INSPECTION DATA REQUIREMENTS

3.10.1 Each shaft shall be tested/ inspected as specified herein:

1.Liquid dye penetrant test of all areas in way of keyways, tapers, threads, and bearings.

2.Total Indicated Runout (TIR) in accordance with the drawing.

3. Taper Inspections shall be in accordance with appropriate sections herein and contact impression requirements as specified herein.

4.Dimensional inspection in accordance with the drawing.

5.The completed Receiving Inspection Report with cost to overhaul shall be submitted to the Contracting Officer within ten (10) business days of receipt of the shaft, for approval prior to starting any repairs.

3.11. MARKING - All shafts shall be marked on the coupling end face with a stamped-in serial number at least 1/8” high on the coupling end face as directed on each delivery order.

3.12. NOTIFICATIONS & INSPECTIONS - The contractor shall notify the Contracting Officer at least ten (10) business days prior to inspections or monitored testing required herein.

4.0 QUALITY ASSURANCE

4.1. GENERAL - The Contractor shall maintain an inspection system, which shall insure that 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 - The 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 any subcontractors, shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-3.

The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4. The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification and shall be submitted to the Quality Assurance

Inspector upon request.

4.5. RESPONSIBILITY FOR INSPECTION - The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel and test equipment in order to conduct all inspection requirements. All inspections shall be performed at the Contractor’s plant or at other facilities acceptable to the

Coast Guard. The Coast Guard Quality Assurance Representative will witness the inspections set forth in this specification. Such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.6. TESTS/INSPECTIONS - The inspections/tests required here and in section 3.10 are the minimum required and are not intended to supplant any controls, examinations, inspections or tests normally employed by the Contractor to assure the quality of the propulsion shafts.

4.6.1. Shaft Inspections – See section 3.10.of this specification.

4.7. FAILURE RESPONSIBILITY - If a shaft fails to pass any inspection or test, the Contractor shall report the failure and their recommended corrective action to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

a. The Contracting Officer reserves the right to totally reject any failed shaft without considering any suggested corrective action.

4.7.2. The inspection/test shall be discontinued until any approved corrective action has been taken.

4.7.3. After all corrective action has been taken the inspection/test shall be continued or repeated, at the option of the Contracting Officer.

4.7.4. Acceptance shall be withheld until re-inspection has shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

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

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

4.8. INSPECTION REPORTS - One copy of any required inspection or tolerance check shall be submitted to the contracting Officer.

4.8.1. A copy of any inspection or tolerance check shall also be turned over to the Quality

Assurance representative upon his arrival at the contractor’s plant.

4.9. PACKING INSPECTION - The Contracting Officer shall be notified prior to the packaging and marking of the completed units in accordance with section 3.12 of this specification.

5.0 PRESERVATION, PACKING, PACKAGING, AND MARKING - Each shaft shall be preserved, packed, packaged and marked as specified herein.

5.1. PRESERVATION - All shafts shall be cleaned and dried in accordance with MIL-DTL-2845 section 3.7.1. No further preservation shall be done.

5.2. PACKING - Each completed shaft shall be packed in accordance with MIL-DTL-2845 section 3.15.6 Level A, except Figure 15 shall be used for the box as modified herein.

a. The sides, bottom, and ends shall be made from 2” thick construction grade lumber sized so that one piece covers the height or width of the area, doubled on the ends. The top shall be made from 1” thick construction grade lumber.

b. Cradles – Shall be made from doubled 2” thick construction grade lumber.

c. Skids- Shall be made from 4” x 4” construction grade lumber. Skids shall be placed on both ends and every 4’ thereafter.

d. The top shall be attached with screws for easy removal, and marked in 2” high red lettering “TOP – REMOVAL WITH SCREW DRIVER” in three places evenly distributed across the top.

5.2.1. Place PVC tubing over all threads and tapers and secure in place.

5.3. COMMON CARRIER PREPARATION - All packaged shafts shall be shimmed after placement on the trailer to firmly support the cross skids in their natural lay.

a. This shimming shall be attached to the cross skidding to prevent the shims from dislodging from the cross skids during transport.

5.4. MARKING - The marking described herein shall be placed in the upper left hand corner of the longest two sides of each box (on opposite ends).

5.4.1. All markings shall be made with machine-made stencils; the lettering shall be at least

1/2” high, in black print lettering on a highly contrasting background.

5.4.2. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, DELIVERY ORDER NUMBER, and SERIAL NUMBERS, GROSS WEIGHT (in lbs.,) condition code i.e.; CONDITION A, unit of issue with quantity (1) and the words COAST GUARD SFLC MATERIAL.

5.4.3. See the marking layout below, and as required on figure 1.

Figure 1.

160 WLIC

STOCK NUMBER 2010-01-076-3907

ITEM NAME SHAFT, PROPULSION

PART NUMBER 160WLIC-4301-003 PIECE 1

SERIAL NUMBER/MFG DATE As Stamped on Shaft

CONTRACT NUMBER As indicated on the Contract

DELIVERY ORDER NO. As indicated on the Contract

SHIPPING WEIGHT As determined by Contractor

PACKING DATE As determined by Contractor

CONDITION CODE CONDITION “A”

QUANTITY & UNIT OF ISSUE 1 – EACH

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

65 WYT

STOCK NUMBER 2010-01-534-9802

ITEM NAME SHAFT, PROPULSION

PART NUMBER 65-WYT-4301-4

SERIAL NUMBER/MFG DATE As Stamped on Shaft

CONTRACT NUMBER As indicated on the Contract

DELIVERY ORDER NO. As indicated on the Contract

SHIPPING WEIGHT As determined by Contractor

PACKING DATE As determined by Contractor

CONDITION CODE CONDITION “A”

QUANTITY & UNIT OF ISSUE 1 – EACH

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

65B WLR & 75WAGL (with I-F MDE)

STOCK NUMBER 2010-01-557-1512

ITEM NAME SHAFT, PROPULSION

PART NUMBER 75-WAGL-4301-4

SERIAL NUMBER/MFG DATE As Stamped on Shaft

CONTRACT NUMBER As indicated on the Contract

DELIVERY ORDER NO. As indicated on the Contract

SHIPPING WEIGHT As determined by Contractor

PACKING DATE As determined by Contractor

CONDITION CODE CONDITION “A”

QUANTITY & UNIT OF ISSUE 1 – EACH

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

5.4.4. BAR CODING - Bar code labels shall be supplied on all CLIN’s except for those that require data submissions only.

a. All bar coded labels shall be in accordance with SFLC specification D-000-0100 (latest

Rev).

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

2. Each label shall contain encoded data for the Stock Number, serial number, and the

Contract Number.

3. The marking required in 5.4 of this specification can be applied separately or as part of the Bar Code Label.

6.0 NOTES

6.1. GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1. MILITARY & DOD DOCUMENTS

a. Specifications and Standards (DODISS Documents)

Standardizations Document Order Desk

700 Robbins Ave.

Building #4, Section D

Philadelphia, PA. 19111-5094

215-697-1187

b. Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

6.1.2. U.S. COAST GUARD DOCUMENTS

a. USCG SURFACE FORCES LOGISTICS CENTER

2401 Hawkins Point Road

Baltimore, MD. 21226-5000

410-762-XXXX

Attn: Contract & Procurement Division CPD-1

6.1.3. COMMERCIAL DOCUMENTS

a. Society of Automotive Engineers, INC. (SAE)

400 Commonwealth Drive

Warrendale, PA 15096

412-776-4841

Fax 412-776-5760 www.sae.org

b. American Society for Testing & Materials (ASTM)

ASTM International

100 Barr Harbor Drive

P.O. 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 42nd Street

(Between 5th and 6th avenues), 4th floor

New York, NY 10036

212-642-4900

Fax 212-398-0023 www.ansi.org

d. American Boat and Yacht Council Inc. (ABYC)

3069 Solomons Island Road

Edgewater, MD 21037-1416

410-956-1050

Fax 410-956-2737 www.abycinc.org about:blank about:blank about:blank about:blank