Attachment 23 - 110 Propeller Inspection Compliance Form - v6 (5-21-2020).pdf

110 Propeller Inspection Compliance Form

Propeller serial no: Date:

Contractor inspector name/title:

1. Material Composition (Work Item 1, Section 3.1.3, per ABS 7, Section 10, Type 4)

Chemical Composition, in Percent – Nickel-Aluminum-Bronze

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

Analysis done on: 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.

Aft end threads fully engaged (check one):

Hole 1 GO NO-GO Hole 5 GO NO-GO

Hole 2 GO NO-GO Hole 6 GO NO-GO

Hole 3 GO NO-GO Hole 7 GO NO-GO

Hole 4 GO NO-GO Hole 8 GO NO-GO

Hydraulic line threads fully engaged (see Detail 12-B for further details; check one): GO NO-GO

Lifting hole threads fully engaged: GO NO-GO

3. Hub Bore Inspection (Work Item 1, Sections 3.3.1, 3.10) - 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 110 WPB

245-004)

Large end dia: 101.6 mm

+ 0.00 mm /- 0.40 mm (101.2 to 101.6 mm)

Small end dia.: 84.8 mm

+ 0.00 mm /- 0.40 mm (84.4 to 84.8 mm)

Oil groove locations

(from each respective hub face): 25 mm +/- 0.40 mm (24.6 to 25.4 mm)

Oil groove depth/radius

(large end)

Oil groove depth/radius

(small end)

Large end dia:

Small end dia.:

Large end oil groove location (from large end hub face):

Small end oil groove location (from small end hub face):

Depth

Radius

Depth

Radius

Blue film thickness 0.0004”

Forward End Blue Fit

Requirement 95%

Aft End Blue Fit

Requirement 95%

Blue Fit Remainder 80%

4. Hub Bore Fit (Work Item 1, Section 3.11)

Measurement taken Required Measured

Draw measurement 4.6 mm to 4.9 mm

Hydraulic nut pressure when draw requirement is met

4,440 to 7,500 psi

Overhang measurement when pressure released from nut

(paragraph 3.11.6.1)

3.6 to 6.9 mm

Movement after 10 minutes? None

Propeller release/removal pressure (paragraph 3.11.7)

Less than or equal to 25,000 psi

5. Surface Finish (Work Item 1, Section 3.13)

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 32 micro inches Ra

6. Balancing (Work Item 1, Section 3.14)

Requirement Measured

Mandrel/concentric ring TIR <0.025 mm (0.001”)

RPMs 842

Propeller weight Estimated ~340 kg (750 lbs)

Residual unbalance Max: 7.1 oz-in

7. Surface Inspection (Work Item 1, Section 3.15)

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 6a and 6b.

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 Inspection Report (Work Item1, Section 3.16)

a. Propeller Blade Radii

Location Required (dimension with applied

ISO 484/2 tolerance)

Measured

Blade 1

630 mm +/- 1.9 mm (628.1 to 631.9 mm)

Blade 2

Blade 3

Blade 4

Blade 5

b. Local Pitches (three sections spanning the percentage stations from the LE: a. 5% to 30%, b. 30% to

70% and c. 70% to 95%)

Blade 1 Radius .5” exclusion to 30% requirement

.5” excl. to

30% measured

30% to 70% requirement

30% to 70% measured

70% to .5” excl.

requirement

70% to .5” excl measured

.4R 1693 mm

+/-34 mm (1659 to 1727 mm)

1567 mm

+/- 31 mm (1536 to 1598 mm)

1442 mm

+/- 29 mm (1413 to 1470 mm)

.5R 1663 mm

+/- 33 mm (1630 to 1696 mm)

1610 mm

+/- 32 mm (1578 to 1643 mm)

1558 mm

(1527 to 1589 mm)

.6R 1609 mm

(1577 to 1641 mm)

1601 mm

(1569 to 1633 mm)

1599 mm

(1587.6 to 1652.4 mm)

.7R 1537 mm

(1506 to 1567 mm)

(1526 to 1589 mm)

1589 mm

(1557 to 1621 mm)

.8R 1433 mm

(1405 to 1462 mm)

1477 mm

+/- 30 mm (1447 to 1506 mm)

1530 mm

(1499 to 1560 mm)

.9R 1322 mm

+/- 26 mm (1296 to 1349 mm)

1380 mm

+/- 28 mm (1353 to 1408 mm)

1453 mm

+/-29 mm (1424 to 1482 mm)

.95R 1281 mm

(1256 to 1307 mm)

1377 mm

(1350 to 1405 mm)

1341mm

+/- 27 mm (1314 to 1368 mm)

Blade 2 requirement

.5” excl. to

30% measured

30% to 70% requirement

30% to 70% measured

70% to .5” excl.

requirement

70% to .5” excl measured

.4R 1693 mm

Blade 3 requirement

.5” excl. to

30% measured

30% to 70% requirement

30% to 70% measured

70% to .5” excl.

requirement

70% to .5” excl measured

.4R 1693 mm

Blade 4 requirement

.5” excl. to

30% measured

30% to 70% requirement

30% to 70% measured

70% to .5” excl.

requirement

70% to .5” excl measured

.4R 1693 mm

Blade 5 requirement

.5” excl. to

30% measured

30% to 70% requirement

30% to 70% measured

70% to .5” excl.

requirement

70% to .5” excl measured

.4R 1693 mm

c. Section Pitches (pitch per radius)

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

Blade 1 Blade 2 Blade 3 Blade 4 Blade 5

.4R 1567 mm

+/- 24 mm (1544 to 1591 mm)

.5R 1611 mm

(1586 to 1635 mm)

.6R 1603 mm

(1579 to 1627 mm)

.7R 1561 mm

+/- 23 mm (1538 to 1585 mm)

.8R 1480 mm

+/- 22 mm (1458 to 1502 mm)

.9R 1385 mm

+/- 21 mm (1364 to 1406 mm)

.95R 1333 mm

+/- 20 mm (1313 to 1353 mm)

d. Average Pitch of Each Blade

Requirement Blade 1 Blade 2 Blade 3 Blade 4 Blade 5

1506 mm

+/- 15 mm (1491 to 1521 mm)

e. Mean Propeller Pitch

Requirement Measured

1506 mm

+/- 11 mm (1495 to 1517 mm)

f. Blade Section Widths

Radius Requirement, full width

Full width, measured

.5R 640 mm

+/- 12.8 mm (627.2 to 652.8 mm)

.7R 747 mm

+/- 14.9 mm (732.1 to 761.9

.8R 704 mm

+/- 14.1 mm (689.9 to 718.1

.95R 410 mm

+/- 8.2 mm (401.8 to 418.2

g. Skew

DELETED.

h. Thickness at Every 10% Station (all units in mm, per blade) h.1 Blade 1 - thicknesses

.4R

TE 90 80 70 60 50 40 30 20 10 LE

Design 20.5 27.5 31.5 33.6 34.3 33.6 31.5 27.5 20.6

Min 19.5 26.5 30.5 32.6 33.3 32.6 30.5 26.5 19.6

Max 21.5 28.5 32.5 34.6 35.3 34.6 32.5 28.5 21.6

Measured

.5R

Design 16.2 21.7 24.8 26.5 27 26.5 24.8 21.6 16.2

Min 15.2 20.7 23.8 25.5 26 25.5 23.8 20.6 15.2

Max 17.2 22.7 25.8 27.5 28 27.5 25.8 22.6 17.2

.6R

Design 12.2 16.2 18.5 19.7 20.1 19.7 18.5 16.1 12.1

Min 11.2 15.2 17.5 18.7 19.1 18.7 17.5 15.1 11.1

Max 13.2 17.2 19.5 20.7 21.1 20.7 19.5 17.1 13.1

.7R

Design 8.9 11.7 13.3 14.2 14.5 14.2 13.3 11.6 8.7

Min 7.9 10.7 12.3 13.2 13.5 13.2 12.3 10.6 7.7

Max 9.9 12.7 14.3 15.2 15.5 15.2 14.3 12.6 9.7

.8R

Design 6.2 8 9.1 9.6 9.8 9.6 9 7.9 5.9

Min 5.2 7 8.1 8.6 8.8 8.6 8 6.9 4.9

Max 7.2 9 10.1 10.6 10.8 10.6 10 8.9 6.9

.9R

Design 4.2 5.2 5.8 6.1 6.2 6.1 5.7 5 3.9

Min 3.2 4.2 4.8 5.1 5.2 5.1 4.7 4 2.9

Max 5.2 6.2 6.8 7.1 7.2 7.1 6.7 6 4.9

.95R

Design 3.7 4.4 4.9 5.2 5.3 5.2 4.9 4.2 3.4

Min 2.7 3.4 3.9 4.2 4.3 4.2 3.9 3.2 2.4

Max 4.7 5.4 5.9 6.2 6.3 6.2 5.9 5.2 4.4 h.2 Blade 2 - thicknesses

Design 20.5 27.5 31.5 33.6 34.3 33.6 31.5 27.5 20.6

Min 19.5 26.5 30.5 32.6 33.3 32.6 30.5 26.5 19.6

Design 16.2 21.7 24.8 26.5 27 26.5 24.8 21.6 16.2

Min 15.2 20.7 23.8 25.5 26 25.5 23.8 20.6 15.2

Design 12.2 16.2 18.5 19.7 20.1 19.7 18.5 16.1 12.1

Min 11.2 15.2 17.5 18.7 19.1 18.7 17.5 15.1 11.1

Design 8.9 11.7 13.3 14.2 14.5 14.2 13.3 11.6 8.7

Min 7.9 10.7 12.3 13.2 13.5 13.2 12.3 10.6 7.7

Design 6.2 8 9.1 9.6 9.8 9.6 9 7.9 5.9

Min 5.2 7 8.1 8.6 8.8 8.6 8 6.9 4.9

Design 4.2 5.2 5.8 6.1 6.2 6.1 5.7 5 3.9

Min 3.2 4.2 4.8 5.1 5.2 5.1 4.7 4 2.9

Design 3.7 4.4 4.9 5.2 5.3 5.2 4.9 4.2 3.4

Min 2.7 3.4 3.9 4.2 4.3 4.2 3.9 3.2 2.4 h.3 Blade 3

Design 20.5 27.5 31.5 33.6 34.3 33.6 31.5 27.5 20.6

Min 19.5 26.5 30.5 32.6 33.3 32.6 30.5 26.5 19.6

Design 16.2 21.7 24.8 26.5 27 26.5 24.8 21.6 16.2

Min 15.2 20.7 23.8 25.5 26 25.5 23.8 20.6 15.2

Design 12.2 16.2 18.5 19.7 20.1 19.7 18.5 16.1 12.1

Min 11.2 15.2 17.5 18.7 19.1 18.7 17.5 15.1 11.1

Design 8.9 11.7 13.3 14.2 14.5 14.2 13.3 11.6 8.7

Min 7.9 10.7 12.3 13.2 13.5 13.2 12.3 10.6 7.7

Design 6.2 8 9.1 9.6 9.8 9.6 9 7.9 5.9

Min 5.2 7 8.1 8.6 8.8 8.6 8 6.9 4.9

Design 4.2 5.2 5.8 6.1 6.2 6.1 5.7 5 3.9

Min 3.2 4.2 4.8 5.1 5.2 5.1 4.7 4 2.9

Design 3.7 4.4 4.9 5.2 5.3 5.2 4.9 4.2 3.4

Min 2.7 3.4 3.9 4.2 4.3 4.2 3.9 3.2 2.4 h.4 Blade 4 - thicknesses

Design 20.5 27.5 31.5 33.6 34.3 33.6 31.5 27.5 20.6

Min 19.5 26.5 30.5 32.6 33.3 32.6 30.5 26.5 19.6

Design 16.2 21.7 24.8 26.5 27 26.5 24.8 21.6 16.2

Min 15.2 20.7 23.8 25.5 26 25.5 23.8 20.6 15.2

Design 12.2 16.2 18.5 19.7 20.1 19.7 18.5 16.1 12.1

Min 11.2 15.2 17.5 18.7 19.1 18.7 17.5 15.1 11.1

Design 8.9 11.7 13.3 14.2 14.5 14.2 13.3 11.6 8.7

Min 7.9 10.7 12.3 13.2 13.5 13.2 12.3 10.6 7.7

Design 6.2 8 9.1 9.6 9.8 9.6 9 7.9 5.9

Min 5.2 7 8.1 8.6 8.8 8.6 8 6.9 4.9

Design 4.2 5.2 5.8 6.1 6.2 6.1 5.7 5 3.9

Min 3.2 4.2 4.8 5.1 5.2 5.1 4.7 4 2.9

Design 3.7 4.4 4.9 5.2 5.3 5.2 4.9 4.2 3.4

Min 2.7 3.4 3.9 4.2 4.3 4.2 3.9 3.2 2.4 h.5 Blade 5 - thicknesses

Design 20.5 27.5 31.5 33.6 34.3 33.6 31.5 27.5 20.6

Min 19.5 26.5 30.5 32.6 33.3 32.6 30.5 26.5 19.6

Design 16.2 21.7 24.8 26.5 27 26.5 24.8 21.6 16.2

Min 15.2 20.7 23.8 25.5 26 25.5 23.8 20.6 15.2

Design 12.2 16.2 18.5 19.7 20.1 19.7 18.5 16.1 12.1

Min 11.2 15.2 17.5 18.7 19.1 18.7 17.5 15.1 11.1

Design 8.9 11.7 13.3 14.2 14.5 14.2 13.3 11.6 8.7

Min 7.9 10.7 12.3 13.2 13.5 13.2 12.3 10.6 7.7

Design 6.2 8 9.1 9.6 9.8 9.6 9 7.9 5.9

Min 5.2 7 8.1 8.6 8.8 8.6 8 6.9 4.9

Design 4.2 5.2 5.8 6.1 6.2 6.1 5.7 5 3.9

Min 3.2 4.2 4.8 5.1 5.2 5.1 4.7 4 2.9

Design 3.7 4.4 4.9 5.2 5.3 5.2 4.9 4.2 3.4

Min 2.7 3.4 3.9 4.2 4.3 4.2 3.9 3.2 2.4

i. Track

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

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

12.6 to -12.6 mm

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° +/- 0.72°

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. Fairing Rod Clearances – Conduct the fairing rod survey and indicate only those readings measuring greater than 0.762mm (0.030”) or with a fairing clearance rate-of-change greater than 0.127 mm (0.005”) per 25 mm (1 inch) maximum. Provide two sheets, one per face and label pages 26a and 26b.

Pressure Face Suction Face

r. Oil groove depths

Circular Oil Distribution Groove

Required Measured

Width, 12mm +0.5mm / -0.0 mm (12 to 12.5 mm)

Depth, 2mm +0.5mm / -0.0 mm (2 to 2.5 mm)

Radius, 10 mm +0.5mm / -0.0mm (10 to 10.5mm)

Radial Oil Distribution and Drainage Groove

Required Measured

Width, 12mm +0.5mm / -0.0 mm (12 to 12.5 mm)

Depth, 2mm +0.5mm / -0.0 mm (2 to 2.5 mm)

Radius, 10 mm +0.5mm / -0.0mm (10 to 10.5mm)

Signature for complete Sections 8.a through 8.r

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 – 110 WPB

c. Starboard or Port

d. Rotation direction (from aft looking forward)

e. National Stock Number (NSN)

f. Design diameter – 1260 mm

g. Design pitch at .7R – 1560 mm

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