Attachment 22 - 87 Propeller Inspection Compliance Form v3 (5-21-2020).pdf

87 Propeller Inspection Compliance Forms

Propeller serial no: Date:

Contractor inspector name/title:

1. Material Composition (per ABS 7, Section 10, Type 4)

Chemical Composition, in Percent – Nickel-Aluminum-Bronze

(NOTE: Single values are maxima, unless noted otherwise)

Analysis done via: Test coupon Direct propeller scan

Element Required amount (%) Measured amount Pass/Fail

Copper 78 (minimum)

Manganese 3.5

Aluminum 8.5 to 11

Nickel 3.0 to 5.5

Iron 3.0 to 5.0

Lead 0.03

Total others 0.50

Testing laboratory/company:

Testing date:

Contractor inspector (written/signature): /

USCG (written/signature): /

2. Bolt Hole Inspections – NOTE: Using a go/no-go gauge, this inspection is a decision point. If either is

UNSAT or requires weld repair, immediately notify the KO.

Threads fully engage? (check one below):

Hole 1 GO NO-GO

Hole 2 GO NO-GO

Hole 3 GO NO-GO

Lifting hole threads fully engaged: GO NO-GO

3. Hub Bore Inspection - NOTE: The bore dimensional inspection is a decision point. Report any failed measurement to the KO immediately upon finding.

Inspection Requirement Measured Pass/Fail

Bore dimensional inspection (for comparison to Coast

Guard Drawing 87 WPB

245-003)

Large end dia: 4.000”

+ 0.005” / - 0.005”

Small end dia.: 3.250”

+ 0.005” / - 0.005”

Large end dia:

Small end dia.:

4. Hub Bore Fit

Measurement taken Required Measured

Draw measurement Refer to Coast Guard Drawing 87

WPB 243-003, Gen. Note. 26

5. Surface Finish (Work Item 1, Section 3.11)

Locations Required Measured

Blade 1 from radius 0.2 outward

63 micro inches Ra

Blade 2 from radius 0.2 outward

Blade 3 from radius 0.2 outward

Blade 4 from radius 0.2 outward

Blade 5 from radius 0.2 outward

Hub forward end 125 micro inches Ra

Hub aft end

Bore/Keyway 63 micro inches Ra

6. Balancing

Requirement Measured

Mandrel/concentric ring TIR <0.001”

RPMs 853

Propeller weight Estimated ~337 lbs

Residual unbalance*** Max: 5.9 oz-in

Contractor inspector (written/signature): /

USCG (written/signature): /

***Residual unbalance determined via U = 6GW/N, where G = 2.5 mm/s, W = 337 lbs and N = 853 RPMs

(Source: MIL-STD-167-1A, paragraph 5.2.2.2).

7. Surface Inspection

Document ALL defects on the following sheets. For the dye penetrant inspection, highlight/annotate ALL defects that fall outside of the allowable parameters set by ABS Part 7, Section 10, Table 1. Provide two sheets, one per face and label pages 5a and 5b.

NOTE: Photographs may be inserted in place of these inspection forms provided the photos collectively encompass the entire propeller and adhere to the instructions for documenting/highlighting/annotating defects. The photographs must be labeled such that the blades, hub locations and defect locations are identifiable. See the following page for the hub diagram.

Pressure Face Suction Face

LH Propeller Hub – Sketch and label the adjacent blades in the above diagram.

RH Propeller Hub – Sketch and label the adjacent blades in the above diagram.

NOTES: Use the above sketches multiple times to capture the hub sections between all blades. Photographs may be inserted in place of these inspection forms provided the photos collectively encompass the entire hub and adhere to the instructions for documenting/highlighting/annotating defects. The photographs must be labeled such that the blades, hub locations and defect locations are identifiable.

Signatures for the propeller hub sketches.

8. Final Test and Inspection Report

a. Propeller Blade Radii

Location Required (tolerance per drawing) Measured

Blade 1

40.94” +/- .08” (40.86” to 41.02”)

Blade 2

Blade 3

Blade 4

Blade 5

b. Local Pitches (measured over three equal segments with a 0.50” exclusion from each edge, i.e., chord length minus 1.0” total divided by 3) with +/- 2.0% pitch tolerance (min – max) applied to the requirement.

Blade 1 Radius Segment 1 requirement

Segment 1 measured

Segment 2 requirement

Segment 2 measured

Segment 3 requirement

Segment 3 measured

.4R 48.40” (47.73” – 49.36”)

49.59”

(48.60” – 50.59”)

52.51” (51.46” – 53.56”)

.5R 52.39” (51.34” – 53.43”)

50.48”

(49.47” – 51.49”)

51.05” (50.03” – 52.07”)

.6R 53.16” (52.10” – 54.23”)

50.44”

(49.44” – 51.45”)

49.90” (48.90” – 50.90”)

.7R 53.75” (52.67” – 54.82”)

49.60”

47.13” (46.19” – 48.07”)

.8R 53.37” (52.30” – 54.44”)

47.59”

(46.64” – 48.54”)

44.87” (43.97” – 45.76”)

.9R 51.81” (50.78” – 52.85”)

44.06”

(43.18” – 44.95”)

40.59” (39.78” – 41.40”)

.95R 49.84” (48.84” – 50.84”)

41.30”

(40.47” – 42.12”)

38.97” (38.19” – 39.75”)

Blade 2 requirement

Segment 1 measured

Segment 2 requirement

Segment 2 measured

Segment 3 requirement

Segment 3 measured

Blade 3 requirement

Segment 1 measured

Segment 2 requirement

Segment 2 measured

Segment 3 requirement

Segment 3 measured

Blade 4 requirement

Segment 1 measured

Segment 2 requirement

Segment 2 measured

Segment 3 requirement

Segment 3 measured

Blade 5 requirement

Segment 1 measured

Segment 2 requirement

Segment 2 measured

Segment 3 requirement

Segment 3 measured

c. Mean Pitch per Radius

Radius Requirement Measured (mean, per ISO 484/2)

Blade 1 Blade 2 Blade 3 Blade 4 Blade 5

.4R 50.507” (49.75” – 51.26”)

.5R 50.999” (50.23” – 51.76”)

.6R 50.757” (50.00” – 51.52”)

.7R 50.180” (49.43” – 50.93”)

.8R 48.921” (48.19” – 49.65”)

.9R 46.031” (45.34” – 46.72”)

.95R 44.119” (43.46” – 44.78”)

d. Mean Pitch per Blade

Requirement Blade 1 Blade 2 Blade 3 Blade 4 Blade 5

48.79”

+/- 0.49” (48.30” – 49.28”)

e. Mean Propeller Pitch

Requirement Measured

48.55”

+/- 0.36” (48.19” – 48.91”)

f. Blade Section Widths

Radius Requirement, full width

Full width, measured

.5R 17.350” +/- .005” (17.345” – 17.355”)

.7R 17.776”

(17.771” – 17.781”)

.8R 16.258”

(16.263” – 16.253”)

.95R 9.304” +/- .276” (9.028” – 9.580”)

h. Thickness at Prescribed Stations (all units in inches with new manufacture tolerance of +/- 0.005”) h.1 Blade 1 – thicknesses – RECORD MAX THICKNESSES, ONLY.

.4R

P O N M L K J H G F E C Design .635 .760 .928 .984 .995 .979 .940 .879 .782 .701 .584 .406

Measured

.5R

Design .479 .595 .748 .823 .844 .844 .819 .770 .681 .601 .491 .425

.6R

Design .364 .463 .593 .677 .697 .695 .678 .643 .578 .510 .424 .283

.7R

Design .280 .359 .481 .544 .556 .551 .538 .518 .463 .411 .347 .259

.8R

Design .226 .289 .395 .456 .462 .455 .438 .414 .383 .360 .324 .245

.9R

Design .177 .213 .271 .334 .355 .354 .344 .330 .310 .289 .253 .190

.95R

Design .158 .186 .234 .279 .292 .296 .295 .284 .260 .241 .216 .159 h.2 Blade 2 – thicknesses

P O N M L K J H G F E C h.3 Blade 3

P O N M L K J H G F E C h.4 Blade 4 – thicknesses

P O N M L K J H G F E C h.5 Blade 5 – thicknesses

P O N M L K J H G F E C

i. Track Deviation/Rake

Note: ISO 484/2, Section 13 provides locations for measurement

Requirement (Max deviation, +/- 1% propeller diameter), +/- .409”

Rake

Point A

Measured

Point B

Measured

Point C

Measured

Blade 1

Blade 2

Blade 3

Blade 4

Blade 5

Max deviation between ANY two blades (max – min)

j. Edges smooth, not sharp edges – Acceptance of data presented in Section 7 herein fulfills this requirement?

Yes / No

k. Angular Spacing of Blade Center Axis

Requirement Blade 1 & 2

Measured

Blade 2 & 3

Measured

Blade 3 & 4

Measured

Blade 4 & 5

Measured

Blade 5 & 1

72.0° +/- 0.5°

l. Surface Finish of Blade, Hub and Bore Areas – Acceptance of data presented in Section 5 herein fulfills this requirement?

m. Surface Inspection (Visual and 100 Percent Dye Penetrant) – Acceptance of data presented in Section 7 herein fulfills this requirement?

n. Hub Bore Inspections and Fit – Acceptance of data presented in Sections 3 and 4 herein fulfills this requirement?

o. Material Composition – Acceptance of data presented in Section 1 herein fulfills this requirement?

p. Balancing Data – Acceptance of data presented in Section 6 herein fulfills the requirement?

(continued below)

q. Fairness – Indicate areas of unacceptable fairness. Provide two sheets, one per face and label pages 18a and

18b.

Pressure Face Suction Face

9. Propeller Identification Markings

The following are marked in ¼” to ½” high text on all newly manufactured propellers (check beside each box when verified):

a. Serial number (provided by Contracting Officer)

b. Ship class – 87 WPB

c. Starboard or Port

d. Rotation direction (from aft looking forward)

e. National Stock Number (NSN)

f. Design diameter – 40.94 inches

g. Design pitch at .7R – 50.18 inches

h. Manufacturer name/date of manufacture

i. Actual propeller weight

j. Material grade – ABS Grade 4

10. Photo Documentation Phases (Work Item 1, Section 3.15)

Provide photographs in accordance with Section 3.15.1